Goldsworthy Engineering, Inc.

Mcdonnell Douglas Corporation

Other

Stoughton Composites, Inc.

William B Goldsworthy

Harald E Karlson

Ethridge E Hardesty

George Korzeniowski

An intermodal vehicle hauler, particularly, for the storage and transport of automotive vehicles such as passenger automobiles and the like. The vehicle hauler is generally rectangular in shape and is comprised of a pair of side walls, a roof and a floor, which are all made of a reinforced plastic composite materials. In a preferred embodiment, the side walls and even the roof may also be formed in a manner so that they are light translucent thereby enabling some light exposure to the interior of the vehicle hauler to facilitate loading and unloading of automotive vehicles.

Reinforced plastic composite intermodal vehicle hauler

A method for high speed continuous production of reinforced plastic sheets and reinforced plastic sheet laminate structures which may have widths ranging from relatively narrow to very wide. One or more layers of resin impregnated, fiber-containing, reinforced plastic composite material is brought into contact with surfaces of one or more endwise abutted relatively flat panels. The panel or panels are then passed between a pair of continuously rotating belts. A pressurized air body is formed in a plenum chamber which faces the interiorly presented surface of at least one of the belts and which air body is between the housing forming the plenum chamber and the interior surface of the belt. Preferably, a similar housing creates a pressurized air body between such similar housing and the other of the belts. In this way, the pressurized body of air forces the belts into intimate contact with the layers forming the reinforced plastic laminate structure. The body of air is generally at a uniform pressure in the area between the belts and associated housings. In like manner, a single sheet of resin impregnated fiber-containing material may be passed between the belts where the resin is cured during the application of pressure to form a rigid single ply sheet structure. The method may use an augmented cure so that a cure of the resin is initiated in a precuring mechanism, and the reaction proceeds to a final cure while the layer or layers pass between the belts. The belts may be heated so as to facilitate the curing of the resin matrix impregnated in the layer or layers containing the fiber-reinforcing material.

Method for producing fiber reinforced sheet structures

Apparatus for producing reinforced plastic sheets and reinforced plastic sheet laminate structures on a high speed continuous basis and which sheets and laminate structures may have widths ranging from relatively narrow to very wide. The apparatus comprises a means for bringing one or more layers of resin impregnated, fiber-containing, reinforced plastic composite material into contact with each other or into contact with surfaces of one or more endwise abutted relatively flat panels.

Apparatus for producing fiber reinforced plastic sheet structures

Reinforced plastic composite articles which have a non-constant cross-sectional shape over their length, such that a first portion of the article has a different cross-sectional shape than a second portion of the article, and which portions may be integral with each other. In one embodiment, the article may have a non-constant cross-sectional shape with a constant cross-sectional volume over its length. In another embodiment, the article may have a non-constant cross-sectional shape and non-constant cross-sectional volume over its length. An apparatus and a method which utilizes a die having a die channel of non-constant cross-sectional shape is employed. In the apparatus, a pair of first and second die-forming members are used, and form in one or both of the die-forming members a die channel having a first portion of a cross-sectional shape which is different than a cross-sectional of a second die channel portion over the length of the die channel. One of the die-forming members may move relative to the other or both may move together at a constant speed in order to effectively pultrude a reinforced plastic composite article.

Method for forming reinforced plastic composite articles

An apparatus and method for producing fiber reinforced plastic composite articles which have a length and where the shape of and volume of material in the composite across its length is not necessarily uniform. The apparatus receives filament containing reinforcing material, as for example, strands of filament reinforcing material impregnated with a hardenable binder such as a curable resin. The apparatus also includes a device for forming cores or plugs from a bulk-molding compound, roughly in the form of the desired shape of a portion of the article to be produced. Thereafter, the resin impregnated fiber containing reinforcing strands are disposed about each of the plugs which are draped over a continuous string to from a chain of the plugs on the string. The impregnated strands preferably enclose the plugs to form a composite therewith. Thereafter, a shrinkable film is wrapped about and encloses each of the strand encased plugs on the chain with the film sealed along its margins to completely enclose the plugs. Thereafter, the film is shrunk in a film shrunk tunnel. A suitable pre-curing device, e.g., a radio frequency generator initiates a cure of the curable resin binder impregnated in the strands. The fiber wrapped strand enclosed composite plugs are introduced into a final mold, containing a pair of split mold elements, which imparts the final shape to each of the articles to be produced. The final mold also applys a curing radiation to the film wrapped strand enclosed plugs to finally cure same to hardened reinforced plastic composite articles. A flash removal assembly provides for removal of excess material and thereafter, the shrinkable film is removed. The final articles are cut into the discrete composite articles.

