Method for manufacturing composite material

Abstract

1. A method for manufacturing a structural member, comprising the steps of: preheating a plurality of fibers (5) to a first temperature; moving the preheated fibers along an assembly line (10); applying a binder (25) having a viscosity less than 25 centipoise to at least one of the preheated fibers; providing a die (30) configured to receive the preheated fibers, the die moving with the preheated fibers along at least a portion of the assembly line; maintaining a temperature of the plurality of fibers at a temperature substantially similar to the first temperature; and compressing the plurality of fibers in the die while maintaining the temperature.

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the priority of U.S. Provisional Patent Application No. 62 / 934,158, filed on November 12, 2019, the entire disclosure of which is incorporated herein by reference.

[0002] The present invention relates to a method for manufacturing a composite material, and more specifically, to a method for manufacturing a fiber - reinforced polymer material.

Background Art

[0003] Fiber - reinforced polymers typically include fiber materials bound by a matrix provided by a binder such as a resin. Conventionally, fiber - reinforced polymers have been manufactured using a pultrusion process, an example of which is shown in FIG. 1.

[0004] In the pultrusion process, the drawn fiber 5 is drawn through the production line 10 by a pulling mechanism 15 such as a set of driving rollers 20. The fiber 5 is drawn into a solution bath 25 containing one of various binders. When wetted, the fiber 5 is drawn through a fixed die 30, which can have one or more heating zones to initiate the curing of the binder. In the pultrusion process, the die 30 serves several functions. It causes a pressure to promote wetting of the fiber 5, heats the binder and the fiber 5, controls the curing of the binder, and controls the final shape of the pultruded product.

Summary of the Invention

Problems to be Solved by the Invention

[0005] Binders have curing characteristics determined by chemical reactions (such as curing, cross - linking, drying, etc.). These curing characteristics are functions of the chemical reaction of the binder, the process temperature, and the residence time at the process temperature. As the production speed increases, it becomes increasingly difficult to ensure proper curing of the binder.

[0006] The conventional drawing forming process shown in FIG. 1 has inherent constraints that significantly impede the speed of the process. The length of the die 30 is a direct constraint on the speed of the process, and process temperature, process friction, and removal of process gas impose other limiting constraints. The binder solution tank 25 exhibits its own drawbacks, which include the difficulty of mixing and maintaining a multi-part reactive binder, the excessive amount of waste, and the high operating costs resulting from the large amount of binder typically required to fill the solution tank 25. Conventionally, when one or more fast-curing thermosetting polymers and / or multi-component thermosetting polymers are utilized as part of the binder, manufacturing fiber-reinforced products has been cost-ineffective, at least for the reasons described above.

Means for Solving the Problems

[0007] In some embodiments, the present invention provides a method of manufacturing a structural member. The method includes preheating a plurality of fibers to a first temperature, moving the preheated fibers along an assembly line, and applying a binder to at least one of the preheated fibers, wherein when the binder is applied, the fibers are spaced apart and spread in a first region. The binder has a viscosity of less than 25 centipoise (cP). The method further includes providing a die having a first portion of a first diameter arranged to receive the preheated fibers and a second portion of a second diameter arranged downstream of the first portion, wherein the first diameter is greater than the second diameter and the die is tapered between the first portion and the second portion. The method further includes guiding the plurality of fibers along the die after applying the binder. The method further includes reducing the distance between the plurality of fibers using the die, wherein after reducing the distance between the plurality of fibers, the fibers spread in a second region smaller than the first region, and further includes maintaining the temperature of the plurality of fibers at a temperature substantially the same as the first temperature after reducing the distance. The method further includes shaping the plurality of fibers at a first shaping station while maintaining the temperature, shaping the plurality of fibers at a second shaping station spaced apart from the first shaping station while maintaining the temperature, and shaping the plurality of fibers at a third shaping station spaced apart from the first shaping station and the second shaping station while maintaining the temperature.

