Method for manufacturing vehicle frame components using composite fiber

Abstract

An apparatus for manufacturing vehicle frame components using composite fiber pultrusion techniques includes one or more sources of a fibrous material. A bath or similar structure is provided for applying a resin material to the fibrous materials from the sources. Following the application of the resin, the fibrous materials are then pulled through a die. The die is formed having an opening therethrough which corresponds in shape to the desired cross sectional shape of the vehicle frame component to be manufactured. As the fibrous materials are pulled through the die, they conform to the shape of the opening formed therethrough. Because of the resin applied thereto, the fibrous materials adhere to one another to form a pultrusion which retains the shape of the opening formed through the die. The formed pultrusion is then pulled through a curing oven which heats the resin to a predetermined curing temperature, causing it to harden a rigid condition. As a result, the pultrusion as a whole acquires a desired rigidity. Movement of the fibrous materials and of the pultrusion is effected by means of a pulling device. Following passage through the pulling device, the pultrusion is cut to desired lengths by a conventional cutting machine. Additionally, openings of desired sizes and shapes may be formed in the pultrusion by a convention perforation machine. Pultrusions of different shapes and sizes may be used to form side rails which are permanently joined together by transversely extending cross members by adhesive to form the vehicle frame component.