Background Art [2] Traditional utility poles and the materials used to make them have distinct dis- advantages. Wooden, concrete and steel utility poles are the most common poles used today. Wooden utility poles are probably the most common utility pole in use today.

Wooden utility poles are susceptible to rot or destruction because of weather and bug infestation. To prevent the destruction of poles, many wooden poles are soaked in creosote. Creosote is a highly toxic substance that has possible links to cancer in humans. The creosote leeches out of the pole and often enters the water table where it pollutes drinking water. Even with the creosote application, wooden poles still have a limited life span. Wooden poles need extensive maintenance and routine replacement.

[3] Concrete poles have been used in place of wood in some places. Unfortunately, concrete poles are extremely heavy. These concrete poles often require a crane or special machinery to assemble the pole in the field. Also, these poles are not good for remote locations because the weight of the pole requires the use of heavy trucks to transport the poles.

[4] Steel poles are lighter than concrete, but remain burdensome. The steel poles still are susceptible to environmental factors, like rust. In addition, steel poles are highly electrically conductive. Thus, steel poles present a danger to people working on or near the poles.

Disclosure of Invention Technical Problem [5] Accordingly, a need exists for a pole system made of lightweight and strong material capable of meeting strength requirements and capable of resisting envi- ronmental effects. In addition, although forming processes to create flat or two- dimensional composite panels may exist, a need exists for a continuous process that is both fast and economical for the fabrication of such poles.

Technical Solution [6] A pultrusion system to form a reinforced panel is disclosed. The system comprising, a composite material pre-form zone; an apparatus to introduce vertical re- inforcements or z-directional reinforcements into a panel with two or more sides. The z-directional reinforcement system further comprising a first bank of injecting devices, wherein the first bank of injecting devices are situated in a first plane; and one or more other banks of injecting devices are situated in one or more other planes that are at an angle to the first plane. The pultrusion system further comprises a wet-out resin injection system, a pultrusion die, and a gripper assembly.

[7] In another embodiment, a method of fabricating a reinforced panel is disclosed.

The steps comprising pre-forming a composite panel, wherein the panel comprises at least one outer fiber-type layer, at least one inner core and at least one inner fiber-type layer; and wherein the panel comprises at least one surface; introducing z directional reinforcements into the panel; applying resin around and through the panel; heating and curing the resin and composite panel; and pulling the panel through the fabrication system.

[8] In a further embodiment, a method to stitch a composite panel is disclosed. The method comprises, a camshaft and rod driving a needle block housed in a tufting head downward towards a panel; the needle block piercing the panel and driving through a roving loop, a needle block freeing a foot lock to press the roving against the panel to prevent removal of roving during a next stitch; a cam forcing one or more hooks to swing back and free roving from a previous downstream loop; one or more hooks engaging between the roving and needle block; releasing needle block upward; and advancing the panel to receive the next stitch.

[9] In yet another embodiment, a multi-dimensional tufting apparatus is disclosed. The apparatus comprises: one or more tufting heads, the one or more tufting heads comprising: a feeding module, a foot lock and springs, a transmission, a needle block and a dancer element; a mandrel to support a panel comprising one or more planes to receive stitches; a frame to support the one or more tufting heads, wherein the frame is offset from the mandrel and the panel such that the tufting heads can be aligned with one or more planes of the panel for stitching placement; and wherein the one or more tufting heads can be offset from each other to enable substantially sequential multiplanar stitching.

Description of Drawings [10] FIG. 1A shows one embodiment of a fiber reinforced panel formed in more than one plane.

[11] FIG. 1B shows one embodiment of a fiber reinforced panel formed in more than one plane and one embodiment of the male and female couplers.

[12] FIG. 2 shows a side view of one embodiment of a pultrusion system for creating fiber reinforced panels that are formed in more than one plane.

[13] FIG. 3 shows an end view of one embodiment of skin deposition system used in a pultrusion system for creating fiber reinforced panels that are formed in more than one plane.

[14] FIG. 4A shows an end view of one embodiment of foam core deposition system used in a pultrusion system for creating fiber reinforced panels that are formed in more than one plane.

[15] FIG. 4B shows a side view of one embodiment of foam core deposition system used in a pultrusion system for creating fiber reinforced panels that are formed in more than one plane.

[16] FIG. 5 shows a side view of one embodiment of a four dimensional reinforcement injection system to place fiber reinforcements into a panel preform formed in more than one plane and used in a pultrusion system for creating fiber reinforced panels.

