A profile and a method of forming the same

Abstract

The present disclosure provides a profile and a forming method thereof, the forming method comprising: forming continuous fibers coated with an infiltrating material into an initial profile; and coating a coating material in a molten state on the initial profile to form a profile, wherein the coating material comprises a thermoplastic material. The forming method of the profile provided by the present disclosure has good mechanical properties of the formed initial profile, and the coating layer formed on the surface of the profile has good weather resistance, ultraviolet resistance, anti-aging, hydrolysis resistance and wear resistance.

Description

Technical Field

[0001] This disclosure relates to the field of composite profile technology, and in particular to a profile and a method for forming the same. Background Technology

[0002] In the past two years, with the gradual rise in commodity prices, the rapid increase in prices of steel and aluminum has led to significant price increases in downstream products such as aluminum alloy doors and windows and aluminum alloy photovoltaic frames. To reduce costs, companies are urgently seeking alternative materials to replace existing aluminum products. Thermosetting, photocuring, and thermoplastic composite materials have been gradually developed and widely used due to their good mechanical properties and low, stable prices. However, due to the inherent characteristics of the resin matrix, composite materials generally have poor weather resistance and are difficult to expose directly to harsh external environments. Therefore, a weather-resistant coating is often applied to the surface of the composite material. Conventional weather-resistant coatings are generally weather-resistant paints, such as photocuring or thermosetting epoxy paints, or solvent-based spray paints. However, these paint coatings require a high degree of surface smoothness of the substrate, strict requirements on the working environment and process conditions, and are expensive. The problem this invention aims to solve is to coat the surface of pultruded products with a weather-resistant thermoplastic material to give the products good aging resistance, UV resistance, high temperature and humidity resistance, and high and low temperature resistance. Summary of the Invention

[0003] The following is an overview of the subject matter described in detail in this disclosure. This overview is not intended to limit the scope of the claims.

[0004] This disclosure provides a method for forming a profile, the method comprising:

[0005] The impregnated continuous fibers are molded into an initial profile;

[0006] The molten coating material is applied to the initial profile to form the profile;

[0007] In the initial profile, the continuous fibers and impregnating materials are expressed as a percentage by weight as follows:

[0008] Continuous fibers: 47.0%–94.0%;

[0009] The impregnation material is 6%–53%.

[0010] The coating material includes thermoplastic materials.

[0011] In some embodiments of this disclosure, the wetting material includes a resin or a thermoplastic material;

[0012] When the impregnation material comprises resin, the resin comprises 10-53% by weight.

[0013] When the impregnation material comprises a thermoplastic material, the weight percentage of the thermoplastic material is 6% to 20%.

[0014] In some embodiments of this disclosure,

[0015] The coating material comprises discontinuous fibers and thermoplastic materials, and the components of the coating material are expressed as a percentage by mass as follows:

[0016] Discontinuous fibers: 0%–60%;

[0017] Thermoplastic materials: 40%–100%.

[0018] In some embodiments of this disclosure, the initial profile comprises continuous fibers and thermoplastic resin; the coating material comprises discontinuous fibers and thermoplastic resin.

[0019] The mass percentage of the continuous fiber is the same as the mass percentage of the discontinuous fiber.

[0020] In some embodiments of this disclosure, applying a coating material to the initial profile to form the profile includes:

[0021] The coating material is extruded through an extrusion device and fed into a coating die;

[0022] The coating material is applied to the surface of the initial profile through the coating mold at a preset temperature and pressure to form a coating layer of a preset thickness, thereby forming the profile.

[0023] In some embodiments of this disclosure, the input speed of the coating material to the coating mold is 15-25 r / min;

[0024] The extrusion speed of the coating material in the extrusion equipment is 350-500 r / min;

[0025] The preset temperature is 180–280°C;

[0026] The preset pressure is 0.8 to 2 MPa.

[0027] In some embodiments of this disclosure, the ratio of the initial profile thickness to the coating thickness is 1:1 to 20:1.

