Fiberglass Reinforced Plastic Products Having Increased Weatherability, System and Method

Abstract

Climbing products containing rails decorated using veil products colored, patterned, painted or in combination with marking methods such as company names and logos and resin formulation designed to withstand exposure to UV radiation with minimal change in appearance which create specific appearances for applications, enhance weathering performance, and facilitate processing efficiency. A combination of a filler free resin or resin with filler and coated veil systems to create a synergistic weather resistance surface with self-contained color, pattern, picture, logo or combination of said same for climbing products. A system for producing components at a rate of greater than 5 ft/min. Various methods, system, a ladder rail.

1 . A system for producing a ladder rail comprising:
 a pultrusion system that produces product at a rate of greater than 5 ft/min, the pultrusion system comprising:   a prewet which wets a middle mat layer with a resin and filler; and   an impregnator which compresses a first veil outer layer, a second veil outer layer, a first mat layer, a second mat layer, a first roving layer and a second roving layer with the middle mat layer, and which wets only the first veil outer layer, the second veil outer layer, the first mat layer and the second mat layer with resin to form the product.   
     
     
         2 . A ladder rail comprising:
 a first veil layer;   a first mat layer having a first color in contact with the first veil layer;   a first roving layer in contact with the first mat layer;   a middle mat layer in contact with the first roving layer;   a second roving layer in contact with the middle mat layer and together the middle mat and first roving layer having a second color;   a second mat layer having the first color in contact with the second roving layer;   a second veil layer in contact with the second mat layer; and   the first veil layer, and the second veil layer having resin with filler that includes clay and CaCO3.   
     
     
         3 . A rail as described in  claim 2  wherein the clay and CaCO3 were at least 2 pph of the resin. 
     
     
         4 . A rail as described in  claim 3  wherein the clay and CaCO3 were at least 5 pph of the resin. 
     
     
         5 . The combination of a filler free resin and coated veil system to create a synergistic weather resistance surface with self-contained color, pattern, picture, logo or combination of said same for climbing products. 
     
     
         6 . A system as described in  claim 5  including resins made of polyester, acrylic, epoxy, urethane, acrylate, or combinations thereof. 
     
     
         7 . A system as described in  claim 6  including veils dyed, printed, pigmented, transfer coated or combinations thereof. 
     
     
         8 . A system as described in  claim 7  wherein veil compositions are glass, polyester, paper, jute or other dispersed fiber systems.