Pultruded articles and methods for making same

Abstract

A structural reinforcement for an article including a carrier ( 10 ) that includes: (i) a mass of polymeric material ( 12 ) having an outer surface; and (ii) at least one fibrous composite insert ( 14 ) or overlay ( 980 ) having an outer surface and including at least one elongated fiber arrangement (e.g., having a plurality of ordered fibers). The fibrous insert ( 14 ) or overlay ( 960 ) is envisioned to adjoin the mass of the polymeric material in a predetermined location for carrying a predetermined load that is subjected upon the predetermined location (thereby effectively providing localized reinforcement to that predetermined location). The fibrous insert ( 14 ) or overlay ( 960 ) and the mass of polymeric material ( 12 ) are of compatible materials, structures or both, for allowing the fibrous insert or overlay to be at least partially joined to the mass of the polymeric material. Disposed upon at least a portion of the carrier ( 10 ) may be a mass of activatable material ( 128 ). The fibrous insert ( 14 ) or overlay ( 960 ) may include a polymeric matrix that includes a thermoplastic epoxy.

1 . A pultruded structure comprising:
 an elongated tubular structure having a first end and a second end;   at least one attachment device adapted for attaching the tubular structure to a vehicle;   one or more strips of an activatable polymeric material on an outer surface, the activatable material adapted for damping of vibration, for resisting flutter, or for bonding to an adjoining structure;   wherein the elongated tubular structure has a longitudinal axis and also has at least one reinforcement portion that includes a continuous glass fiber reinforcement embedded in a polyurethane matrix and has a plurality of glass fibers aligned generally parallel with the longitudinal axis.   
     
     
         2 - 5 . (canceled) 
     
     
         6 . The structure of  claim 1 , wherein the continuous glass fibers are preloaded in the at least one reinforcement portion. 
     
     
         7 . The structure of  claim 1 , wherein the elongated tubular structure has a constant profile along the longitudinal axis. 
     
     
         8 . The structure of  claim 1 , wherein from about 40 to about 80% by weight of the beam is fibers. 
     
     
         9 - 11 . (canceled) 
     
     
         12 . A method of making the structure of  claim 1 , wherein the elongated tubular structure is pultruded. 
     
     
         13 . A method of making a composite article, comprising the steps of:
 i. pultruding a first polymeric composite structure having a plurality of glass fibers embedded in a polyurethane matrix;   ii. fabricating a second polymeric composite structure having a plurality of fibers embedded in a polymeric matrix; and   iii. securing the second polymeric composite structure with the first polymeric composite structure to define a composite article that includes each of the first polymeric composite structure and the second polymeric composite structure.   
     
     
         14 . The method of  claim 13 , wherein the first polymeric composite structure includes a plurality of continuous glass fibers embedded in a polymeric matrix in a concentration of about 40% to about 80% by weight of the polyurethane composite structure. 
     
     
         15 - 16 . (canceled) 
     
     
         17 . The method of  claim 13 , wherein the second polymeric composite structure includes a plurality of glass fibers embedded in a polymeric matrix in a concentration of about 20% to about 80% by weight of the second polymeric composite structure. 
     
     
         18 . The method of  claim 13 , wherein the second polymeric composite structure includes a plurality of fibers embedded in a polymeric matrix and wherein the polymeric matrix includes an epoxy, Nylon, a polyester, a polyether, or combinations thereof. 
     
     
         19 . (canceled) 
     
     
         20 . The method of  claim 13 , wherein the step of fabricating the second polymeric composite structure includes a step of extruding the second polymeric composite, injection molding the second polymeric composite, pultruding the second polymeric composite, thermoforming the second polymeric composite, compression molding the second polymeric composite, or any combination thereof. 
     
     
         21 . The method of  claim 13 , wherein the step of securing the first polymeric composite and the second polymeric composite includes a step of adhering the first polymeric composite with the second polymeric composite, mechanically connecting the first polymeric composite with the second polymeric composite, a step of welding the first polymeric composite with the second polymeric composite or a combination thereof. 
     
     
         22 . The method of  claim 20 , wherein the step of securing the first polymeric composite and the second polymeric composite includes a step of inserting a coupling device between the first polymeric composite and the second polymeric composite, and a step of adhering the first polymeric composite with the second polymeric composite via the coupling, mechanically connecting the first polymeric composite with the second polymeric composite via the coupling, welding the first polymeric composite with the second polymeric composite via the coupling, or any combination thereof. 
     
     
         23 . The method of  claim 13 , wherein the shape of the first polymeric composite and the shape of the second polymeric composite are complementary so that they are in generally mating relationship with each other. 
     
     
         24 . The method of  claim 21 , wherein the first polymeric composite and the second polymeric composite are similarly sized and/or shaped. 
     
     
         25 . The method of  claim 21 , wherein the first polymeric composite and the second polymeric composite are differently sized and/or shaped. 
     
     
         26 . The method of  claim 13 , wherein one or more of the first polymeric composite and the second polymeric composite comprise fibers formed in a mat. 
     
     
         27 . A method of making a pultruded article, comprising the steps of:
 a) pulling a plurality of continuous fibers through a die for defining a continuous profile that has at least two portions that are not coplanar and have differing thickness relative to each other;   b) contacting the plurality of continuous fibers with one or more polymeric materials;   c) applying a sufficient amount of energy to form a pultruded article having a polyurethane-based polymeric matrix in contact with the continuous fibers and embedding the continuous fibers therein.   
     
     
         28 . The method of  claim 27 , wherein the die is about 0.2 to about 1 meters in length. 
     
     
         29 . The method of  claim 28 , wherein the rate of the pultruding is at least about 0.5 meters per minute. 
     
     
         30 . The method of  claim 28 , wherein the die includes an opening therein into which the polymeric materials are introduced so that the step of contacting occurs within the die. 
     
     
         31 - 74 . (canceled)