[0028] In some embodiments of this disclosure, after forming a coating layer of a predetermined thickness, the forming method further includes:

[0029] The initial profile after the coating layer is formed is cooled by a gradient cooling method; the gradient cooling includes at least a first cooling stage and a second cooling stage; the temperature of the first coolant in the first cooling stage is 60-120°C and the cooling time of the first cooling stage is 30-60s; the temperature of the second coolant in the second cooling stage is 5-25°C and the cooling time of the second cooling stage is 30-60s.

[0030] The initial profile after the coating layer is formed is dried using an airflow at a preset temperature; the preset temperature is 40-50°C, the airflow velocity is 5-7 m / s, and the drying time is 5-10 s.

[0031] A second aspect of this disclosure provides a profile formed by the above-described profile forming method.

[0032] In some embodiments of this disclosure, the thickness ratio of the initial profile to the coating layer in the profile is 1:1 to 20:1.

[0033] The profile and its forming method provided in this disclosure have good mechanical properties. The initial profile formed by mixing the impregnating material and continuous fibers has good mechanical properties. The coating material composed of weather-resistant thermoplastic material can provide the profile surface with good weather resistance, UV resistance, aging resistance and hydrolysis resistance. In addition, since the coating material has good hardness, it can effectively improve the wear resistance of the coating layer formed on the profile surface. Attached Figure Description

[0034] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present disclosure and, together with the description, serve to explain the principles of these embodiments. In these drawings, similar reference numerals are used to denote similar elements. The drawings described below are some embodiments of the present disclosure, but not all embodiments. Other drawings will be readily available to those skilled in the art based on these drawings without inventive effort.

[0035] Figure 1 A flowchart illustrating a method for forming a profile, as shown in an exemplary embodiment of this disclosure;

[0036] Figure 2 A flowchart illustrating a method for forming a profile, as shown in an exemplary embodiment of this disclosure;

[0037] Figure 3 A flowchart illustrating a method for forming a profile, as shown in an exemplary embodiment of this disclosure; Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, the technical solutions in the disclosed embodiments will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this disclosure. All other embodiments obtained by those skilled in the art based on the embodiments of this disclosure without creative effort are within the scope of protection of this disclosure. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of this disclosure can be arbitrarily combined with each other.

[0039] The weather-resistant coatings commonly used on profile surfaces are generally weather-resistant paints, such as UV-cured or thermosetting epoxy paints, or solvent-based spray paints. However, these paint coatings have high requirements for the smoothness of the substrate surface, strict requirements for the working environment and process conditions, and are expensive.

[0040] To address the aforementioned technical problems, this disclosure provides an exemplary embodiment of a method for forming a profile, wherein the initial profile formed has good mechanical properties; and the coating layer formed on the surface of the profile has good weather resistance, UV resistance, aging resistance, hydrolysis resistance, and wear resistance.

[0041] The method for forming the profile provided by the present invention will now be described in detail with reference to the accompanying drawings.

[0042] An exemplary embodiment of this disclosure provides a method for forming a profile, such as... Figure 1 As shown, it includes the following steps:

[0043] S100A: The impregnated continuous fiber is formed into an initial profile.

[0044] For example, the initial profile can be formed by curing or extrusion molding to form the initial profile. The curing method can include heat curing and UV curing. The heating temperature of at least one first region in heat curing can be set to 100-150°C, the heating temperature of at least one second region can be set to 150-180°C, and the heating temperature of at least one third region can be set to 180-210°C. The irradiation wavelength of UV curing can be set to 280-500nm. The extrusion molding temperature can be set to 130-190°C, and the molding pressure can be set to 50-70MPa.

[0045] S200A: Applying molten coating material onto the initial profile to form the profile.

[0046] For example, the coating material includes a thermoplastic material, and in the initial profile, the continuous fibers and impregnation material are expressed as a percentage by weight as follows:

[0047] Continuous fibers: 47.0%–94.0%;

[0048] The impregnation material is 6%–53%.

[0049] For example, continuous fibers may include long fibers or medium-length fibers, specifically including boron fibers, glass fibers, carbon fibers, silicon carbide fibers, aramid fibers, ultra-high strength polyethylene fibers, etc.