Apparatus and method for producing reinforced plastic composite articles

Reinforced plastic composite articles and apparatus and method for

Apparatus for producing reinforced plastic sheets and reinforced plastic sheet laminate structures on a high speed continuous basis and which sheets and laminate structures may have widths ranging from relatively narrow to very wide. The apparatus comprises a means for bringing one or more layers of resin impregnated, fiber-containing, reinforced plastic composite material into contact with each other or into contact with surfaces of one or more endwise abutted relatively flat panels. The apparatus is provided with a pair of continuously rotating belts having a gap there between which receives the laminated sheets. A housing forming a plenum chamber faces the interiorly presented surface of one of the belts and causes a body of pressurized air to be formed between the housing and the interiorly presented surfaces of the belt. Preferably, a similar housing creates a pressurized air body between such similar housing and the other of the belts.

Apparatus for producing fiber-reinforced plastic sheet structures

A method for high speed continuous production of reinforced plastic sheets and reinforced plastic sheet laminate structures which may have widths ranging from relatively narrow to very wide. One or more layers of resin impregnated, fiber-containing, reinforced plastic composite material is brought into contact with surfaces of one or more endwise abutted relatively flat panels. The panel or panels are then passed between a pair of continuously rotating belts. A pressurized air body is formed in a plenum chamber which faces the interiorly presented surface of at least one of the belts and which air body is between the housing forming the plenum chamber and the interior surface of the belt. Preferably, a similar housing creates a pressurized air body between such similar housing and the other of the belts. In this way, the pressurized body of air forces the belts into intimate contact with the layers forming the reinforced plastic laminate structure. The body of air is generally at a uniform pressure in the area between the belts and associated housings. In like manner, a single sheet of resin impregnated fiber-containing material may be passed between the belts where the resin is cured during the application of pressure to form a rigid single ply sheet structure. The method may use an augmented cure so that a cure of the resin is initiated in a precuring mechanism, and the reaction proceeds to a final cure while the layer or layers pass between the belts. The belts may be heated so as to facilitate the curing of the resin matrix impregnated in the layer or layers containing the riber-reinforcing material.

Method for producing fiber-reinforced plastic sheet structures

A method and apparatus for continuously fabricating three-dimensional (3D) filament reinforced foam insulation slabs. Rows of X or longitudinal filaments are fed longitudinally into a machine in spaced, stacked horizontal planes. Rows of Y or transverse filaments are fed transversely into the machine in spaced, stacked horizontal planes. Z or vertical filaments are fabricated into units of four vertical spaced lengths of strands which fit into each of the vertical column squares formed by the X-Y filaments to form the continuous X-Y-Z orthogonal array. Urethane or equivalent foam is discharged onto a moving belt beneath the filamentary array which is moved in the same direction and at the same rate as the belt carrying the foam. The foam material froths or foams upwardly through the filamentary array as they move along to the next station for curing. After sufficient cure, the foamed array is cut from the frames and into desired length, forming planks.

Apparatus for continuously fabricating three-dimensional filament

Reinforced plastic tapered tubular rod products and the method and apparatus for producing the same. Tapered steel mandrels of desired length and cross-sectional shape are connected in endwise alignment to form a continuously moving mandrel structure. The mandrels each have an enlarged head and a tapered nose at the opposite end thereof so that the nose extends into a recess formed in the enlarged head of the next proceeding mandrel. These mandrels are fed through a multiplicity of winding wheels in which filament containing strands issued from spools on the wheels are helically wound upon the mandrels. The winding wheels are individually programmable so that the geometry of the reinforcement can be varied ply by ply to obtain the desired longitudinal thickness and the desired torsional stiffness in the end product. The mandrels are held in their endwise connected alignment and retained between the winding wheels by an upper feeding mechanism in the form of an upper conveyor and a lower conveyor located respectively above and below the winding wheels. The lower sets of winding wheels are provided with shrink tapes which are wound about the outer surface of the reinforcement fibers applied to the reinforcement bands wound on the mandrels. The mandrels are thereafter separated from each other and in such manner that the reinforced plastic products which are resin impregnated and finally cured can be removed from the mandrels and thereupon used in the final end products.