[0008] In some embodiments, the present invention provides a method of manufacturing a structural member. The method includes preheating a plurality of fibers to a first temperature, moving the preheated fibers along an assembly line, and applying a binder to at least one of the preheated fibers, wherein when the binder is applied, the fibers are spaced apart and spread in a first region. The binder has a viscosity of less than 25 centipoise (cP). The step of applying the binder includes at least one of spraying the binder onto at least one of the plurality of fibers and extruding the binder from a pressure chamber and drawing at least one fiber through the extruded binder. The method further includes guiding the preheated fibers along a die after applying the binder and reducing the distance between the plurality of fibers using the die, wherein after reducing the distance between the plurality of fibers, the fibers spread in a second region smaller than the first region. The method further includes maintaining the temperature of the plurality of fibers at a temperature substantially the same as the first temperature after reducing the distance. The method further includes shaping the plurality of fibers using a first shaping station while maintaining the temperature, shaping the plurality of fibers using a second shaping station spaced apart from the first shaping station while maintaining the temperature, and shaping the plurality of fibers using a third shaping station spaced apart from the first and second shaping stations while maintaining the temperature.

[0009] In some embodiments, the present invention includes a method of manufacturing a continuous structural member. The method includes preheating a plurality of fibers to a first temperature, moving the preheated fibers along an assembly line, applying a binder having a viscosity of less than 25 centipoise (cP) to at least one of the preheated fibers, providing a die shaped to receive the preheated fibers, wherein the die moves with the preheated fibers along at least a portion of the assembly line, maintaining the temperature of the plurality of fibers at a temperature substantially the same as the first temperature, and compressing the plurality of fibers within the die while maintaining the temperature.

[0010] Other features and aspects of the present invention will become apparent upon consideration of the following detailed description and the accompanying drawings.

Brief Description of the Drawings

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[0012] Before describing in detail some embodiments of the present invention, it is to be understood that the present invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The present invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting.

[0013] FIGS. 2 and 3 show an assembly line 100 for manufacturing a composite material (i.e., a matrix composite material) for a fiber-reinforced polymer (FRP) structure. The structural composite material can form a wide variety of structural members such as reinforcing bars, I-beams, C-channels, tubular bodies, structural laminates, and the like. The illustrated assembly line 100 includes a roving station 105, a binder application station 110, and a plurality of molding stations 115. In some embodiments, additional stations or alternative stations can be included within the assembly line 100. The assembly line 100 is generally linear and defines a central axis 120 along which the structural composite material is manufactured (FIG. 3). As will be described in more detail herein, the assembly line 100 enables the high-speed continuous manufacture of the FRP structural composite material.

[0014] The roving station 105 includes a plurality of spools or bobbins 125 that support and distribute the twist or roving of fibers 130 that will be included in the structural composite material. In the illustrated embodiment, the fibers 130 include basalt, but the fibers 130 can include glass, aramid, carbon, or some other desired fiber material. The bobbin 125 can be coupled to a power drive system that controls the fiber feed rate. In such an embodiment, a dancer or other automatic tension control device (not shown) can be provided to maintain a consistent tension on the fibers 130.

[0015] After being distributed from the bobbin 125, the fibers 130 pass through a guide assembly 135 that positions the fibers 130 for wetting at the binder application station 110 (Figs. 3 and 4). In some embodiments, the guide assembly 135 can position the fibers 130 in a plane to provide a relatively large rectangular surface area for wetting. Alternatively, the guide assembly 135 can position the fibers 130 in other patterns such as a cylindrical, tubular, or helical pattern.

[0016] In some embodiments, the roving station 105 includes one or more heating elements (not shown) for preheating the fibers 130 to a desired temperature before the fibers 130 are distributed to the binder application station 110. The heating elements can be disposed inside or outside the bobbin 125. For example, heated air can be directed at the fibers 130 as they exit the roving station 105. The step of preheating the fibers 130 can reduce the energy input required at the binder application station 110 and can help stabilize the binder curing process, as will be described in more detail below.

[0017] Due to the relatively small diameter of the fibers (when compared to the diameter of the grouped fibers in the die and forming station), the time and / or energy required to preheat the individual fibers is less than would be required to heat one or more of the grouped fibers in the forming station. The forming station is operable to maintain the high temperature of the preheated fibers. In some embodiments, the binder is heated before being applied to the fibers 130.