[0050] In this embodiment, the initial profile is formed by mixing continuous fibers and surface-coating impregnation materials, which ensures the mechanical properties of the resulting initial profile. The coating material composed of weather-resistant thermoplastic material can provide the profile surface with good weather resistance, UV resistance, aging resistance and hydrolysis resistance. In addition, the coating material containing thermoplastic material has good hardness, so it can effectively improve the wear resistance of the coating layer formed on the profile surface.

[0051] In one embodiment, the impregnation material comprises a resin or a thermoplastic material; when the impregnation material comprises a resin, the weight percentage of the resin is 10% to 53%; when the impregnation material comprises a thermoplastic material, the weight percentage of the thermoplastic material is 6% to 20%.

[0052] In this embodiment, the continuous fibers are mixed with liquid resin, which effectively enhances the adhesion of the initial profile. Moreover, the increase in resin can reduce the fiber content while ensuring the profile performance, thereby improving the welding performance of the profile. The continuous fibers and molten thermoplastic material are mixed and molded into the initial profile, which ensures the longitudinal and transverse properties of the resulting initial profile, giving the initial profile tensile and compressive strength.

[0053] For example, the resin can be one or more of thermosetting resins such as epoxy resin, acrylic resin, and polyurethane, and the resin can also be one or more of photocurable resins such as epoxy acrylate, polyurethane acrylate, polyester acrylate, and polyether acrylate. The thermoplastic material can include one or more of weather-resistant nylon, polyphenylene ether, and ASA (Acrylonitrile Styreneacrylate copolymer) plastic. When the resin is a thermosetting resin, the surface of the continuous fiber can be coated with thermosetting resin, and then pultruded to a molding die and output as an initial profile by thermocuring. When the resin is a photocurable resin, the surface of the continuous fiber can be coated with photocurable resin, and then pultruded to a molding die and formed as an initial profile by photocuring. When the impregnation material is a thermoplastic material, the surface of the continuous fiber can be impregnated with a molten thermoplastic material after heating, and then extruded through a molding die to form an initial profile.

[0054] In one embodiment, the coating material comprises discontinuous fibers and thermoplastic materials, and the components of the coating material are expressed as a percentage by mass as follows:

[0055] Discontinuous fibers: 0%–60%;

[0056] Thermoplastic materials: 40%–100%.

[0057] In this embodiment, the coating material can be composed solely of thermoplastic materials. The resulting coating layer exhibits excellent smoothness and high toughness, which is beneficial for improving the impact resistance of the profile. It also meets various requirements such as achieving device thinness, solvent resistance, heat fusion properties, and weather resistance, while being relatively cost-effective and yielding high product quality. Alternatively, the coating material can be formed by mixing discontinuous fibers and molten thermoplastic materials. The addition of discontinuous fibers significantly increases the heat resistance of the coating material. Furthermore, the addition of discontinuous fibers restricts the movement between polymer chains in the plastic, thus greatly reducing the shrinkage rate of the thermoplastic material and significantly improving its rigidity, preventing stress cracking in the coating layer.

[0058] For example, discontinuous fibers may include chopped fibers, specifically boron fibers, glass fibers, carbon fibers, silicon carbide fibers, etc.

[0059] In one embodiment, when the initial profile comprises continuous fibers and thermoplastic resin, and the coating material comprises discontinuous fibers and thermoplastic resin, the mass percentage of continuous fibers and the mass percentage of discontinuous fibers can be the same. That is, the composition of the initial profile and the coating material can be the same. This can improve the adhesion stability between the coating material and the initial profile, effectively avoiding the problem of coating layer peeling off during long-term use. In addition, because the composition is consistent, when the coating material is applied to the surface of the initial profile, the overall external smoothness of the profile is higher, resulting in a better appearance. Alternatively, the mass percentage of continuous fibers and the mass percentage of discontinuous fibers can also be different. In this case, the coating material and the initial profile can still maintain good stability, and the resulting profile has good mechanical properties and a better appearance.

