Method and apparatus for manufacturing a reinforcement

Abstract

A method includes wetting fibers with a resin capable of being cured by at least two different cure treatments. At least partially curing the resin by subjecting the resin to a first cure treatment and at least partially curing the resin by subjecting the resin to a second cure treatment. A plurality of fibers are located adjacent each other so that a plurality of valleys are formed between the plurality of fibers along an outer side of the reinforcement. The resin is cured to retain the valleys in the outer side of the reinforcement. The outer side of the reinforcement is adhered to the structural member. An apparatus including a fiber locating mechanism adapted to retain the peaks and valleys during curing of the resin without rigidly confining the outer side of the reinforcement.

1 . The method of manufacturing a reinforcement for a structural member comprising: 
 wetting fibers with a resin capable of being cured by at least two different cure treatments;    at least partially curing the resin by subjecting the resin to a first cure treatment;    at least partially curing the resin by subjecting the resin to a second cure treatment.    
   
   
       2 . A method of manufacturing a reinforcement according to  claim 1 , wherein at least one of the cure treatments is selected from the group consisting of subjecting the resin to light, an electron beam, a radio frequency and heat.  
   
   
       3 . A method of manufacturing a reinforcement according to  claim 1 , wherein the first cure treatment includes subjecting the resin to UV light and wherein the second cure treatment includes subjecting the resin to heat.  
   
   
       4 . A method of manufacturing a reinforcement according to  claim 1 , further comprising tensioning the fibers.  
   
   
       5 . A method of manufacturing a reinforcement according to  claim 1 , further comprising longitudinally aligning the fibers.  
   
   
       6 . A method of manufacturing a reinforcement according to  claim 1 , further comprising forming a layer from the fibers.  
   
   
       7 . A method of manufacturing a reinforcement according to  claim 1 , further comprising adding a plurality of fibers adapted to provide cross-direction support for the reinforcement.  
   
   
       8 . A method of manufacturing a reinforcement according to  claim 1 , wherein curing the resin is done while a side of the reinforcement is unconfined.  
   
   
       9 . A method of manufacturing a reinforcement according to  claim 1 , further comprising selecting a synthetic fiber as the plurality of fibers.  
   
   
       10 . A method of manufacturing a reinforcement according to  claim 1 , further comprising selecting a thermosetting plastic as the resin.  
   
   
       11 - 20 . (canceled)  
   
   
       21 . An apparatus for manufacturing a reinforcement for a structural member comprising: 
 a fiber wetting station adapted to contact a plurality of fibers with resin;    a fiber locating mechanism which is adapted to locate the plurality of fibers adjacent each other so that a plurality of valleys are formed between the plurality of fibers along an outer side of the reinforcement and so that a plurality of peaks associated with the fibers are formed, the fiber locating mechanism being further adapted to retain the peaks and valleys during curing of the resin without rigidly confining the outer side of the reinforcement; and    a resin curing station adapted to irradiate the outer side of the reinforcement to at least partially cure the resin.    
   
   
       22 . An apparatus for manufacturing a reinforcement according to  claim 21 , wherein the fiber locating mechanism is adapted to form the peaks and the valleys with an elongated shape.  
   
   
       23 . An apparatus for manufacturing a reinforcement according to  claim 21 , wherein the wetting station is further adapted to coat all sides of the plurality of fibers with resin.  
   
   
       24 . An apparatus for manufacturing a reinforcement according to  claim 21 , further comprising an additional fiber locating mechanism adapted to locate a second plurality of fibers in contact with the resin so the second plurality of fibers provide cross-direction support for the reinforcement.  
   
   
       25 . An apparatus for manufacturing a reinforcement according to  claim 21 , wherein the resin curing station has at least two of a light source, an electron beam source, a radio frequency source and a heat source.  
   
   
       26 . An apparatus for manufacturing a reinforcement according to  claim 25 , wherein the at least two sources are provided by a single device.  
   
   
       27 . An apparatus for manufacturing a reinforcement according to  claim 21 , further comprising a tensioning mechanism adapted to place fibers under tension during curing.  
   
   
       28 . An apparatus for manufacturing a reinforcement according to  claim 27 , wherein the tensioning mechanism has ceramic eyelets oriented at an angle to a path of fiber passing through the ceramic eyelet.  
   
   
       29 . An apparatus for manufacturing a reinforcement according to  claim 27 , wherein the tensioning mechanism has an unwind brake associated with a spool adapted to supply fibers.  
   
   
       30 . An apparatus for manufacturing a reinforcement according to  claim 27 , wherein the tensioning mechanism is adapted to provide a compressive force against a fiber.