[0018] Referring to FIGS. 2 and 3, the binder application station 110 is disposed downstream of the roving station 105 such that the fibers 130 exiting the guide assembly 135 are drawn into the binder application station 110 and wetted with a binder such as a resin. In some embodiments, the binder is a combination of monomers such as very low viscosity short chain length monomers or dicyclopentadiene (DCPD) or tricyclopentadiene (TCPD). In some embodiments, the binder includes one or more low viscosity polyurethane polymers and systems such as a two-component mDI-based elastomer.

[0019] The binder has a viscosity of less than 25 centipoise (cP) at a temperature in the range of 20°C to 55°C. In some embodiments, the binder has a viscosity of less than 20 centipoise at 20°C to 55°C. In some embodiments, the binder has a viscosity of less than 15 centipoise at 20°C to 55°C. In some embodiments, the binder has a viscosity of less than 10 centipoise at 20°C to 55°C.

[0020] The very low viscosity binder quickly spreads between the fibers 130 and moves with the fibers 130 through the assembly line 100 at high speed without the need for a traction agent. Thereby, a consistent final product can be obtained even at ultra-high speeds.

[0021] The binder application station 110 is operable to accurately meter and apply a desired amount of binder to the fibers. Specifically, an appropriate amount of binder can be directly applied to the fibers according to the desired ratio of binder to the fibers. This is in stark contrast to a binder solution tank that does not control the amount of binder applied to the fibers shown in FIG. 1. Excess binder needs to be removed, and as a result, more waste is generated. Also, the entire binder solution tank needs to be maintained at an appropriate temperature, which is a waste of energy, especially when a portion of the heated binder is removed from the fibers, to heat the excess binder. Also, since the ratio of fibers to binder is not controlled, the products manufactured in the binder solution tank may lack consistency. In the present invention, the amount of binder applied to the fibers can be controlled to ensure the desired quality and consistency of the products manufactured.

[0022] Figures 3 - 5 show one embodiment of the binder application station 110. In the illustrated embodiment, the binder application station 110 includes a pressurized well 140. The pressurized well 140 receives binder from a binder source 145 such as a hopper or storage container (FIG. 2). The well 140 includes an end plate 150 having an inlet opening 155 through which the binder can be injected (FIG. 5). Next, the binder is extruded under pressure through a plurality of grooves 160 that extend radially outward from the inlet opening 155. The grooves 160 communicate with a wetting region 165 disposed on the outer periphery of the end plate 150.

[0023] During operation, the binder is continuously extruded through the groove 160 into the wetting region 165. The fibers 130 pass through the wetting region 165 so as to be wetted by the binder, and the formation of the matrix composite material begins. In the illustrated embodiment, the end plates 150 include two wetting regions 165 that are offset from each other by approximately 180 degrees. Thus, the fibers 130 can be arranged along two paths that are wetted simultaneously. To facilitate complete application of the binder to the fibers 130, the fibers 130 are spaced apart while moving through the wetting region 165. In other embodiments, the end plates 150 can include any number of wetting regions. The operating pressure of the wells 140, the number and size of the grooves 160 can be variable to provide a desired wetting rate.

[0024] Figures 6 and 7 show a part of the binder application station 110a according to another embodiment. The binder application station 110a can be used in any of the embodiments described herein. In some embodiments, the binder application station 110a is used in addition to the binder application stations illustrated and described in other embodiments, while in other embodiments, the binder application station 110a is used in place of the binder application stations illustrated and described in other embodiments. In the illustrated embodiment, the binder application station 110a includes a die 170 that guides the incoming fibers 130 into a generally tapered or conical device. The die 170 can move longitudinally (i.e., along the central axis 120). This movement can facilitate forming the incoming fibers 130 into a generally continuous wall or sheet. The binder application station 110a includes an injection nozzle 175 that is operable to receive the binder from a binder source 145 (Figure 2) and inject a stream of the binder against the incoming fibers 130. The position of the nozzle 175 can be changed longitudinally to adjust the injection characteristics of the binder.

[0025] In yet another alternative embodiment, the binder application station can include a binder solution bath. After passing through the solution bath, the fibers 130 can pass through a series of parallel rollers for mechanically agitating the binder and physically forcing it onto the fibers passing therethrough. The binder content of the impregnated fibers can be controlled using wipers and / or rollers. Additionally, the binder content can be controlled by directing a portion of the fibers 130 to bypass the binder solution bath.