Reinforced plastic tapered rod products and the method and apparatus for

Method for continuously fabricating three-dimensional filament

A method and apparatus for continuously weaving fibers or filaments, particularly glass fiber filaments, into a scrim cloth, to serve as reinforcement in the fabrication of filament reinforced foam insulation slabs. The scrim cloth consisting of uniformly spaced filaments in the X (longitudinal) direction and Y (transverse) direction is fabricated by traversing the Y filaments between hooks attached to long moveable oppositely spaced side panels and by paying off bands of spaced X filaments at various locations between the Y traversing mechanism. One layer of scrim cloth is fabricated at each station, the desired number of stations for the respective layers being located sequentially along the length of the machine. In fabricating a single layer of cloth at any station, a rotatable vertical tube through which a continuous Y filament is payed from a remotely mounted spool, is moved on a cross slide mechanism transversely back and forth between the hooks on the side panels of the machine, the filament from the lower end of the tube being initially tied to the first hook. The motion of the cross slide and an arm mounted on the rotatable tube orients the Y filament on one hook or set of hooks on one side panel as the cross slide changes direction, and after traversing the distance between the side panels the cross slide and arm on the tube orients the Y filament on an oppositely facing hook or set of hooks on the opposite side panel. The X filaments for each layer are inserted as a band of spaced filaments, each such X filaments moving in the direction of longitudinal side panel travel and resting on the Y filaments.

Method and apparatus for fabricating open weave scrim cloth

A method and apparatus are described for the making of a three dimensional filament reinforced foam insulation member. Generally parallel arrays of vertically stacked fabric or cloth having filaments running in an X-Y axis are reinforced by third axis Z directional filaments pre-cut to a desired length and inserted down through openings referred to as vertical columns hereinafter through the said array. The Z filaments are air directed through the stack of open weave. After the formation of the filament reinforced weave the assembly is impregnated with foam to form a unitary member. The apparatus to form the article and carry out the method above consists of a conveyor carrying stacked open weave fabric through an open ended enclosure wherein there are provided first vertical tubes and second vertical tubes. The second vertical tubes are injected into the stack or array of open weave. The first vertical tubes are telescopically inserted into the tops of the said second vertical tubes. A filament is fed vertically downwardly into the first vertical tube and cut to a predetermined length. Compressed air in a chamber surrounding the said first vertical tube assists in forcing the filaments into the said second vertical tube. The said second vertical tube may be vibrated to prevent hang up of the desired Z directional filament. The said second set of vertical tubes are retracted from the array after the array is completely reinforced with Z directional filament. Thereafter foam insulating may fill the reinforced array. Additional cutters may be provided for trim purposes to remove excess Z directional filaments extending above the array.

Fiber insertion device for continuous 3D foaming machine and method

An apparatus and a method for fabricating on-site storage structures with reinforced composite materials, as well as the storage structures produced in accordance with the apparatus and method. In one aspect of the invention, reinforcing material which comprises at least one layer of fiber containing strand material, and one or more layers of fiber containing mat material are resin impregnated and passed through a draw-die orifice. Upon passing through the draw-die orifice this material is deposited in a continuously formed spiral where the turns forming the spiral are registered with each other. A cure of the resin material is initiated as the impregnated reinforcing material passes through the draw-die orifice. The cure is initiated by means of a curing device which applies dielectric energy to the impregnated reinforcing material, to thereby form a rigid spiral turn which becomes bonded to the next adjacent registered layer. In another aspect of the present invention, matrix impregnated reinforcing material is pultruded through a draw-die orifice and cured during the formation thereof as a continuous strip. This strip has the overall cross sectional shape and size of a turn in the storage structure and is coiled and retained in a dispensing container. This strip is then dispensed from the dispensing container and passed through an application head which deposits the strip in the form of a turn on a previously deposited turn and rigidly secures and bonds this turn to such previously deposited turn.

On-site wall structure formation

A composite strand of thermosetting synthetic plastic resin reinforced with fibers of conductive or semi-conductive material is produced by a pultrusion machine and process which forms and impregnates the composite strand and pulls it through the stage of impregnation, followed by curing, and forming. At the impregnation stage liquid thermosetting resin is mixed with hardener and the fiber strand saturated with the mixture and rough formed. During the initial curing stage a cure is started by heating the fibers by use of inductive electrical wave energy and the heated fibers in turn heat the resin. Before final curing, the saturated strand is pulled through the finish die where it may be externally heated and wherein the saturated strand is given its final cross-sectional shape and external finish, and cured to completion immediately prior to final emergence at the exit end of the finish die.

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Palos Verdes Estates, CA, United States of America

William B Goldsworthy