[17] FIG. 6 shows an isometric view of one embodiment of a four dimensional rein- forcement injection system to place fiber reinforcements into a panel preform formed in more than one plane and used in a pultrusion system for creating fiber reinforced panels.

[18] FIG. 7 shows one embodiment of how the reinforcements are placed in the different planes of a panel preform.

[19] FIG. 8A shows two views of one embodiment of a needle design that can be used to tuft fiber reinforcements into the different planes of a panel preform.

[20] FIG. 8B shows two views of one embodiment of a hook design that can be used to tuft fiber reinforcements into the different planes of a panel preform.

[21] FIG. 8C shows one embodiment of how a needle and hook create a series of tufts.

[22] FIG. 9A shows a wire diagram of the front view of one embodiment of a fiber injection device used to tuft fibers into one plane of the panel preform.

[23] FIG. 9B shows a wire diagram of a first side view of one embodiment of a fiber injection device used to tuft fibers into one plane of the panel preform.

[24] FIG. 9C shows a wire diagram of a second side view of one embodiment of a fiber injection device used to tuft fibers into one plane of the panel preform.

[25] FIG. 9D shows an isometric wire diagram, with the face plate of the tufting head assembly and the face plate to the main drive gears removed, of one embodiment of a fiber injection device used to tuft fibers into one plane of the panel preform.

[26] FIG. 9E shows one view of an embodiment of an eccentric cam used to tuft fibers into one plane of the panel preform.

[27] FIG. 9F shows a side view of a wire diagram of one embodiment of a fiber injection device used to tuft fibers into one plane of the panel preform.

[28] FIG. 9G shows an isometric wire diagram of one embodiment of the looper assembly.

[29] FIG. 10A shows a side view of one embodiment of an injection die and forming die used in a pultrusion system for creating fiber reinforced panels that are formed in more than one plane.

[30] FIG. 1OB shows a front view of one embodiment of an injection die used in a pultrusion system for creating fiber reinforced panels that are formed in more than one plane.

[31] FIG. 11 shows one embodiment of a puller system used in a pultrusion system for creating fiber reinforced panels that are formed in more than one plane according to the present invention.

[32] FIG. 12 shows a profile view of one embodiment of an inline octagonal sawing station for cutting panels.

[33] FIG. 13 shows one embodiment of a tufting head for stitching panels.

[34] FIG. 14 shows one embodiment of a tufting head with breakout views of a feeding module and foot lock.

[35] FIG. 15 shows one embodiment of a tufting head showing a needle block and foot lock.

[36] FIG. 16 shows one phase of a stitching process using a tufting head.

[37] To clarify, each drawing includes reference numerals. These reference numerals follow a common nomenclature. The reference numeral will have three digits. The first digit represents the drawing number where the reference numeral was first used. For example, a reference numeral used first in drawing one will have a number like 1XX while a number first used in drawing five will have a number like 5XX. The second two numbers represent a specific item within a drawing. One item in FIG. 1 will be 101 while another item will be 102. Like reference numerals used in later drawing represent the same item. For example, reference numeral 102 in FIG. 3 is the same item as shown in FIG. 1.

Mode for Invention [38] The present invention includes a reinforced panel and an apparatus and system of making the panel. Each of the preceding embodiments of the invention will be described in turn.

Composite Panels [39] Referring to FIG. 1A and 1B, the present invention relates to a panel 100. The panel may be formed by a first skin 106 (inner skin), an inner core 104, and a second skin 102 (outer skin). The composite laminate may have varying materials used for the first skin 106, the inner core 104, or the second skin 102. A skin 106 or 102 can also be formed from multiple layers of fibrous material and resin. The fibrous material may comprise any fiber type for example, fiberglass, carbon, aramid, Kevlar, carbon nanofiber, or other types of fiber. The resin may comprise any thermoplastic or ther- mosetting resin for example, polyester, phenolic resins, polypropylene (PP), or other similar resins.

[40] The inner core 104 may also be formed using several types of materials. These materials may also include fibrous materials and resin. However, in an exemplary embodiment, the inner core 104 may comprise a closed cell foam material for example, a phenolic foam, styrene, polyurethane, or other type foam. To reduce weight, the foam material may be any foam with a density of. 5 to 5 lbs/foot3. The core thickness can range from about 1/2 inch (2.5 cm) to about 5 inches (12.5 cm).

