Weyerhaeuser Company Limited

Johan D Koppernaes

Frank C Beall

A composition, apparatus and method for making resin bonded composite pultruded products using a thermosetting resin is disclosed. The resin includes a condensation resin which has a high solids content. A pultrusion system includes reinforcing material supply, a pultrusion die adapted to be heated, injection device for injecting resin into the die, and pulling device for drawing product through the die. The method includes supplying strands of the reinforcing material to the die and grasping the strands with the pulling device, injecting a condensation-type monomer resin into the die to impregnate the reinforcing material within the die, and pulling the resin-impregnated strands through the die at a rate that permits the resin to condense to an essentially cured state by the time the composite product is withdrawn from the die. The die is a modular die such that various sections of the die may be selected as desired to change process parameters. The die is divided lengthwise into a plurality of regions or sections, typically comprising an entry section, a resin injection section, a transition section and a profile section, which are joined together to create the desired die characteristics. Also disclosed is an adaptation die to convert a conventional non-injection die into an injection die. The adaption die comprises an entry section, a resin injection section and a transition section adapted for connection to the conventional die.

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Charlestown, MA, United States of America

Johan D Koppernaes