[0026] In this alternative embodiment, the assembly line 100 can further include an oven batcher station between the binder application station and one or more forming stations 115 for heating the binder-impregnated fibers 130, ending the wetting process, starting the curing process, and coarsely forming the wet fibers. Additionally, the oven batcher station can include one or more drive rollers for pulling the fibers from the roving station 105 through the binder application station.

[0027] Referring to FIGS. 2, 4, 8, and 9, the assembly line 100 further includes a continuously conforming translational die 180 that wraps around the wet fibers 130 as they exit the binder application station 110. The illustrated die 180 is an elongated strip of paper fed from a roll 185 (FIG. 4). The paper die 180 advances along a central axis 120 adjacent to the wet fibers 130, and a series of Teflon guide plates 190 gradually roll the die 180 around the wet fibers 130 until the die completely surrounds and encloses the wet fibers 130 (FIGS. 8 and 9). When the wet fibers 130 enter the first portion or inlet 195 of the die 180, the fibers 130 are compressed from a relatively large rectangular area to a smaller generally circular area corresponding to the diameter of the die at the inlet 195.

[0028] Die 180 proceeds together with the wet fibers 130 through the remaining assembly line 100. As will be described in more detail below, die 180 facilitates the movement of wet fibers 130 through the forming station 115 by preventing the wet fibers 130 from adhering to the forming station 115. In addition, die 180 restrains the wet fibers 130 during curing, facilitates the mixing of the binder and the fibers 130 to ensure complete wetting, and further helps to maintain a consistent curing pressure and temperature.

[0029] The process speed or product production rate of the assembly line 100 and any other continuous FRP manufacturing process conforms to the following formula. Process speed = Die length / Resin curing time

[0030] The continuously conforming translational die 180 moves with the wet fibers 130 and can be made many times longer than the fixed die 30 used in a typical draw forming process (Figure 1). Thus, the assembly line 100 can operate at a process speed many times greater than the process speed of a typical draw forming process. For example, if the translational die has a length of 2,000 feet and it takes 2 minutes for the binder to cure, the assembly line 100 would have a potential process speed of 1,000 feet per minute. In some embodiments, the assembly line 100 is configured to have a process speed greater than about 20 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 20 feet per minute and about 50 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 50 feet per minute and about 100 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 100 feet per minute and about 250 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 100 feet per minute and about 500 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 100 feet per minute and about 1000 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 20 feet per minute and about 100 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 20 feet per minute and about 1,000 feet per minute. In other embodiments, the assembly line 100 is configured to have a process speed between about 100 feet per minute and about 1,000 feet per minute.

[0031] The paper die 180 can be coated with a release agent such as silicone to facilitate removal of the die 180 from the finished structural composite material. Further, the paper die 180 can be made relatively porous to allow gases and vapors to be released through the die 180. Alternatively, the die 180 can be made substantially airtight.

[0032] The die 180 can include combinations of other substrates or materials that are applied to the wet fibers 130 in various ways. For example, in some embodiments, the die 180 can include a powder or liquid (e.g., molten wax) that is applied to the wet fibers 130 and then solidified or cured using ultraviolet light, temperature, chemical reactants, or other suitable means. In other embodiments, the die 180 can include a vapor-permeable microporous membrane such as GORE-TEX. In other embodiments, the die 180 can include a macroporous material such as a fabric or fiber mat. In still other embodiments, the die 180 can include one or more metal films such as non-sacrificial stainless steel, a carbon steel cover, or copper.

[0033] In some embodiments, the die 180 can be wetted by a binder to bond the die 180 to the matrix composite, resulting in a monolithic structure that includes all or part of the die 180. Thus, the die material can be selected to provide the resulting structural composite material with additional desired properties. For example, the die 180 can include a conductive material to impart conductivity to an otherwise non-conductive composite material. The die material can have an affinity for an external binding component (e.g., Portland cement) to facilitate integration of the structural composite material (e.g., rebar) into its particular application (e.g., reinforced concrete).

[0034] Referring now to FIGS. 2 through 4, the forming station 115 is disposed downstream of the binder application station 110. In the illustrated embodiment, the assembly line 100 includes first, second, and third forming stations 115 spaced along a central axis 120 (FIG. 2). In other embodiments, the assembly line 100 can include any number of forming stations 115.