Preferably, the core width ranges from about 1/2 inch to about 4 inches (10 cm). The inner core 104 may also comprise a hollow cavity. This cavity may be formed by the placement of a substance between the skins 102 and 106 during the formation of the panel 100, and after the panel 100 is wetted and cured, the material can be removed either by a chemical or physical process. The inner core 104 may further comprise for example, cementious substances, fire-proof materials, sound-dampening materials, elastomers, other rubber-like materials, plastic-type materials, or other types of materials that meet the physical properties of the final panel 100.

[41] The panel also includes z-direction reinforcements 108. As used herein, the term z- directional is meant to encompass reinforcements perpendicular to a plane of the panel as well as those reinforcements that range from close to 0° to close to 180° relative to the plane of the panel. These reinforcements may also be made from varying materials, for example fibers, metals, composites, or natural materials (such as wood). In an exemplary embodiment, the reinforcements 108 comprise a composite formed from fiber and resin. The fibers may comprise organic or inorganic fibers and resin, for example, fiberglass, carbon, aramid, Kevlar, carbon nanofiber, or other types of fiber.

The resin may comprise any thermoplastic or thermosetting resin for example, polyester, phenolic resins, or other similar resins. As one skilled in the art will recognize, the materials used to form the panel 100 are immaterial to the invention.

[42] As shown in FIG. 1A, the panel 100 may be formed in more than one plane. In other words, the panel can have several sides to form a pole of varying geometries.

The embodiment of panel 100 has four sides 110,112, 114, and 116. The panel 100 il- lustrated in FIG. 1A comprises four sides of approximately equal length. In other em- bodiments of the panel 100 the sides may have different lengths. Also, a panel 100 may have more or fewer than four sides 110,112, 114 and 116. A one sided panel with tufted reinforcements is possible, but this type of panel is not ideal for creating structures. The panel 100 shown in FIG. 1B also includes devices 802a and 802b to couple two or more panels together to form different structures. These coupling devices are not necessary but may enable the coupling of two or more panels to form a structure. The panel 100 also shows that reinforcements 108 are placed into each side 110,112, 114, and 116 of the panel 100. As illustrated in FIG. 1A and 1B, for instance, the reinforcements 108 in panel 100 may be placed perpendicularly to each side 110,112, 114, and 116 of the panel 100. One skilled in the art will recognize that other arrangements of the reinforcements 108 are possible and will be explained in more detail below.

[43] While FIG. 1 illustrates an eight sided pole, one skilled in the art will recognize that a single panel 100 may have a plurality of sides, each side may be set at different or similar angle # to each other side. Also, in some embodiments, the panel may assume shapes with two sides that are in parallel but separated by one or more other sides that are at an angle # to the parallel sides. In various embodiments, the panel may comprise a plurality of geometrical configurations. For example, a panel 100 may be formed into an arc, ellipse, or semi-circle. Alternatively, the panel 100 may comprise one or more sides, for example, a square, a triangle, a pentagon, a hexagon, or a tetrahedron. One skilled in the art will recognize that the present invention can adjust to this shape by providing a numerous array of tufts 108, wherein one tuft or a small set of tufts 108 are each placed perpendicular or nearly perpendicular to a segment of the arc of the skin.

Composite Panel Fabrication System [44] Several forming processes to create flat or two-dimensional composite panels may exist, but a process and system to pultrude reinforced composite panels formed in two or more planes has not been developed. An exemplary manufacturing system 200 is shown in FIG. 2 and described hereinafter. For illustration purposes only, the manu- facturing process describes making a three sided panel with male and female couplers on the sides of the panel 201. The panel will have a first skin 106 (also referred to as an inner skin), a core 104, and a second skin 102 (also referred to as an outer skin).

The reinforcements will be tufted fibers injected into each side separately and per- pendicular to the plane of that side. This system 200 is only exemplary, but the system can be modified to form the several different composite panels with the several different panel structures mentioned or described earlier. For example, the system may easily be modified to form a four sided panel as described below. The invention is not meant to be limited to that one embodiment of the panel 201 or system 200 used to create the one panel, but the system 200 encompasses all the modifications needed to use the panel manufacturing system to form any of the panels mentioned earlier. These modifications will be recognized by one skilled in the art.