[0060] In some exemplary embodiments, the initial profile may be composed of continuous fibers and resin, wherein the continuous fibers may include glass fibers and the resin may include epoxy resin; the coating material may be composed of a thermoplastic material, wherein the thermoplastic material may include weather-resistant nylon; the mass percentage of each component of the initial profile may include:

[0061] Glass fiber content: 47.0%–94.0%;

[0062] Epoxy resin content: 10.0%–53.0%.

[0063] In some exemplary embodiments, the initial profile may be composed of continuous fibers and resin, wherein the continuous fibers may include silicon carbide fibers and carbon fibers, and the resin may include epoxy acrylate and polyurethane acrylate; the coating material may be composed of a thermoplastic material, which may include ASA plastic; the mass percentage of each component of the initial profile may include:

[0064]

[0065] In some exemplary embodiments, the initial profile may be composed of continuous fibers and resin, wherein the continuous fibers may include glass fibers and the resin may include polyurethane; the coating material may be composed of thermoplastic materials and discontinuous fibers, wherein the thermoplastic materials may include polyphenylene ether and the discontinuous fibers may include boron fibers; the mass percentage of each component of the initial profile may include:

[0066] Glass fiber content: 47.0%–94.0%;

[0067] Polyurethane 10.0–53.0%;

[0068] The mass percentage of each component in the coating material can include:

[0069] Boron fiber content: 0%–60.0%;

[0070] Polyphenylene ether 40.0%–100.0%.

[0071] In some exemplary embodiments, the initial profile may be composed of continuous fibers and resin, wherein the continuous fibers may include glass fibers and the resin may include polyester acrylate; the coating material may be composed of thermoplastic materials and discontinuous fibers, wherein the thermoplastic materials may include weather-resistant nylon and the discontinuous fibers may include boron fibers and glass fibers; the mass percentage of each component of the initial profile may include:

[0072] Glass fiber content: 47.0%–94.0%;

[0073] Acrylic resin 10.0–53.0%;

[0074] The mass percentage of each component in the coating material can include:

[0075] Glass fiber content: 0–45.0%;

[0076] Aramid fiber content: 0–25.0%;

[0077] Weather-resistant nylon 40%–100%.

[0078] In some exemplary embodiments, the initial profile may be composed of continuous fibers and thermoplastic materials, wherein the continuous fibers may include carbon fibers and the thermoplastic materials may include ASA plastic; the coating material may be composed of thermoplastic materials, such as weather-resistant nylon; the mass percentage of each component of the initial profile may include:

[0079] Carbon fiber content: 47.0%–94.0%;

[0080] ASA plastics: 6.0%–20.0%.

[0081] In some exemplary embodiments, the initial profile may be composed of continuous fibers and thermoplastic materials. The continuous fibers may include glass fibers and silicon carbide fibers, and the thermoplastic materials may include weather-resistant nylon and polyphenylene oxide. The coating material may be composed of thermoplastic materials, which may include polyphenylene oxide and ASA plastic. The mass percentage of each component of the initial profile may include:

[0082]

[0083] The mass percentage of each component in the coating material can include:

[0084] Polyphenylene ether 25.5–65.0%;

[0085] ASA plastics: 35.0%–74.5%.

[0086] In some exemplary embodiments, the initial profile may be composed of continuous fibers and thermoplastic materials, wherein the continuous fibers may include glass fibers and the thermoplastic materials may include weather-resistant nylon; the coating material may be composed of thermoplastic materials and discontinuous fibers, wherein the thermoplastic materials may include polyphenylene ether and the discontinuous fibers may include boron fibers; the mass percentage of each component of the initial profile may include:

[0087] Glass fiber content: 47.0%–94.0%;

[0088] Weather-resistant nylon 6.0–20.0%;

[0089] The mass percentage of each component in the coating material can include:

[0090] Boron fiber 0%–60%;

[0091] Polyphenylene ether 40%–100%.

