# US 2020/0400025 A1 · Pultrusion of Profiles Having Non-Uniform Cross Sections > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2020/0400025 A1 - Document ID: US20200400025A1 - Status: Published application - Kind: A1 - Application number: 16/904,926 - Filed: 2020-06-18 - Published: 2020-12-24 - Earliest claimed: 2019-06-20 - Assignees: Tsc, LLC - Applicants: Tsc, LLC - Inventors: Rob Sjostedt - Web page: https://patentgrep.com/patent/US20200400025A1 ## CPC - F01D 5/147: {Construction, i.e. structural features, e.g. of weight-saving hollow blades (F01D5/148, F01D5/16 and F01D5/20 take precedence; blade shape F01D5/141; blades with cooling or heating channels or cavities F01D5/18; heating, heat-insulating or cooling means on blades F01D5/18)} - B29C 70/521: {and impregnating the reinforcement before the die} - B29C 70/525: {Component parts, details or accessories; Auxiliary operations} - B29D 99/0028: {hollow blades} - B64C 27/473: Constructional features - B29K 2063/00: Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material - B29K 2307/04: Carbon - B29K 2309/08: Glass - B29L 2031/003: {having a profiled transverse cross-section} - B64C 2027/4736: {from composite materials} - F03D 1/0675: {of the blades} - F05D 2240/30: Characteristics of rotor blades, i.e. of any element transforming dynamic fluid energy to or from rotational energy and being attached to a rotor - F01D: NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES (machines or engines for liquids F03; non-positive displacement pumps F04D) - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - B64C: AEROPLANES; HELICOPTERS - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - F03D: WIND MOTORS - F05D: INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS ## Abstract Composite profiles, such as rotor blades, airfoils, I-beams, and box beams having non-uniform cross sections, and a system, method and process for pultrusion of composite profiles. The pultrusion of a heavier or thicker cross section portion of the composite profile is performed in-line and upstream from pultrusion of a thinner or lighter portion of the pultruded profile using a separate die for the thicker portion of the cross section, or leading edge slug, in order to optimize the processing conditions, productivity, and consistency of the composite profiles. ## Claims ### Claim 1 A method for pultrusion of a composite profile having a non-uniform cross section comprising: providing a leading edge slug die for pultruding a leading edge slug of the composite profile; providing a primary pultrusion die downstream from the leading edge slug die for pultruding a profile body of the composite profile; threading a first set of fibers into the leading edge slug die; threading a second set of fibers into the primary pultrusion die; heating the leading edge slug die; heating the primary pultrusion die; adding a first resin to a leading edge slug wet out bath; pulling the first set of fibers and the first resin through the leading edge slug die to form the leading edge slug; adding a second resin to a main wet out bath; and integrating the leading edge slug with the profile body to form the composite profile by pulling the leading edge slug through the primary pultrusion die while pulling the second set of fibers and the second resin through the primary pultrusion die to form the profile body. ### Claim 2 (depends on 1) The method of claim 1 wherein pulling the first set of fibers and the first resin through the leading edge slug die to form the leading edge slug further comprises inserting a wire rope for forming a leading edge weight insert. ### Claim 3 (depends on 1) The method of claim 1 further comprising partially curing the leading edge slug with the leading edge slug die. ### Claim 4 (depends on 3) The method of claim 3 further comprising completing curing of the leading edge slug with the primary pultrusion die. ### Claim 5 A composite profile having a non-uniform cross section manufactured by a process comprising the steps of: providing a leading edge slug die for pultruding a leading edge slug of the composite profile; providing a primary pultrusion die downstream from the leading edge slug die for pultruding a profile body of the composite profile; threading a first set of fibers into the leading edge slug die; threading a second set of fibers into the primary pultrusion die; heating the leading edge slug die; heating the primary pultrusion die; adding a first resin to a leading edge slug wet out bath; pulling the first set of fibers and the first resin through the leading edge slug die to form the leading edge slug; adding a second resin to a main wet out bath; and integrating the leading edge slug with the profile body to form the composite profile by pulling the leading edge slug through the primary pultrusion die while pulling the second set of fibers and the second resin through the primary pultrusion die to form the profile body. ### Claim 6 (depends on 5) The composite profile manufactured by the process of claim 5 wherein the first resin comprises a vinyl ester resin and the second resin comprises an epoxy resin. ### Claim 7 (depends on 5) The composite profile manufactured by the process of claim 5 wherein the first set of fibers comprises carbon fibers and the second set of fibers comprises glass fibers. ### Claim 8 (depends on 5) The composite profile manufactured by the process of claim 5 further comprising inserting a wire rope into the leading edge slug for forming a leading edge weight insert. ### Claim 9 (depends on 5) The composite profile manufactured by the process of claim 5 further comprising partially curing the leading edge slug with the leading edge slug die. ### Claim 10 (depends on 9) The composite profile manufactured by the process of claim 9 further comprising completing curing of the leading edge slug with the primary pultrusion die. ### Claim 11 A pultrusion tooling system for pultruding a composite profile having a non-uniform cross section comprising: a leading edge slug die for pultruding a first portion of the composite profile having a first cross section thickness; a primary pultrusion die for pultruding a second portion of the composite profile having a second cross section thickness, wherein the second cross section thickness is less than the first cross section thickness; a leading edge wet out bath for adding a first resin to the first portion of the composite profile; a mandrel for shaping the second portion of the composite profile; an overwrap infeed tool for wrapping fibers around the mandrel; and a main wet out bath for adding a second resin to the second portion of the composite profile. ### Claim 12 (depends on 11) The pultrusion tooling system of claim 11 further comprising a wire rope spool for inserting a wire rope into the first portion of the composite profile. ### Claim 13 (depends on 11) The pultrusion tooling system of claim 11 wherein a length of the leading edge slug die is greater than a length of the primary pultrusion die.