[45] The manufacturing system 200 includes a preform zone 202, an injection die/finish die zone 204, a cooling zone 206, and a puller zone 208. The pultrusion system may also include a cut-out and milling zone 210 and a part take out zone 212. In accordance with the invention, the multi-phase forming process produces a composite panel from rolls of fibrous fabric, a plurality of foam core boards or pieces, substantially continuous lengths of suitable fiber rovings, and heat processible resins. After producing a continuous length panel, the panel may be milled or sawed to produce a panel having a certain length. The forming process 200 is employed to make continuous lengths of composite reinforced panels. Each of the different zones and the process of using the manufacturing system will be described in more detail below.

[46] The pultrusion process flows from right to left in FIG. 2. The Preform Zone 202 comprises an inner fabric area 216, a foam loading area 218, an outer fabric area 220 and a stitching area 222. The preform zone may further comprise a material loading area 214. The term preform is used to describe the panel construction before the panel is wetted-out with resin and sent through the formation die. For this exemplary embodiment, the preform will have an inner or first skin 106, a foam core 104, and a second or outer skin 102. Each of these areas will be explained below. FIG. 2 provides a side view of the different devices in the pultrusion system. FIG. 2 and later figures will be used to describe the different devices in the pultrusion system.

[47] The material loading area 214 is a set of devices and tools to preposition the panel materials in the pultrusion process. The material loading area is a place to store or keep both the core material 224 and skin fabric material 226. The fabric material 226 is shown as a roll of fabric. This roll of fabric can be placed on a rod 228 to use for unrolling the fabric 226. This rod may be attached to an apparatus to lift the roll and place it on a rack in a fabric area. The lifting apparatus can be hoisted by a lift 232 attached to an overhead gantry 234 by means of a cable 236. Once lifted into the air, the lift 232 can slide down the gantry 234 on a set of wheels or rollers. The fabric 226 can be taken to the fabric area overhead and set into a rack when needed. The process may comprise any numer of fabric dispensers in the inner fabric area depending on the number of layers of fabric that make up the inner and outer skins. As explained earlier, in this embodiment the core material is a foam board 224. These foam boards are likely light enough to be lifted by a hoist and placed into the foam loading area 218.

[48] The inner fabric area is shown in a side view in FIG. 2 and in an end view in FIG.

3. As stated earlier, the rolls of fabric 226 can be placed on a rack 302 using a rod 228.

The fabric dispensers comprise two rolls of fabric 226. One roll of fabric is used first and when it runs out, the other roll is to be spliced at the end of the first roll without stopping the process. The second roll thus ensures continuity of the process. In various embodiments, one or more fabrics 226 may be unwound and used. For example, FIG.

2 illustrates two rolls of fabric 226 for dispensing, 226a and 226 b. However, one skilled in the art will recognize that for a single layer of fabric, only one roll of fabric 226 is required. In various embodiments, a fabric 226 may be woven in one of many orientations and each fabric 226 may be made from a different material. In addition, the fabric 226 may comprise unidirectional materials or fiber rovings. The embodiment shown has one to two fabrics 226 forming the inner skin 106. The fabric can be unrolled off the rod 228 and through one or more guides 304. The guides 304 may create tension in the fabric 226, straighten or flatten the fabric 226, or prepare the fabric 226 for use. The guides 304 may help maneuver the fabric onto a folding shoe 306. The folding shoe 306 manipulates the fabric 226 from a flat sheet into a polygonal shape. The shape is determined by the desired shape of the panel 201. To create the ap- propriate shape the fabric 226 is laid on a mandrel 308. The mandrel 308 is an elongated member that determines the shape of the panel preform. Thus, the mandrel 308 may be any curved, angled or polygonal-shaped member. In this embodiment, the mandrel 308 is a three sided shape having equal width sides. Thus, the panel preform should have three equal sides. The folding shoe 306 shapes and presses the fabric 226 over the entire mandrel 308. Besides rolls, the panel forming process 200 may use other fiber material bundles that are set in a folded configuration and pulled from a box or other container. One skilled in the art will recognize other methods of dispensing skin materials into the pultrusion process.

[49] Referring still to FIG. 2, in this embodiment, the inner fabric area 216 and the outer fabric area 220, comprise equipment to dispense a different layer of fabric 226b onto the first layer of fabric 226a. In this embodiment, there are two separate fabric dispensing units. The first fabric 226a is unrolled off of rod 228 and through one or more guides 304. The guides 304 help maneuver the fabric 226a onto a folding shoe 306. The fabric proceeds up the mandrel 308 and the second fabric 226b is dispensed on top of the first layer of fabric 226a. The process is repeated for the outer skin in the outer fabric area 220. The first layer of fabric 226c is dispensed on top of the foam core 224 followed by a second layer of fabric 226d.