[0092] In some exemplary embodiments, the initial profile may be composed of continuous fibers and thermoplastic materials, wherein the continuous fibers may include glass fibers and the thermoplastic materials may include ASA plastic; the coating material may be composed of thermoplastic materials and discontinuous fibers, wherein the thermoplastic materials may include ASA plastic and the discontinuous fibers may include glass fibers; the mass percentage of each component of the initial profile may include:

[0093] Glass fiber content: 47.0%–94.0%;

[0094] ASA plastics: 6.0–20.0%;

[0095] The mass percentage of each component in the coating material can include:

[0096] Glass fiber content: 0-60.0%;

[0097] ASA plastics: 40%–100%.

[0098] In one embodiment, the ratio of the initial profile thickness to the coating thickness is 10:1 to 20:1.

[0099] For example, the ratio of the initial profile thickness to the coating thickness can be determined based on the composition ratio of the coating material.

[0100] like Figure 2 As shown, step S200A includes the following steps:

[0101] S210A: The coating material is output to the coating die via an extrusion device.

[0102] For example, the extrusion speed of the coating material in the extrusion equipment can be 350-500 r / min; the input speed of the coating material into the coating die can be 15-25 r / min; the die head temperature of the extrusion equipment can be 190-210°C, the temperature of the feeding section can be set to 180-200°C, the temperature of the compression end can be set to 170-190°C, and the temperature of the homogenization end can be set to 220-260°C.

[0103] S220A: The coating material is applied to the surface of the initial profile through a coating mold at a preset temperature and pressure to form a coating layer of a preset thickness, thereby forming the profile.

[0104] For example, the preset temperature can be 220-280°C; the preset temperature is the heating temperature of the coating material by the coating mold when the coating material is injected into the mold cavity of the coating mold. The coating material is kept in a molten state by heating the coating material by the coating mold, so as to ensure the uniformity and integrity of the coating layer after the initial profile is output from the coating mold, and to avoid the problem of incomplete coating. The preset pressure can be 0.8-2MPa; the preset pressure is the pressure on the coating material between the initial profile and the mold cavity of the coating mold when the coating material is injected into the mold cavity of the coating mold. The preset pressure is applied to ensure the tightness of the coating layer and to avoid the generation of air bubbles during the coating process of the molten coating material, which would affect the quality of the coating layer formed by subsequent curing.

[0105] In this embodiment, the initial profile is introduced into the cavity of the coating mold, and the coating material is melted and extruded by the extrusion equipment. The melt is integrated and extruded at a certain angle with the initial profile in the coating mold through the connecting channel, so that the residual gas in the space between the coating mold and the initial profile is squeezed out and occupied by the melt, thereby achieving the removal of residual gas. This maximizes the impregnation and coating of the initial profile with the melt until the fully coated initial profile is discharged from the outlet of the coating mold. The coating layer formed by the coating mold can firmly adhere to the surface of the initial profile, thereby providing good protection for the profile coating material.

[0106] Another exemplary embodiment of this disclosure provides a method for forming a profile, such as... Figure 3 As shown, it includes the following steps:

[0107] S100B: Forming continuous fibers coated with impregnated material into an initial profile.

[0108] S200B: Applying molten coating material onto an initial profile to form a profile.

[0109] In this embodiment, steps S100B and S200B are the same as the aforementioned steps S100A and S200A, and will not be described again here.

[0110] S300B: The initial profile after the coating layer is formed is cooled and dried to form a profile.

[0111] For example, a gradient cooling method can be used to cool the initial profile after the coating layer is formed. The gradient cooling includes at least a first cooling stage and a second cooling stage. In the first cooling stage, the temperature of the first coolant can be 60-70°C, and the cooling time can be 30-60 seconds. In the second cooling stage, the temperature of the second coolant can be 15-25°C, and the cooling time can be 30-60 seconds. The coating layer is initially cooled by the higher-temperature first coolant in the first cooling stage, allowing the coating layer to initially solidify. This avoids the high-temperature coating material directly entering a low-temperature environment, which could cause internal stress in the coating layer structure under rapid cooling and lead to cracking later. The coating layer is then finally cooled by the lower-temperature coolant in the second cooling stage, achieving final solidification. The gradient cooling of the coating layer by the gradually decreasing first and second coolants ensures the stability of the coating layer attached to the surface of the initial profile. The initial profile after the coating layer is formed is dried by airflow at a preset temperature; the preset temperature can be 40-50℃, the airflow velocity can be 5-7m / s, and the drying time can be 5-10s.

