Pultruded t-slot rails

Abstract

AT-slot component includes a pultruded member that is pultruded through a pultrusion die to form a T-slot component having a T-slot groove and a length, a width, and a height. The member is made from a material having a fiber reinforcement content of about 80% or greater.

Description

[0001] PULTRUDED T-SLOT RAILS

[0002] Cross-Reference to

[0003]

[0004] This application claims priority to U.S. Provisional Application No. 63 / 761,980, filed on February 23, 2025, the disclosure of which is incorporated herein by reference in its entirety.

[0005] Field

[0006] The present invention relates to a new T-Slot railing made using a pultrusion process using non-metallic material.

[0007]

[0008] T-slots rails are commonly used for creating frames and structures that are strong, versatile, lightweight, sturdy, and cost-effective. T-slot rails are typically made of aluminum using aluminum extrusion. Aluminum extrusion is a process that forces aluminum through a die to create a specific profile. Aluminum stock is pushed through a die in the shape of a “T,” creating a profile with a “T”-shaped groove. An image showing an extruded aluminum T-slot 1 is shown in Fig. 1. The “T”-shaped groove 2 allows other pieces of aluminum (or other materials) with a T-shaped tip to slide into the groove 2. T-slot rails 1 are strong, with their final strength ultimately depending on the alloy used to make the T-slot profiles and the specific profile shape. The most common aluminum alloys extruded for this purpose are 6060-T6 and 6105, both of which offer a moderate-to-high tensile strength.

[0009] T-slot rails 1 are typically square or rectangular but could be other shapes, including round, C-shaped, or other shapes. They have a T-shaped groove or slot 2 on at least one side. The T-shaped slot 2 can be on some or all of the sides of the rail 1. The slots 2 allow for connection with many different types of hardware and for customization and versatility of designs and applications. Common sizes for square T-slot rails 1 may be 1” x 1,” 1.5” x 1.5,” 2” x 2”, 1 L>” x 3”, or other sizes, including custom sizes.

[0010] T-slot profiles provide high versatility and adaptability, which makes them varied and customizable. Frames that are constructed using T-slots allow for rapid assembly and disassembly. This makes it easy to move or change, as needed. T-slots can be used to erecttemporary or permanent enclosures. T-slots can also be used to make linear slide systems, which take advantage of precisely controlled movement by small carriages along the T-slot rail.

[0011] Some structures that utilize T-slot rails 1 include machine bases and frames, equipment safety enclosures and guard systems, utility carts, workstations, test stations, and tables, materials handling systems, portable gantry systems, and office and workshop furniture, like desks, cabinets, and storage units. T-slots rails 1 traditionally made of aluminum provide inherent durability and corrosion resistance, making them helpful in many environments. T-slot aluminum rails 1 are used in automation systems because of their sturdiness, low maintenance costs, and good thermal conductivity.

[0012] T-slot rails 1 can be assembled without the need for complex tools or extensive modifications. T-slot rails 1 can be used with connectors, which eliminates the need to weld components to obtain robust construction properties. T-slots rails 1 can be used to mount brackets, panels, and other accessories.

[0013] Example T-slot profiles are depicted in Figs. 2-8. Fig. 2 depicts a 1 / z x 3” four T-slotted extrusion profile. Fig. 3 depicts a 1” x 1” four T-slotted extrusion profile, Fig. 4 depicts a 1 'A” x 1 ’A” Lite T-slotted extrusion profile, Fig. 5 depicts a 1” x 1 !4” Mono T-slotted extrusion profile, Fig. 6 depicts a 1” x 1” Tri T-slotted extrusion profile. Fig. 7 depicts a 1 ’A” x 1 ’A” Quarter Round T-slotted extrusion profile. Fig. 8 depicts a 1 VT x 1 Vi ' Single Open T-slotted extrusion profile. Multiple other known T-slotted extrusion profiles are known and commercially available. The present invention can be used for any of these profiles.

[0014] Detailed Description

[0015] The T-slot rail 10 of the present invention is made using a standard pultrusion process from a resin system material. Examples of materials that may be used in connection with the present invention include, but are not limited to, Polyurethane, Epoxy, Dicyclopentadiene (DCPD) resin, Bismal eimide (BMI) resin, Cyanate Ester (CE), Hybrid resin systems, other thermosetting resin systems, and other thermosetting polymers.

[0016] By way of example, in Fig. 2, a comparison of an aluminum alloy used in making an aluminum T-slot rail is compared with a like T-slot rail made of a polyurethane material, showing the different properties between the two materials. As is evident, the weight of polyurethane islower than aluminum while the strength of the material is greater than aluminum. Lower weight materials that provide greater strength have wide-ranging advantages.

[0017] Known deficiencies associated with Aluminum T-slot framing systems include undesirable electrical conductivity, undesirable thermal conductivity, poor performance in caustic environments (acidic environments, salt spray, mining deficiency etc.), lower yield strengths, higher weight, lower tensile strength, radical thermal expansion and contraction over temperature swing (high coefficient of linear thermal expansion (CLTE)), and a very high carbon footprint.

[0018] The present invention utilizes resin systems that include fiber reinforcement materials having a fiber content of about 80% or greater. These resin systems, which include reinforced t-slot framing systems, offer a previously unavailable solution due to the advancements of resin and resin to fiber crosslinking technology that has not been available in the market to date. Resin systems offer a number of important following advantages over Aluminum and other resin framing systems, including non-electrically conductive material, thermal conductivity that is significantly (729 times) less thermally conductive that aluminum, extremely chemical resistant in caustic environments and subsea environments, very high yield strength (very good rebound attributes), very high tensile strength, very low thermal expansion or contraction over large temperature swings (low CLTE), and a low carbon footprint.