[50] The fabrics 226 proceed up the mandrel 308 to the foam loading area 218. FIG. 4A shows a front view of the one embodiment of the foam loading area 218. The foam loading area 218 comprises a foam dispensing device 400. The foam dispensing device 400 accepts a stack of foam pieces or foam boards 224. The foam boards 224 in one embodiment are preformed into the shape of the final panel 201. For instance, in the present example, the foam boards have three equidistant sides 402a, 402b, and 402c.

In other embodiments, the foam boards 224 may be flat foam pieces, where one foam piece is used for each side of the panel 201. Any number of pieces of foam may form a single section of the core and the invention is not limited to the type of foam board used in this description. Other embodiments of the foam boards 224 are possible and included in the present invention. For instance, expandable foam may be injected onto the skin and sent through a die to form the core layer. The foam boards 224 are lowed onto the inner skin and have the same shape generally as the mandrel. Each foam board abuts the previous and succeeding foam boards that are placed on the mandrel before and after the current foam piece.

[51] In this embodiment, one or more brackets 404 holds the side edge 406 of the bottommost foam board. When the foam piece 224 is to be set onto the inner skin 106, the brackets 404 retract, and a foam board 224 drops onto the mandrel 308. The brackets 404 quickly reverse and reengage after the foam piece 224 is dropped to catch the next bottommost foam board 224 and hold the stack of foam boards 224.

[52] To control the movements of the brackets, any mechanical system may be used including, but not limited to, gears, hydraulics, clutches, belts, pulleys, and air cylinders. The succeeding description is an exemplary embodiment of the system used to dispense the foam, and the present invention is not limited to that one embodiment.

The brackets can be clamped using a set of clamps onto a tube (not shown) that extends longitudinally between the frame 432 end pieces. In other embodiments, the brackets may be integrated or one piece with the tube. This tube has a bracketed end piece 416. A belt, chain, or other motion transfer device 417 is connected or wound around the bracket and a timing pulley 418. In turn, the timing pulley 418 is connected to a synchronous pulley 420 by a mechanical device, such as the exemplary timing belt 422. Each side of the dispensing rack contains the preceding devices. The synchronous pulleys on each side of the dispensing rack are connected by another mechanical device, such as the exemplary synchronous belt 424. This belt ensures that the brackets on each side of the dispensing rack are actuated at the same time to allow the foam piece to drop.

[53] One of the synchronous pulleys is connected to a dispensing armature 426. At the end of the arm 426, an air cylinder 428 is attached to the arm 426. The cylinder may also be attached to a bracket or flange 430 on the side of the frame 432 of the rack.

This cylinder may then be connected by a hose of other air flow system (not shown) to a pump (not shown). The pump may be actuated by a computer, an electronic controller, or mechanical controller (not shown). When a piece of foam needs to be dispensed, the controller actuates the air valve. Air is sent to the cylinder. The cylinder extends and rotates the end of the arm. The arm rotates the synchronous pulley. On the other side of the rack, the motion from the first synchronous pulley is transferred and replicated at the second synchronous pulley because of movement in the synchronous belt. The synchronous pulleys turn the timing pulleys. The timing belt attached to the timing pulley rotates the tube. The tube rotates and moves the brackets from under the side edge 406 of the bottommost foam piece. To reengage the brackets, air can be drawn from the cylinder and the process is reversed.

[54] To abut one piece of foam to the end of the preceding piece of foam, a sliding frame or pusher (not shown) can be used to push the foam piece forward in the pultrusion process. The sliding frame rides along a track on the frame. Referring to FIG. 4B, the sliding frame is connected to a sliding drive belt 438. This drive belt is strung between two drive pulleys 446. A sliding belt 447 is also connected to the drive pulleys 446 and can be seen winding around and amongst several pulleys until it terminates at two belt brackets 440. A set of the pulleys 443 that are connected to the sliding belt are on the sliding bracket 442. The sliding bracket is, in turn, connected to a sliding air cylinder 444, at one end of the cylinder. Like the air cylinder 428, the sliding air cylinder 444 is mounted to the frame 432 on the other side of the cylinder 444. A hose (not shown) pushes and draws air in and out of the cylinder 444. The hose can be connected to some pump or air flow system, which is controlled by the controller mentioned earlier.