[0112] Gradual cooling is used to achieve gradual curing of the coating layer, thereby accelerating the curing speed of the molten coating material, speeding up the process, and ensuring the stability of the coating layer adhering to the initial profile surface. This avoids the problem of cracking in the coating layer caused by internal stress generated in the structure after rapid cooling.

[0113] S400B: Cutting and packaging of profiles.

[0114] For example, profiles can be cut and packaged according to actual needs to form finished products of specific specifications.

[0115] In this embodiment, continuous fibers can be uniformly and thoroughly mixed with liquid resin or molten thermoplastic material. Then, through a molding die, the initial profile can be formed by curing or extrusion molding. Curing methods can include heat curing and UV curing. The molded profile is then passed through a coating die, which is connected to an extrusion device. The extrusion device continuously injects heated molten thermoplastic material into the coating die. The profile passes through the coating die and comes into contact with the coating material inside. Under specific die temperature and pressure, it is drawn out from the die opening. A coating layer is formed on the surface of the profile, and the thickness of this coating layer can be precisely controlled by the coating die. The profile carrying the coating layer is then cooled and dried. This ensures the mechanical properties of the coating layer and gives it a better appearance. The power for the entire profile can be provided by traction. After completing the above steps, the profile can be cut and packaged according to customer size standards to form finished products of specific specifications.

[0116] An exemplary embodiment of this disclosure also provides a profile formed by the above-described method for forming profiles.

[0117] In this embodiment, the initial profile with the surface covered with the impregnation material ensures the mechanical properties of the resulting initial profile. The coating material composed of weather-resistant thermoplastic material can provide the profile surface with good weather resistance, UV resistance, aging resistance and hydrolysis resistance. In addition, the coating material containing thermoplastic material has good hardness, so it can effectively improve the wear resistance of the coating layer formed on the profile surface.

[0118] In one embodiment, the thickness ratio of the initial profile to the coating layer in the profile is 10:1 to 20:1.

[0119] For example, the ratio of the initial profile thickness to the coating thickness can be determined based on the composition ratio of the coating material.

[0120] The following are specific embodiments of the method for forming profiles according to the present invention.

[0121] Table 1. Specific composition of the initial profiles in each embodiment.

[0122]

[0123] Table 2 shows the specific composition of the coating materials in each embodiment.

[0124]

[0125] The specific formulations for Examples 1-8 are as follows:

[0126] Example 1

[0127] The mass percentage of each component in the initial profile can include:

[0128] 90.0% glass fiber;

[0129] Epoxy resin 10.0%;

[0130] The mass percentage of each component in the coating material can include:

[0131] 100.0% weather-resistant nylon.

[0132] Example 2

[0133] The mass percentage of each component in the initial profile can include:

[0134]

[0135]

[0136] The mass percentage of each component in the coating material can include:

[0137] ASA plastic 100.0%.

[0138] Example 3

[0139] The mass percentage of each component in the initial profile can include:

[0140] Glass fiber 47.0%;

[0141] Polyurethane 53.0%; the mass percentage of each component in the coating material may include:

[0142] Boron fiber 60.0%;

[0143] Polyphenylene ether 40.0%.

[0144] Example 4

[0145] The mass percentage of each component in the initial profile can include:

[0146] Glass fiber 68.5%;

[0147] Acrylic resin 31.5%; the mass percentage of each component in the coating material may include:

[0148] 25.0% glass fiber;

[0149] Aramid fiber 20.0%;

[0150] Weather-resistant nylon 55.0%.

[0151] Example 5

[0152] The mass percentage of each component in the initial profile can include:

[0153] Carbon fiber 94.0%;

[0154] ASA plastic 6.0%; the mass percentage of each component in the coating material may include:

[0155] 100.0% weather-resistant nylon.

