Engineering Passion

iPul pultrusion systemsMore speed in pultrusion

In cooperation with

Fascinating insightA tour round the iPul system

Material handlingManual filling, filling via barrel pumps or IBC containers Stations with individual programming of mixing times.

Fiber rack and fiber guidesfor glass and carbon fibers

Injection boxfor optimum wetting of fibers with highly reactive matrix systems

Moldwith different temperature zones for hardening and final shaping

Metering machinewith mixing head for polyurethane, epoxy resin or polyamide – for different discharge areas with tailored temperature concept.

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Central controlregulates and stores all process parameters, e.g. discharge output and haul-off speed.

Haul-offSynchronized puller with spindle drive – available with different clamping forces for complex profile geometries. Alternatively a crawler or belt haul-off can be used for simpler geometries.

Sawfor precise cutting and prefabrication

Support table or winder

More speed in pultrusion Productivity and cost-efficiency for straight and curved profiles

The new economical system solution allows production speeds of up to 3 m/min and works with a closed injection box. Besides simple and complex linear pro-file geometries, curved profiles can also be produced.

In the iPul pultrusion process, glass or carbon fibers are pulled off and fed through the injection box by fiber guides. The metering machine heat-balances and mixes the matrix material (polyurethane, epoxy or polyamide systems) in a mix-ing head in optimal process technology conditions and conveys the mixture into the injection box. Here, the fibers are

saturated to an optimum level with highly reactive matrix materials at an inner pres-sure of 5 to 100 bar. Then, the final shap-ing and curing of the profile takes place in various heating zones within the mold (e.g. 100 to 250 °C).

The extruded profile can be removed using either an electro-pneumatic extractor device or a belt/crawler haul-off. The pro-files are then cut to the desired length or can be wound or prefabricated. The cen-tral system control regulates the process technology parameters and the haul-off speed.

2. RimStar Nano metering machineInnovative metering system with accurate temperature sensing, suitable for matrix systems such as polyurethane, epoxy resin or polyamide.

Features

Low-pressure mixing head with dynamic mixing element and optional addition of separating agent

Tailored temperature concept

Compact design with frame on rollers

Continuous recirculation of components

Well-designed self-explanatory operating software with online remote service

With iPul, KraussMaffei is revolutionizing pultrusion, the procedure for the con-tinuous production of highly filled fiber-reinforced plastic components. Pultruded pro-files are thus opening up new areas of application.

4 iPulMore speed in pultrusion

1. Material handling Optimized material mixing process and automatic filling of material into the day tank from barrels or IBC containers.

Features

Individually programmed mixing times

Material recirculation

Special stirrers

Dry-run protection

Ventilation to prevent bubble formation

3. iPul pultrusion line Different system concepts for straight and curved profiled and for simple and complex geometries.

Features

Fiber rack and fiber guides for glass or carbon fibers

Electro-pneumatic extractor device with different haul-off forces for complex pro-file geometries or crawler/belt haul-off for simple geometries

Defined length cut with saw and use of winders and other prefabrication units

Reliable increase of haul-off speed and thus productivity up to 3 m/min

Central control – regulation of discharge output according to haul-off speed and central storage of process parameters

Pressure jacket for a deep sea pipeline. Radius pultrusion allows longer risers and flowlines.

RimStar Nano metering machine for epoxy resin, polyurethane or polyamide.

Fiber-reinforced window profiles allow narrow frames with high insulation capability, even for large window areas.

Low-pressure mixing head with dynamic static mixer and recirculation.

Concrete reinforcement rods (rebars) made of fiber composite materials are stable and corrosion-resistant.

Central user interface: process parameters are adjusted to the haul-off speed, production data stored.

Application areas: – Automotive– Infrastructure– Construction industry

(windows, rebars)– Energy sector (wind energy)

Your advantages: – Machine, mold and process

innovations from a single source– Highly efficient, high-quality

turnkey systems– Fully automated processes– Process optimization, consultation

and training

4. Mold technology From component analysis to the configu-ration of the right mold design in accor-dance with the required haul-off speed.

Features

Injection box for optimal fiber wetting and use of highly reactive 2K PU, epoxy and PA systems

Molds with individual heating zones for final shaping

Increased productivity with multiple cavities

Concepts for fast opening and locking of molds

5. Technological support Consultation, layout recommendations, process optimization and training as well as production support and customer- orientated service.

Features

Capacity for developing new ideas

Prototype manufacture

Good network of material suppliers and institutes

Many years of experience with highly reactive matrix systems

Quick interface clarification

Detection and resolution of problems via Teleservice

Global sales and service structure

Spare parts stocks

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KraussMaffei works closely with Thomas Technik to develop innovative ideas and provide turnkey series production plants.

For an optimum production chain for the iPul process, we are pooling our competence together with our cooperation

partner Thomas Technik + Innovation. Our objective is to advance the marketing of turnkey systems for the production of profiles for the construction industry, the automotive industry, the energy industry and the aerospace industry together. Our pooled expertise allows us to give our customers qualified consultation.

Your advantages: – Pooled expertise throughout

the entire production chain– Development, prototype manufacture

and testing of new components– Optimized interface between the

individual system components– Process-oriented component design,

development and production

6 iPulMore speed in pultrusion

Feasibility studySimulation of fiber infiltration

Consultation in the choice of materials

Support in the calculation

Mold design Prototype manufacture

Definition of production parameters

Component analysis Mold prototype

Technological leadership through cooperation

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Radius pultrusion Thomas Technik und Innovation KG

The cooperation with Thomas Technik, the inventor of radius pultrusion, makes it easier for our customers to access this innovative process and opens up new areas of application. We create tailor-made solutions for the production of curved profiles.

Production markets develop constantly and new visions are created almost on a daily basis. In order to profit from these visions, we must develop the right con-cept for you and provide you with a unique precision mold that satisfies your specific needs. We transform inspiration into products that impress.

The gripper closes and holds the end of the profile tight.

Fiber rack Metering machine Heated mold Puller Saw

The mold moves on the profile. The gripper opens. The mold moves to its initial position. No relative move-ment between the mold and the profile.

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Preparation of fibers and matrix

Pultrusion line startup and adjustment

Production of multiple cavities with high speeds

Automated prefabrication and storage of profiles

Support for new developments

Layout and optimization of production procedure

Maintenance planSpare parts packageOnline support

Series production Production consultation

Radius pultrusion allows the production of curved profiles on an industrial scale

Key

KraussMaffei is working with a network of partners to refine pultrusion technology. Here, the haul-off speed is decisively increased without negative impact on the high quality standards demanded.

System, process and mold technology all under one roof. Together with partner Thomas Technik, KraussMaffei is able to implement the entire process chain from the design of components to the tailored iPul system. We provide turnkey solutions with a high degree of system expertise from many years of process experience.

Pooled competences allow the holistic further develop-ment of plants and process technology together with the customer. This cooperative approach will consolidate and further extend our position as technology and market leaders in the long term.

iPul pultrusion systemsMore speed in pultrusion

www.kraussmaffei.com/pultrusion 1.0

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