SAMPE Journal - September/October 2016 - 54
Feature Article
Figure 8. Process layout of the developed combined pultrusion and extrusion process.
Design of the Developed Process Layout
According to the prerequisites defined above, it is
necessary to run the two processes thermally separated
as long as possible (short time for thermal degradation of
thermoset PU matrix) and it is necessary to individually
control the pre-curing of the PU matrix in order to meet
the ideal point of joining. Keeping this in mind, the
process layout shown in Figure 8 has been developed.
The process starts as a pultrusion process with a
common injection box. The pultrusion die is shortened
from the usual length of 700 mm to 300 mm. This leads,
at a process speed of 1.0 m/min, to a residence time of 18
seconds , which is sufficient to raise the viscosity of the
PU matrix to the target figure of 1.000 Pas. According to
Figure 7, a temperature slightly above 100 °C is needed
to reach the target viscosity within the given time. This
temperature is quite common for PU pultrusion and can
be raised further to speed up the process.
The pre-consolidated and pre-cured pultruded profile
is fed into a co-extrusion-die. Both processes remain
thermally separated until the joining is performed. After
applying the thermoplastic top layer, the hybrid profile
leaves the die and passes through a cooling zone. As
soon the thermoplastic top layer is solidified and the
composite core is fully cured, the profile can be gripped
by the haul-off unit.
Die Technology
The extrusion die technology is shown in Figure 9.
The inner part of the die is responsible for the pultrusion
process, whereas the outer part of the die manages
the extrusion process. From the joining area on, both
processes run as one process simultaneously.
The pre-consolidated and pre-cured composite
profile (feed profile) enters the die in a channel, which is
thermally separated from the outer extrusion process by
an air gap. The thermoplastic melt is fed from the side
and distributed by a flow splitter on a conical core tube.
The feed profile is guided into the joining area through the
center of the core tube. Joining takes place immediately
after the feed profile has escaped the core tube, when it
is exposed to the thermoplastic melt. The forming of the
shape of the thermoplastic top layer is then performed in
a classical extrusion set-up, which features a transition
zone and a parallel zone. These different zones, which
are realized by a total of three nozzle plates, gradually
form the top layer of the profile.
Figure 9. Design of the
co-extrusion-die.
54
SAMPE Journal, Volume 52, No. 5, September/October 2016
Table of Contents for the Digital Edition of SAMPE Journal - September/October 2016
Contents
SAMPE Journal - September/October 2016 - Cover1
SAMPE Journal - September/October 2016 - Cover2
SAMPE Journal - September/October 2016 - Contents
SAMPE Journal - September/October 2016 - 2
SAMPE Journal - September/October 2016 - 3
SAMPE Journal - September/October 2016 - 4
SAMPE Journal - September/October 2016 - 5
SAMPE Journal - September/October 2016 - 6
SAMPE Journal - September/October 2016 - 7
SAMPE Journal - September/October 2016 - 8
SAMPE Journal - September/October 2016 - 9
SAMPE Journal - September/October 2016 - 10
SAMPE Journal - September/October 2016 - 11
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SAMPE Journal - September/October 2016 - 13
SAMPE Journal - September/October 2016 - 14
SAMPE Journal - September/October 2016 - 15
SAMPE Journal - September/October 2016 - 16
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SAMPE Journal - September/October 2016 - 18
SAMPE Journal - September/October 2016 - 19
SAMPE Journal - September/October 2016 - 20
SAMPE Journal - September/October 2016 - 21
SAMPE Journal - September/October 2016 - 22
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SAMPE Journal - September/October 2016 - 24
SAMPE Journal - September/October 2016 - 25
SAMPE Journal - September/October 2016 - 26
SAMPE Journal - September/October 2016 - 27
SAMPE Journal - September/October 2016 - 28
SAMPE Journal - September/October 2016 - 29
SAMPE Journal - September/October 2016 - 30
SAMPE Journal - September/October 2016 - 31
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SAMPE Journal - September/October 2016 - 33
SAMPE Journal - September/October 2016 - 34
SAMPE Journal - September/October 2016 - 35
SAMPE Journal - September/October 2016 - 36
SAMPE Journal - September/October 2016 - 37
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SAMPE Journal - September/October 2016 - 40
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SAMPE Journal - September/October 2016 - 50
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SAMPE Journal - September/October 2016 - 54
SAMPE Journal - September/October 2016 - 55
SAMPE Journal - September/October 2016 - 56
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SAMPE Journal - September/October 2016 - 60
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SAMPE Journal - September/October 2016 - 79
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SAMPE Journal - September/October 2016 - 81
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SAMPE Journal - September/October 2016 - 84
SAMPE Journal - September/October 2016 - 85
SAMPE Journal - September/October 2016 - 86
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SAMPE Journal - September/October 2016 - 89
SAMPE Journal - September/October 2016 - 90
SAMPE Journal - September/October 2016 - 91
SAMPE Journal - September/October 2016 - 92
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SAMPE Journal - September/October 2016 - 94
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SAMPE Journal - September/October 2016 - 96
SAMPE Journal - September/October 2016 - 97
SAMPE Journal - September/October 2016 - 98
SAMPE Journal - September/October 2016 - 99
SAMPE Journal - September/October 2016 - 100
SAMPE Journal - September/October 2016 - 101
SAMPE Journal - September/October 2016 - 102
SAMPE Journal - September/October 2016 - 103
SAMPE Journal - September/October 2016 - 104
SAMPE Journal - September/October 2016 - 105
SAMPE Journal - September/October 2016 - 106
SAMPE Journal - September/October 2016 - 107
SAMPE Journal - September/October 2016 - 108
SAMPE Journal - September/October 2016 - 109
SAMPE Journal - September/October 2016 - 110
SAMPE Journal - September/October 2016 - 111
SAMPE Journal - September/October 2016 - 112
SAMPE Journal - September/October 2016 - 113
SAMPE Journal - September/October 2016 - 114
SAMPE Journal - September/October 2016 - 115
SAMPE Journal - September/October 2016 - 116
SAMPE Journal - September/October 2016 - 117
SAMPE Journal - September/October 2016 - 118
SAMPE Journal - September/October 2016 - 119
SAMPE Journal - September/October 2016 - 120
SAMPE Journal - September/October 2016 - Cover3
SAMPE Journal - September/October 2016 - Cover4
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