US 12,138,870 B2
Method for producing a reinforcement rod from a fibrous composite material using ultraviolet radiation
Joe Sorensen, Mazeppa, MN (US); and Josh Maggert, Winona, MN (US)
Assigned to Strongwell Corporation, Bristol, VA (US)
Filed by Strongwell Corporation, Bristol, VA (US)
Filed on Feb. 9, 2023, as Appl. No. 18/107,952.
Application 18/107,952 is a continuation of application No. 17/498,035, filed on Oct. 11, 2021, abandoned.
Prior Publication US 2023/0191726 A1, Jun. 22, 2023
Int. Cl. B29C 70/52 (2006.01); B29L 31/06 (2006.01)
CPC B29C 70/521 (2013.01) [B29L 2031/06 (2013.01)] 7 Claims
OG exemplary drawing
 
1. A method for making a cured pultruded reinforcement rod from a fibrous composite material using ultraviolet radiation comprising the following steps, wherein the following steps are capable of being performed in a continuously operating process:
impregnating continuous fibers with a thermosetting resin comprising a photoinitiator or a blend of more than one photoinitiator;
passing an uncured pultruded reinforcement core rod, the uncured pultruded reinforcement core rod having a diameter of 0.5 inches or larger, through a preforming device, wherein the uncured pultruded reinforcement core rod has a substantially uniform distribution of fibers in the thermosetting resin throughout a cross-section of the uncured pultruded reinforcement core rod after leaving the preforming device;
winding one or more strand of material around an outer surface of the uncured pultruded reinforcement core rod after it exits the preforming device to provide a textured or ribbed outer surface of the uncured pultruded reinforcement core rod, wherein the one or more strand of material is under tension while being wound around the outer surface of the uncured pultruded reinforcement core rod, and wherein winding the one or more strand of material around the outer surface of the uncured pultruded reinforcement core rod consolidates the impregnated continuous fibers of the uncured pultruded reinforcement core rod without substantially deforming the impregnated continuous fibers of the uncured pultruded reinforcement core rod so that the impregnated continuous fibers maintain a substantially linear orientation throughout a length of the uncured pultruded reinforcement core rod; and
producing the cured pultruded reinforcement rod in one second or less using a single curing step to fully cure the thermosetting resin using ultraviolet radiation or ultraviolet light;
wherein the photoinitiator or the blend of more than one photoinitiator forms a reactive species when exposed to the ultraviolet radiation or ultraviolet light.