Abstract: A method and apparatus for pultrusion of polyurethane resin is provided. The method comprises impregnating fibres with polyurethane resin to produce polyurethane impregnated fibres, and then pulling the polyurethane impregnated fibres through a pultrusion die. The pultrusion die defines a pultrusion path with a heated reaction zone of from about 20 to about 60 cm in length. The apparatus comprises a pultrusion die in combination with a polyurethane resin, the pultrusion die comprising, a body defining a pultrusion path with a heated reaction zone from about 20 to about 60 cm in length.

Abstract: There is provided a method of pultrusion using multiple resins. In the method a continuous interior reinforcement layer and a continuous exterior reinforcement layer are supplied and the interior reinforcement layer is infused with a first resin and then combined with the exterior reinforcement layer to form a pultrusion reinforcement structure. The pultrusion reinforcement structure passes into an infusion die where a second resin infuses the exterior reinforcement layer, and then passes into a curing die to cure the resins and form a composite article. The second resin comprises an aliphatic isocyanate polyurethane resin with a greater concentration of aliphatic isocyanate than is present in the first resin to give the composite article superior UV resistance. A pultruded composite article produced by the pultrusion method is also provided.

Abstract: There is provided a multi-layered composite article having an inner core of a first composite material and one or more than one outer layers of a second composite material, the second composite material comprising an aliphatic isocyanate polyurethane overlaying the inner core. A method of manufacturing such a composite article is also provided. The method comprises providing a core comprising a reinforcement impregnated with a first resin; mixing an aliphatic isocyanate component and a polyol component to produce a reaction mixture; impregnating a second reinforcement with the reaction mixture to produce an impregnated reinforcement; applying the impregnated reinforcement over an outside surface of the core; and allowing the reaction mixture to set to produce a composite article with one or more than one outer layers of aliphatic isocyanate composite material.

Abstract: A two component chemically thermoset composite resin matrix for use in composite manufacturing processes includes a solvent free polyisocyanate component and a solvent free polyol component. The solvent free polyisocyanate component is either an aromatic polyisocyanate, an aliphatic polyiscyanate or a blend of both. The solvent free polyol component is either a polyether polyol, a polyester polyol or a blend of both. The polyisocyanate component and the polyol component are in relative proportions in accordance with an OH/NCO equivalent ratio of 1:1 to 1:2. The components form a relatively low cost polyurethane composite resin having a useful range of physical properties, without the emission of volatile organic compounds during curing.