[55] To operate the sliding frame, the controller actuates the valve that releases air into the air cylinder. The air cylinder extends and pushes the sliding bracket in a horizontal direction between the two belt brackets. The sliding belt is forced to move and rotate the drive pulleys. The drive pulleys cause the drive belt to move and pull the sliding frame along the track. The controller can time the movement of the brackets and the sliding frame to insure these movements are made in concert. In other words, the controller ensures that the sliding frame is at its beginning position when the foam is dispensed, the brackets lift the stack of foam boards before the sliding frame starts to move, the sliding frame moves the foam from underneath the foam stack, and the sliding frame is returned to its beginning position before the next foam board is dispensed. One skilled in the art will recognize that these mechanical systems are only exemplary and may be changed or modified to dispense the foam in other ways.

[56] The dispensing process is repeated continuously as the pultrusion system is operating. Thus, foam boards 224 should be continuously loaded into the dispensing system 400. To accomplish this repeated loading, a set of stairs (not shown) may be provided to allow a hoist system to carry stacks of foam boards 224 from the material loading area 214 to the stack of foam boards 224 on the dispensing system. In another embodiment, a lift may be used to move the foam boards 224 into position using the gantry system 234. In other embodiments, a separate conveying system can be used to move the foam pieces into position.

[57] A slight vacuum 410 may be formed on the underside of the mandrel 308 to tightly mate the foam boards 224 with the inner skin 106. In other embodiments, a mechanical mechanism, an electrostatic, or other device may accomplish the tight mating of the foam board 224 and the inner skin 106. One skilled in the art will recognize other means of dispensing the foam boards 224. In addition, one skilled in the art will recognize how to modify the dispensing system to provide several flat foam boards or several foam pieces instead of pre-formed foam boards. These different means and modifications are included in the present invention.

[58] After the foam board loading area 218, a second set of fabrics or fibrous materials 226 are applied to the outer face of the foam boards 224 at the outer fabric area 220.

Again, the fabric 226 may be unwound and formed to the foam pieces 224 with a folding shoe 306. The folding shoe 306 also acts as the mechanical implement to ensue tight mating of the two skins 226 and the foam core 224 before stitching. This outer fabric area 220 is similar to the inner fabric area 216 and will not be described further.

[59] A gantry 234 and support structure may be constructed over the fabric areas 216 and 220 and the foam loading area 218. This gantry 234 allows rolls of fibrous material 226 and foam pieces 224 to be pre-positioned during processing. The prepositioned material can be quickly integrated into the flow of the materials into the stitching and forming process. Thus, the system 200 can operate continuously without needing to stop to reload materials.

Multi-dimensional Tufting System [60] After the application of the outer skin 226, the materials form a panel preform. This preform is then sent to a stitching area 222 shown in FIG. 5. The stitching area 222 acts as a mechanical coupler for the preform pieces. The stitching area 222 may include two or more roving injection devices 602 that can place a plurality of rovings across and through each side of the panel 201. For instance, the present embodiment creates a four sided panel, and therefore, four injection devices 602 are used to place rovings in each of the four sides. One injection device 602 is used for each side, and therefore, there may be more or fewer injection devices 602 depending of the design of the panel 100.

[61] An example of a four head tufting system for a half octagonal panel is shown in FIG. 5. In this embodiment, the tufting heads 602 are supported by a half octagonal frame 652 offset from the mandrel 308 and the foam core 224 such that the tufting heads can be aligned with one or more planes of the panel for stitching placement. The frame 652 is supported by the base frame 650. The tufting head assembly 602 will be described in further detail below. The location of each tufting head is staggered to avoid the tufting needles in colliding or interfering with each other. In this embodiment, the fibers are tufted in the faces 224a and 224c first by the tufting heads 602a and 602c facing forward. Then, the two sides of the panel 224b and 224d are tufted later by the heads 602b and 602d facing backward.

[62] The tufting heads are slanted at an angle to the centerline of the panel. This angle is related to the angle of insertion Theta of the fibers and the angle of the planes Phi of the panel. Thus, as the desired angle of insertion and angle of the planes changes the angle of the tufting head also changes. Each tufting device can operate as a single, in- dependent unit. In the embodiment shown, there are four insertion tufting heads 602a, 602b, 602c, 602d. These tufting heads may operate in tandem or independently from the other heads.

