US 12,145,330 B2
Pultruded articles and methods for making same
Craig Chmielewski, Shelby Township, MI (US); Henry E. Richardson, Washington, MI (US); Jeffrey T. Shantz, Metamora, MI (US); Nick Holstine, Royal Oak, MI (US); Milko Dimovski, Clinton Township, MI (US); Alex Mangiapane, Macomb Township, MI (US); Liwen Li, Troy, MI (US); and Joseph Thomas, Lapeer, MI (US)
Assigned to Zephyros, Inc., Romeo, MI (US)
Filed by Zephyros, Inc., Romeo, MI (US)
Filed on Oct. 26, 2021, as Appl. No. 17/511,266.
Application 17/511,266 is a division of application No. 15/555,999, abandoned, previously published as PCT/US2016/021725, filed on Mar. 10, 2016.
Claims priority of provisional application 62/296,378, filed on Feb. 17, 2016.
Claims priority of provisional application 62/200,380, filed on Aug. 3, 2015.
Claims priority of provisional application 62/130,908, filed on Mar. 10, 2015.
Prior Publication US 2022/0126533 A1, Apr. 28, 2022
Int. Cl. B29C 70/52 (2006.01); B29C 70/86 (2006.01); B29K 63/00 (2006.01); B29K 101/12 (2006.01)
CPC B29C 70/521 (2013.01) [B29C 70/52 (2013.01); B29C 70/86 (2013.01); B29K 2063/00 (2013.01); B29K 2101/12 (2013.01)] 4 Claims
OG exemplary drawing
 
1. A method of making a pultruded article, comprising the steps of:
a) contacting a mass of elongated fibers with at least two ingredients, with a reaction product of at least two ingredients, or a combination thereof, that infiltrate the mass of elongated fibers and react in situ to form a pultrusion having a thermoplastic polymeric material matrix having a glass transition temperature of less than about 2000 C, said contacting prior to or during step b and wherein one or more of the two or more reactants permit a delayed crosslinking reaction to occur;
b) pulling the plurality of continuous fibers through a die for defining a continuous profile that has at least two portions that are not coplanar and have differing thickness relative to each other;
c) feeding a supply of base material into the die;
d) applying a sufficient amount of energy to cause a continuous primary reaction of the two or more reactants to continuously to form a thermoplastic pultruded article having a polyurethane-based polymeric matrix in contact with the continuous fibers and embedding the continuous fibers therein and also bonding to the base material; and e) pulling the resulting pultruded article over a heated mandrel for imparting a curvature or other variable shape over at least a portion of the pultruded article and the resulting article having an ultimate tensile strength (UTS) of at least 300 MPa to less than 1000 MPa, further wherein the resulting article has a tensile modulus of at least 10 GPa to less than 50 GPa, wherein the method takes place under at least a first and a second temperature condition, so that the first temperature condition allows a reaction to occur between the at least two ingredients and the second temperature condition allows for infiltration of the at least two ingredients into the mass of elongated fibers.