[0035] Each of the forming stations 115 includes at least one guide that contacts the fiber 130 to perform forming. In some embodiments, the guide can include one or more rollers having one or more slots sized to receive the fiber 130 and perform forming. In some embodiments, the guide can include one or more fixed or rotating dies having one or more openings sized to receive the fiber 130 and perform forming. Each of the slots in the rollers and the openings in the fixed dies can have different shapes and sizes to shape the fiber 130 into different shapes and sizes.

[0036] Each of the illustrated forming stations 115 includes a plurality of rollers 200. The rollers 200 are arranged in pairs, each including a groove 205 through which the fiber 130 wound around the die is taken up and formed (FIG. 10). In some embodiments, a pair of rollers 200 can be positioned in different directions. For example, a pair of rollers 200 can be alternately arranged between a horizontal direction and a vertical direction. Some or all of the rollers 200 can be driven using a variable speed drive motor to draw the die 180 and the fiber 130 through the assembly line 100.

[0037] Referring further to FIGS. 2 and 3, each forming station 115 can further include a heat transfer panel (not shown) to enable precise control of the process temperature. For example, each forming station 115 can be controlled to cure the binder at a rate corresponding to the process speed and maintain the wet fibers 130 at a stable, controlled temperature. The specific temperature is determined by the type of binder used and the process speed of the assembly line. In some embodiments, an epoxy resin is used as the binder and the fibers are maintained at a temperature from about 50° C. to about 90° C. Thus, the binder curing process can be completed while the formed wet fibers 130 move through the forming station 115.

[0038] The process temperature can be controlled in multiple zones along the length of each forming station 115 to increase or decrease the curing rate along the length of the die 180. The roller 200 applies pressure to the die 180 to provide the required curing pressure. As the die 180 and the fibers 130 pass between adjacent forming stations 115, the product can be cooled as needed (either by exposure to the ambient environment between adjacent forming stations 115 or through a controlled cooling zone), and gas or vapor by-products can be released through the die 180. This is not possible in a typical draw forming process because the fixed die 30 (FIG. 1) is generally impermeable. In some embodiments, one or more forming stations 115 cool the die 180 and the fibers 130 to a temperature below the glass transition temperature of the binder. Thus, the die 180 and the fibers 130 dispensed from the forming station 115 can maintain their shape. In other embodiments, the die 180 and the fibers 130 are not cooled below the glass transition temperature until after the die 180 and the fibers 130 exit the forming station 115 and until the final operation to the desired final shape and / or any surface configuration (such as ribs, protrusions, recesses, and / or other suitable surface configurations, etc.) of the die 180 and the fibers 130 is complete.

[0039] In a typical process, the spacing between any stations needs to be minimized so that appropriate support for the fibers is provided along the entire length of the assembly line. In contrast, the illustrated forming stations 115 are spaced a predetermined distance apart in the die flow direction so that the die 180 provides sufficient support to the fibers 130 between the forming stations 115. The spacing between each forming station 115 allows for the release of air and water from the die 180 and the fibers 130. Further, the spaced-apart forming stations 115 extend over a longer distance than if the forming stations 115 were directly adjacent. The increase in the total distance of the forming stations 115 allows the die 180 to move through the forming stations 115 at high speed while still partially or fully curing within the forming stations 115. Thus, by using more forming stations 115 and spaced-apart forming stations 115, the process speed can be increased, and as a result, productivity and profitability can be enhanced. Also, the distance between each forming station 115 reduces the capital costs of assembly and installation compared to an arrangement where the forming stations are adjacent over the entire length of the forming assembly. The forming stations 115 can be modular, and one or more than one forming station 115 can be added, removed, or repaired without substantial production loss. Instead of shutting down production for the entire assembly line (as required for a unit using a single, fixed die), production will be a short shutdown to allow for the addition, removal, or replacement of one or more than one forming station 115. The removed forming station 115 can be repaired or stored while the assembly line is operating.

[0040] Referring to FIGS. 11 to 16, one or more of the forming stations 115 can also dynamically manipulate the die 180 and the fibers 130 to promote complete wetting and homogeneous curing. Wetting is improved by shear viscosity changes caused by dynamically changing the cross-sectional area of the matrix composite. Further shear mixing of the matrix composite can be caused by selectively increasing or decreasing the mechanical pressure applied by the forming station 115. In some embodiments, the forming station 115 can be configured to result in an incomplete wet-out of the fibers 130 in order to improve the flexibility of the fibers 130 during curing.