[63] In this embodiment, each tufting head pierces the panel at a relatively perpendicular angle to the specific side of the panel. The tufting heads are sized to inject rovings into parts of the corners of the panel 100. After being extracted, the needles leave the rovings inside the panel as shown in FIG. 1A. As evident from FIG. 1A, the needles of the different tufting heads overlap in the corners 101 of the panel 100. In practice, the needles injecting rovings into the corners 101 would collide if the tufting heads tufted simultaneously and in the same position. Thus, one or more of the injection devices is placed a distance down the line from the other devices. This modified process is shown in FIG. 6.

[64] Hereinafter, the terms roving injection device and tufting machine can be used in- terchangeably. However, the present invention is not limited to that one embodiment, as stitching, sewing, pin reinforcement, and other devices are also envisioned to be used in the pultrusion process. In addition, as used herein the terms tuft and stitch are used interchangeably. Fibers or fiber bundles can be unwound from a creel or rack either using tangent pulling or center pulling, but preferably using tangent pulling to prevent twisted fibers. The fibers can be pulled through a preheating oven that evacuates moisture. The fibers are threaded into the tufting head 604 of the tufting device 602. The tufting head 604 has a plurality of needles used to puncture the outer skin, drive through the core, and puncture the inner skin. The needle has a fiber bundle threaded through a hole in the neck of the needle. The fiber bundle is drawn through the hole created by the needle. A looper or retention device on the other side of the panel can retain the fiber bundle as a loop, while the needle is retracted. The number of needles on each tufting head may vary. The gauge is determined by the number of needles in the stitching head for the amount of space covered by the tufting head. In the embodiment shown, there are 27 needles set at a'/2 pitch. In other words, there is a needle in the tufting head every 1/2 inch across the length of the tufting head. The gauge can be any density of needles depending on the desired qualities of the final panel. In addition, each separate injection device can have a different and unique gauge.

[65] An example of how the tufting heads place reinforcements into the panel is shown in FIG. 7. FIG. 7 shows a half hexagonal panel instead of the half octagonal panel shown FIG. 5 and FIG. 6. Again, panels can be of different shapes and number of sides. In this embodiment, each tufting head pierces the panel at a relatively per- pendicular angle to the specific side of the panel. The tufting heads are sized to inject rovings into parts of the corners 702 of the panel 201. After being extracted, the needles leave the rovings inside the panel as shown in view 704. As evident from view 706, The needles of the different tufting heads overlap in the corners 702 of the panel 201. In practice, the needles injecting rovings into the corners 702 would collide if the tufting heads tufted simultaneously and in the same position. Thus, one or more of the injection devices are offset a distance down the line from the other devices. Ac- cordingly, in an alternate embodiment the fibers may be tufted in the top of the panel first. Then, the two sides of the panel may be tufted later in time. Thus, the tufting of the top and sides of the panel may occur simultaneously without interference. The tufting heads are slanted at an angle to the centerline of the panel. This angle is related to the angle of insertion Phi of the fibers and the angle of the planes Theta of the panel.

Thus, as the desired angle of insertion and angle of the planes changes the angle of the tufting head also changes. Each tufting device can operate as a single, independent unit. In the embodiment shown, there are three insertion implements. These tufting devices may operate in tandem or independently from the other implements.

[66] An embodiment of a tufting needle and a loop retention device are shown in FIG.

8A and 8B, respectively. The needle and looper devices known in the art are designed only to penetrate backing. The needle and looper system demonstrated in FIG. 8A-8C are designed to penetrate a panel up to and greater than 4 inches thick. In general, the length of the needle approximates about half the thickness of the panel to be tufted. In this embodiment, the needle 800 has a nonlinear shape. At some distance from the proximal end 801 of the needle 800, the needle has a first deviation 804, and some distance from that deviation, a second deviation 806 is formed into the needle 800.

These deviations 804 and 806 form a jog 808 in the needle 800. The needle 800 forms a point 810 at the distal end of the needle 800. In the jog 808, a hole 812 is placed in the neck of the needle 800 to accept the fibers used in the tuft 108. The loop retention device 814 is formed in the shape of a looper. Hereinafter, the loop retention device 814 will be referred to as a looper. However, the loop retention device 814 is not limited to that embodiment. The looper is formed from a neck 816 and a tine 818.

Referring to FIG. 8C, in operation, the needle 800 punctures the panel 100. At the opposite side of the panel 100, the needle 800 exposes the jog 808 in the needle 800.