[0156] Example 6

[0157] The mass percentage of each component in the initial profile can include:

[0158] Ultra-high strength polyethylene fiber 52.5%;

[0159] Silicon carbide fiber 33.5%;

[0160] Weather-resistant nylon 6.5%;

[0161] Polyphenylene ether 7.5%.

[0162] The mass percentage of each component in the coating material can include:

[0163] Polyphenylene ether 41.5%;

[0164] ASA plastics account for 58.5%.

[0165] Example 7

[0166] The mass percentage of each component in the initial profile can include:

[0167] 80.0% glass fiber;

[0168] Weather-resistant nylon 20.0%;

[0169] The mass percentage of each component in the coating material can include:

[0170] Boron fiber 50.0%;

[0171] Polyphenylene ether 50.0%.

[0172] Example 8

[0173] The mass percentage of each component in the initial profile can include:

[0174] 53.5% glass fiber;

[0175] Weather-resistant nylon 46.5%;

[0176] The mass percentage of each component in the coating material can include:

[0177] Boron fiber 53.5%;

[0178] Polyphenylene ether 46.5%.

[0179] The various properties of the profiles can be tested using appropriate testing methods:

[0180] UV resistance: UV lamps, such as UVA or UVB, can be used to irradiate the profiles of each embodiment under ultraviolet light with a wavelength of 280-400nm for 5-8 hours. The surface color change of each embodiment after UV irradiation can be observed visually. If the surface color change is small or nonexistent, it is judged as having good UV resistance. If the color change is large, it is judged as having poor UV resistance.

[0181] Abrasion resistance: The abrasion resistance of the profiles in each embodiment can be tested by the drop sand method. Specifically, a hopper for storing abrasive can be formed above the profile. By controlling a certain amount of abrasive to flow out to the surface of the profile, the abrasion resistance of the coating is expressed by the amount of abrasive required to wear down a unit film thickness of the coating.

[0182] Tensile strength: The change rate of tensile strength before and after the high-pressure accelerated aging life test, which is measured by a tensile strength tester (manufacturer: Instron) after 24 hours at a temperature of 80°C and 100% humidity using an autoclave, can be used to evaluate the profile's resistance to damp heat aging.

[0183] Abrasion resistance: Place the profile on a flat surface and use a pointed pin to move along the surface of the profile with small loads (0.5 kg increments) one by one. Each profile needs to be tested at least 5 times with the pointed pin until the coating is scratched. The load at which scratches appear on the surface of the coating is used as the criterion for judging abrasion resistance.

[0184] Table 2 Technical Specifications of Each Embodiment

[0185]

[0186] As can be seen from the table above, the profile formed by the profile forming method of the present invention has good UV resistance, wear resistance and abrasion resistance, and the profile as a whole has good tensile strength. In addition, since thermoplastic materials themselves have good hydrolysis resistance, the profile with the coating layer formed on the surface also has good hydrolysis resistance.

[0187] In summary, the profile formed by the profile forming method provided by the present invention has good weather resistance, the coating material attached to the surface of the profile can provide good protection for the profile, the quality of the product can well meet the requirements of customers, and the manufacturing cost of the profile is low, which is suitable for production needs.

[0188] The various embodiments or implementation methods described in this specification are presented in a progressive manner. Each embodiment focuses on the differences from other embodiments, and the same or similar parts between the embodiments can be referred to each other.

[0189] In the description of this specification, references to the terms "embodiment," "exemplary embodiment," "some implementation," "illustrated implementation," "example," etc., refer to specific features, structures, materials, or characteristics described in connection with an implementation or example that are included in at least one implementation or example of this disclosure.

[0190] In this specification, the illustrative expressions of the terms used do not necessarily refer to the same implementation or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more implementations or examples.

[0191] In the description of this disclosure, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this disclosure and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this disclosure.

[0192] It is understood that the terms "first," "second," etc., as used in this disclosure may be used to describe various structures, but these structures are not limited by these terms. These terms are only used to distinguish one structure from another.