[0041] In some embodiments, the guide can be configured to gradually increase the mechanical pressure applied over the length of the die 180. In some embodiments, the increase in pressure is caused by moving the fibers 130 through a tapered fixed die having an opening with a diameter that decreases along the length. In other embodiments, the increase in mechanical pressure can be caused by moving the fibers 130 through a series of fixed dies, each having an opening that is progressively smaller. In some embodiments, the holes in the fixed die can have different shaped and sized openings for dynamically changing the cross-sectional shape of the die 180 and the fibers 130.

[0042] In the embodiment shown in FIG. 11, roller 200 is configured to incrementally increase the mechanical pressure applied over the length of die 180. For this reason, the cross-sectional area of die 180 can be decreased through each successive pair of rollers 200. This promotes complete wetting and compression of fiber 130. In other embodiments, roller 200 can be configured to dynamically change the cross-sectional shape of die 180 and fiber 130 (FIGS. 12 - 15). For example, die 180 can be wound in an oval shape that assumes different directions in alternating roller pairs 200 to promote additional shear mixing (FIG. 12). Or, die 180 can be wound in a variety of other shapes such as elliptical, circular, rectangular, square, triangular, etc. (see, e.g., FIG. 13). In other embodiments, one or more forming stations 115 can twist die 180 and fiber 130 around central axis 120 (FIG. 14). In still other embodiments, one or more forming stations 115 can alternately increase and decrease the cross-sectional area of die 180 (FIG. 15). In still other embodiments, roller 200 can be offset to impart undulations to die 180 and fiber 130 (FIG. 16). Each of the forming stations 115 can have a different arrangement and configuration of rollers 200 and / or fixed dies.

[0043] In some embodiments, assembly line 100 can further include a dissipation station 210 for thermally abrading the cured surface of the composite structure (FIG. 2). Dissipation station 210 can be used to remove the die, expose a portion of the fibers, and / or provide a carbonaceous char that can have an affinity for external binding components such as Portland cement.

[0044] In some embodiments, the assembly line 100 can further include a post-curing station 215. The post-curing station 215 can include one or more heating elements for providing any necessary secondary curing time and temperature control. Additionally, the post-curing station 215 can include one or more machining devices operable to shape the structural composite material into a desired final shape. For example, the structural composite material can be bent, cut, or folded into a C-channel, helical shape, or other desired shape.

[0045] In some embodiments, the assembly line 100 can further include a packaging station 220. The packaging station 220 can include one or more cutting devices operable to cut the structural composite material to a desired length for sale and shipping. The structural composite material can be marked with product information, brand information, or other indicia and then packaged for shipping.

[0046] During operation, the plurality of fibers 130 are dispensed from the roving station 105 and move along the assembly line 100 to the binder application station 110. The fibers 130 are generally spaced apart as they enter the binder application station 110. The fibers 130 are adapted to spread out over a first relatively large surface area. After being wetted with the binder, the wet fibers 130 are guided to a first portion 195 of a die 180 proximate the binder application station 110, and the die 180 is rolled around the wet fibers 130. As the die 180 is wrapped around the wet fibers 130, the fibers 130 are compressed together. The wet fibers 130 wrapped by the die 180 are then fed into the shaping station 115.

[0047] At the forming station 115, the die 180 and the wet fibers 130 are compressed between guides such as a pair of rollers 200 or a fixed die to mix the binder and the fibers 130 and form the product shape. The die 180 isolates the wet fibers 130 from the rollers 200 and / or the fixed die to prevent the binder from adhering to the rollers 200 and / or the fixed die. Heat is applied throughout the forming station 115 to promote the curing of the binder. When the die 180 moves between adjacent forming stations, the matrix can be cooled and / or release by-products of gas and vapor.

[0048] In some embodiments, sand can be added to the die 180 and / or the fibers 130 before or after the curing is complete. The sand can be selected to improve the physical bonding properties between the final composite material of the fibers 130 and the binder and the material to which the final composite material is bonded, such as concrete.

[0049] The various features of the present invention are set forth in the following claims.

