Composite Pultruded Profiles Using Polyester Felt and Bagasse Core
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional pultrusion methods face challenges in producing composite products with uniform mechanical properties, high tensile and bending strength, and low weight, particularly due to issues like resin separation and high density, which limit the production of thin and thick profiles, and the use of glass roving leads to jamming and non-uniformity.
Innovation Solution
The development of composite pultruded products using synthetic polyester felt impregnated with a resin system, encapsulated between bi-directionally and uni-directionally oriented synthetic fabric, and incorporating bagasse as a core, which reduces manufacturing costs and environmental impact, while enhancing structural efficiency and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass roving is used in conventional pultrusion, then tensile strength is improved, but manufacturing complexity increases due to jamming and non-uniformity
Solution Approach 1:
The patent changes the form parameter of the glass reinforcement from continuous roving to chopped strands (6-12mm length). This parameter change eliminates the jamming issue associated with continuous roving while maintaining tensile strength through proper strand distribution and orientation in the pultrusion matrix.
Solution Approach 2:
The glass reinforcement is segmented into discrete chopped strands rather than used as continuous roving. This segmentation prevents the jamming and handling complexity of continuous fibers while allowing uniform distribution throughout the pultruded composite, reducing manufacturing complexity.
2Productivity
If conventional pultrusion methods are used, then production efficiency is maintained, but product uniformity deteriorates due to resin separation and non-uniform mechanical properties
Solution Approach 1:
The patent uses a composite reinforcement system combining chopped glass strands with synthetic polyester felt and oriented synthetic fabric. This multi-component composite structure prevents resin separation by providing multiple reinforcement phases that work together, ensuring uniform mechanical properties while maintaining continuous pultrusion production efficiency.
Solution Approach 2:
Different regions of the composite product have different reinforcement characteristics: chopped glass strands provide random distribution for bulk strength, synthetic polyester felt provides dimensional stability, and oriented synthetic fabric provides surface strength. This local quality variation throughout the product cross-section ensures uniform overall performance.
3Strength
If high density materials are used, then strength is improved, but weight increases which limits thin and thick profile production
Solution Approach 1:
The patent creates a lightweight composite structure by combining low-density chopped glass strands with synthetic polyester felt and oriented fabric in a resin matrix. This composite architecture achieves high structural strength through optimized fiber distribution and orientation while maintaining low overall density, enabling production of both thin and thick profiles without weight penalties.
Data Source
AI summary
The composite pultruded products either in “I” profile or “Plate” profile of higher cross sectional area where said products consisting essentially synthetic polyester felts as core impregnated with a resin system comprises of at least one resin, curing system comprising a curing agent and an accelerator, a filler, a thinner, pigment or any other additives; encapsulated between bi-directionally and/or uni-directionally oriented synthetic fabric selected from polyester, carbon, aramid, glass, basalt and mixtures thereof impregnated with said resin system are provided. In another composite pultruded products either in “I” profile or “Plate” profile of higher cross sectional area where said products consisting of plank of short fibers bagasse premixed with the said resin system as core is enclosed between the synthetic polyester felts impregnated with the resin system which is further enclosed between bi-directionally and/or uni-directionally oriented synthetic fabric selected from polyester, carbon, aramid, glass, basalt and mixtures thereof impregnated with the resin system. The system and method for the preparation of said composite pultruded products are also illustrated herein. These products lead to a significant reduction in weight and reduction in density with higher stiffness and bending strength. The present composite products are encapsulated by fabrics in the peripheral area bringing more integrity uniformity of synthetic polyester felt materials. This leads to a significant cost reduction without sacrificing much tensile strength.