[0193] In one or more accompanying drawings, the same elements are represented by similar reference numerals. For clarity, many parts in the drawings are not drawn to scale. Furthermore, certain well-known parts may not be shown. For simplicity, a structure obtained after several steps may be depicted in a single drawing. Many specific details of this disclosure, such as the structure, materials, dimensions, processing methods, and techniques of the devices, are described below to provide a clearer understanding of the disclosure. However, as those skilled in the art will understand, this disclosure may be implemented without adhering to these specific details.

[0194] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this disclosure, and are not intended to limit them. Although this disclosure has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this disclosure.

Claims

1. A method for forming a profile, characterized in that, The forming method includes: The continuous fibers coated with impregnated material are molded into an initial profile; The step of forming the continuous fibers coated with impregnating material into an initial profile includes: forming the continuous fibers coated with impregnating material into an initial profile by curing molding or extrusion molding. The curing process includes heat curing or UV curing. The heating and curing molding method is set as follows: the heating temperature of at least one first region is 100-150°C, the heating temperature of at least one second region is 150-180°C, and the heating temperature of at least one third region is 180-210°C. The UV curing molding method is set to an irradiation wavelength of 280–500 nm; The extrusion molding temperature is set to 130–190°C, and the molding pressure is set to 50–70 MPa. The molten coating material is applied to the initial profile to form the profile; In the initial profile, the continuous fibers and impregnating materials are expressed as a percentage by weight as follows: Continuous fibers: 47.0%~94.0%; Impregnating material 6%~53%; The coating material includes thermoplastic materials; The coating material includes discontinuous fibers and thermoplastic materials, wherein the discontinuous fibers are used to restrict the mutual movement between polymer chains of the plastic; The step of coating the initial profile with a molten coating material to form the profile includes: The coating material is extruded through an extrusion device and fed into a coating die; The coating material is applied to the surface of the initial profile through the coating mold at a preset temperature and pressure to form a coating layer of a preset thickness, thereby forming the profile. The input speed of the coating material into the coating mold is 15~25 r / min; The extrusion speed of the coating material in the extrusion equipment is 350-500 r / min; The ratio of the initial profile thickness to the coating thickness is 1:1 to 20:1; The extrusion equipment has a die head temperature of 190~210℃, a feeding section temperature of 180~200℃, a compression end temperature of 170~190℃, and a homogenization end temperature of 220~260℃.

2. The method for forming a profile according to claim 1, characterized in that, The impregnation material includes resin or thermoplastic material; When the impregnation material comprises resin, the resin accounts for 10-53% by weight. When the impregnation material comprises a thermoplastic material, the weight percentage of the thermoplastic material is 6% to 20%.

3. The method for forming the profile according to any one of claims 1-2, characterized in that, The components of the coating material are expressed as a percentage by mass as follows: Discontinuous fibers: 0%~60%; Thermoplastic materials: 40%~100%.

4. The method for forming the profile according to claim 3, characterized in that, The mass percentage of the continuous fiber is the same as the mass percentage of the discontinuous fiber.

5. The method for forming a profile according to claim 1, characterized in that, The preset temperature is 180~280℃; The preset pressure is 0.8~2MPa.

6. The method for forming a profile according to claim 1, characterized in that, After forming a coating layer of a predetermined thickness, the forming method further includes: The initial profile after the coating layer is formed is cooled by a gradient cooling method; the gradient cooling includes at least a first cooling stage and a second cooling stage; the temperature of the first coolant in the first cooling stage is 60~120℃ and the cooling time of the first cooling stage is 30~60s; the temperature of the second coolant in the second cooling stage is 5~25℃ and the cooling time of the second cooling stage is 30~60s. The initial profile after the coating layer is formed is dried using an airflow at a preset temperature; the preset temperature is 40~50℃, the airflow velocity is 5~7m / s, and the drying time is 5~10s.

7. A profile, characterized in that, The profile is formed by the profile forming method according to any one of claims 1-6.

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