Description of the reference numerals

[0050] 5 Fiber 10 Production line 15 Drawing mechanism 20 Driving roller 25 Solution tank 30 Die

Claims

1. A method of manufacturing a structural member, comprising: applying a binder having a viscosity of less than 25 centipoise (cP) at 30°C to at least one of a plurality of fibers, wherein when the binder is applied, the fibers are spaced apart and spread into a first region; providing a die having a first portion of a first diameter and a second portion of a second diameter disposed downstream of the first portion, wherein the first diameter is greater than the second diameter and the die is tapered between the first portion and the second portion; after applying the binder, guiding the plurality of fibers along the die at a speed of at least 25 feet per minute; reducing the distance between the plurality of fibers using the die, such that after reducing the distance between the plurality of fibers, the fibers extend over a second region smaller than the first region; after reducing the distance, shaping the plurality of fibers at a shaping station; wherein the binder comprises tricyclopentadiene (TCPD).

2. The shaping station is a first shaping station, and the method further comprises: after shaping the fibers at the first shaping station, shaping the plurality of fibers at a second shaping station spaced apart from the first shaping station; and after shaping the plurality of fibers at the second shaping station, shaping the plurality of fibers at a third shaping station spaced apart from the first shaping station and the second shaping station.

3. The method further comprises: preheating the plurality of fibers to a first temperature; moving the preheated fibers along an assembly line; after reducing the distance, maintaining the temperature of the plurality of fibers at a temperature substantially the same as the first temperature; and during shaping the plurality of fibers at the shaping station, maintaining the temperature.

4. The die comprises a porous material to allow air to escape from the die, and one component of the binder has a viscosity of less than 10 centipoise (cP) at 30°C.

5. ​ ​ The step of moving the plurality of fibers from the forming station; After moving the plurality of fibers from the forming station, the step of curing the plurality of fibers; The method according to claim 1, further comprising.

6. The method according to claim 1, further comprising the step of applying the binder to the die before reducing the distance between the plurality of fibers using the die.

7. A method of manufacturing a structural member, comprising: Moving the fibers along an assembly line at a speed of at least 25 feet per minute; Applying a binder to at least one of the fibers, wherein one component of the binder has a viscosity of less than 10 centipoise (cP) at 30°C, and the binder contains tricyclopentadiene (TCPD), and when the binder is applied, the fibers are spaced apart and spread in a first region; After applying the binder, guiding the fibers along a die; Reducing the distance between the plurality of fibers using the die, such that after reducing the distance between the plurality of fibers, the fibers extend over a second region smaller than the first region; Forming the plurality of fibers at a forming station; A method comprising.

8. The method according to claim 7, wherein the die comprises a porous material, thereby allowing air to escape from the die.

9. The method according to claim 7, further comprising the step of applying the binder to the fibers before reducing the distance between the plurality of fibers using the die.

10. The method according to claim 7, wherein the step of applying the binder includes spraying the binder onto at least one of the plurality of fibers.

11. The method according to claim 7, wherein the step of applying the binder includes extruding the binder from a pressurized chamber and drawing at least one of the fibers through the extruded binder.

12. The method according to claim 7, wherein the step of applying the binder includes spraying the binder onto at least one of the plurality of fibers and extruding the binder from a pressurized chamber and drawing at least one of the fibers through the extruded binder.

13. A method for manufacturing a continuous structural member, comprising: Moving fibers along an assembly line at a speed of at least 25 feet per minute; Applying a binder to at least one of the fibers, the binder including at least one short-chain-length monomer having a viscosity of less than 10 centipoise (cP) at 30°C, the at least one short-chain-length monomer including tricyclopentadiene (TCPD); Providing a die shaped to receive the fibers, the die moving with the fibers along at least a portion of the assembly line; Compressing the plurality of fibers within the die; A method comprising the above steps.

14. The method according to claim 13, further comprising applying the binder to the fibers before reducing the distance between the plurality of fibers using the die.

15. The method according to claim 13, wherein the step of applying the binder includes spraying the binder onto at least one of the plurality of fibers.

16. The method according to claim 13, wherein the step of applying the binder includes extruding the binder from a pressure chamber and drawing at least one of the fibers through the extruded binder.

17. The method according to claim 13, wherein the die includes a porous material, thereby allowing air to escape from the die.

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