[0019] In one example, the fiber reinforcement material has a fiber content of about 80% or greater. In another example, the fiber reinforcement material has a fiber content of 80% or greater. In another example, the fiber reinforcement material has a fiber content of about 81%, about 82%, about 83%, about 84%, about 85%, about 86%, about 87%, about 88%, about 89%, about 90%, about 91%, about 92%, about 93%, about 94%, about 95%, about 96% or greater.

[0020] The present invention provides a composite product that could take the place of aluminum T-slot rails. In addition to being of higher strength and lighter weight, the cost of the product is lower.

[0021] An image of a pultruded polyurethane T-slot rail 10 is presented in Fig. 10. The resin systems may be pigmented, if desired, to provide different colors. For example, the material may be pigmented black. The product may have a range of sizes consistent with all presently known T-slot products on the market and other products that utilize a T-slot slot or groove 12. The resulting product weighs less than aluminum competitors, is non-electrically conductive, has greater strength to weight ratio than aluminum competitors, and is thermally insulative. The T-slot rail 10 of the present invention is manufactured using known Pultrusion processes. Examples of pultrusion processes are described in applicant’s previously filed co-pending patent applications, as well as pultrusion processes known in the art.

[0022] Both aliphatic and aromatic urethanes may be used in the present invention, as well as other known materials. It is anticipated that additional resins will be developed in the future that may be utilized in producing the pultruded T-slot rails 10 described and claimed herein.

[0023] In one embodiment, a T-slot component includes a pultruded member that is pultruded through a pultrusion die to form a T-slot component having a T-slot groove and a length, a width, and a height. The member is made from a material having a fiber reinforcement content of about 80% or greater.

[0024] The material may be one or more of Polyurethane, Epoxy, Dicyclopentadiene (DCPD) resin, Bismaleimide (BMI) resin, Cyanate Ester (CE), or a hybrid resin system. The material may be a thermosetting polymer. The material may be an aliphatic or an aromatic urethane.

[0025] The fiber reinforcement content may be about 80% to about 85%, the fiber reinforcement content may be about 80% to about 90%. The fiber reinforcement content may be 80%, 81%, 82%, 83%, 84%, or 85%. The material may be pigmented.

[0026] The member weighs less than a like aluminum component. The member is non-electrically conductive. The member may have a greater strength to weight ratio than a like aluminum component. The member may be thermally insulative. The member may be chemically resistant in caustic environments and / or subsea environments. The member may have a lower thermal expansion or contraction rate over a range of temperature swings as compared to a like aluminum member.

[0027] While various features are presented above, it should be understood that the features may be used singly or in any combination thereof. Further, it should be understood that variations and modifications may occur to those skilled in the art to which the claimed examples pertain. The examples described herein are exemplary. The disclosure may enable those skilled in the art to make and use alternative designs having alternative elements that likewise correspond to the elements recited in the claims. The intended scope may thus include other examples that do not differ or that insubstantially differ from the literal language of the claims. The scope of the disclosure is accordingly defined as set forth in the appended claims.What has been described above includes examples of one or more embodiments. It is, of course, not possible to describe every conceivable modification and alteration of the above devices or methodologies for purposes of describing the aforementioned aspects, but one of ordinary skill in the art can recognize that many further modifications and permutations of various aspects are possible. Accordingly, the aspects described are intended to embrace all such alterations, modifications, and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the details description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim. The term “consisting essentially,” if used herein, means the specified materials or steps and those that do not materially affect the basic and novel characteristics of the material or method. All percentages and averages are by weight unless the context indicates otherwise. If not specified above, the properties mentioned herein may be determined by applicable ASTM standards, or if an ASTM standard does not exist for the property, the most commonly used standard known by those of skill in the art may be used. The articles “a,” “an,” and “the,” should be interpreted to mean “one or more” unless the context indicates the contrary.

Claims

THE CLATMSWhat is claimed is:

1. A T-slot component comprising:a pultruded member that is pultruded through a pultrusion die to form a T-slot component having a T-slot groove and a length, a width, and a height,wherein the member is made from a material having a fiber reinforcement content of about 80% or greater.

2. The component of claim 1, wherein the material is one or more of:Polyurethane,Epoxy,Dicyclopentadiene (DCPD) resin,Bismal eimide (BMI) resin,Cyanate Ester (CE), ora hybrid resin system.

3. The component of claim 1, wherein the material is a thermosetting polymer.

4. The component of claim 1, wherein the material is an aliphatic or an aromatic urethane.

5. The component of claim 1, wherein the fiber reinforcement content is about 80% to about 85%.

6. The component of claim 1, wherein the fiber reinforcement content is about 80% to about 90%.

7. The component of claim 1, wherein the fiber reinforcement content is 80%, 81%, 82%, 83%, 84%, or 85%.

8. The component of claim 1, wherein the material is pigmented.

9. The component of claim 1, wherein the member weighs less than a like aluminum component.

10. The component of claim 1, wherein the member is non-electrically conductive.

11. The component of claim 1, wherein the member has a greater strength to weight ratio than a like aluminum component.

12. The component of claim 1, wherein the member is thermally insulative.

13. The component of claim 1, wherein the member is chemically resistant in caustic environments and / or subsea environments.

14. The component of claim 1, wherein the member has a lower thermal expansion or contraction rate over a range of temperature swings as compared to a like aluminum member.

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