The needle 800 passes the side of the panel 100 enough to expose the hole 812. The tine 818 proceeds into the jog 808 between the needle and the fibers threaded through the hole 812. As the needle 800 is retracted, the tine 818 holds the fibers in place. The tine 818 also retracts after a period of time, and the fibers left form a loop 803. The preceding embodiments do not describe the size of the needle or looper because those dimensions depend on the type of panel being constructed and the type of loops and fibers used in the construction. One skilled in the art will recognize other embodiments of the needle and looper that are possible.

[67] On each plane of the panel 100, an insertion device or tufting head is positioned to tuft the panel 100. As used herein, tufting head is used to generally describe an insertion device for inserting z-direction reinforcements into a panel. An embodiment of a tufting head is shown in FIG. 9A through FIG. 9N. The tufting head 602 includes a stitching head 604, a drive 904, a looper module 906, and a series of gears, cams, belts, chains, clutches, or other mechanical devices to operate the parts in concert. The stitching head 604 is a block of one or more stitching needles 800 integrated into an array. As explained previously, the needles 800 may be of any shape that can pierce the preform panel 100 (not shown) and place the stitch 108 through the perforation.

The stitching head 604 is capable of vertical movement, or movement in the Z- direction. In some embodiments, the pultrusion system may need to pause mo- mentarily as a set of stitches 108 is sent through the panel 100. When the needle 800 is finished retracting, the panel 100 proceeds a short distance and another set of stitches 108 is placed into the panel 100. However, the exemplary embodiment includes a stitching head 604 that is capable of moving in multiple directions. Thus, the tuft 108 may be placed into the continuously moving panel 100 without the pultrusion system pausing for the insertion.

[68] The proceeding description will refer to a tufting head 602 spatially oriented as to have the stitching needles 800 in a vertical position. However, the tufting head 602 can be spatially oriented at any angle or position in relation to the panel and the ground to stitch through any side of the panel. The following description will use the following terms interchangeably, vertical motion, Z-axis motion, and'up and down'or horizontal motion, X-axis motion, and'back and forth'.

Transmission System [69] Referring to FIG. 9D, the main shaft 910 drives the stitching shaft 916 through the transmission 612, which includes a first sprocket 612a, a chain 612b, and a second sprocket 612c, and the clutch 912. The stitching shaft 916 is driven only when the clutch 912 is actuated by a controller or control command system (not shown). This controller may be a computer, electronic device, or mechanical device. In the exemplary embodiment, the controller is the same electronic or computer device used to control the foam dispensing unit 400.

[70] A'stitching-to-loopers'transmission unit 960, as shown in FIG. 9C and FIG. 9D, comprises a body 961, a transmission 962, which further comprises a first sprocket 962a, a chain 962b, and a second sprocket 962c, a shaft 916, and a second transmission 951, which includes a first sprocket 951a, a chain 951b, and a second sprocket 951c. This'stitching-to-loopers'unit transmits the rotational motion from the stitching shaft 916 to the loopers shaft 952.

[71] Referring to FIG. 9C, the main shaft 910 drives the reciprocating shaft 927 through the transmission 614, which includes a first sprocket 614a, a chain 614b, and a second sprocket 614c, and a clutch 926 that is located behind sprocket 614c. Shaft 927 is driven only when clutch 926 is actuated by the controller (not shown).

Stitching Head Horizontal Motion [72] Referring to FIG. 9A, FIG. 9B, FIG. 9F, and FIG. 9E, the two vertical guide shafts 922a and 922b are attached to two plates 932a and 932b. Plates 932a and 932b are fastened to a carriage block 929, wherein the carriage block 929 can ride hor- izontally on two fixed guide shafts 930a and 930b. Carriage block 929 has a central cavity surrounding a shaped cam 928. The shaped cam 928 can be rigidly coupled to the reciprocating shaft 927. Carriage block 929 holds a cam following roller 928a. The contact between the cam following roller 928a and the shaped cam 928 is maintained by a set of springs 934a and 934b, attached to the carriage block 929 on one end and to a fixed support on the other end. The shaped cam rotates in a clockwise direction. The carriage block has two components to the horizontal stroke. A first portion of the stroke goes in the direction of movement of the pultruded panel, as shown in FIG. 9E.

The other portion of the stroke goes in an opposite direction of the movement of the panel. The portion of the stroke moving in the direction of the panel occurs from R1 to R2 and the other portion of the stroke occurs from R2 to R1. The shaped cam 928 has a dual spiral outer shape, as shown in FIG. 9E. In other words, for 2/3 of a revolution, the shaped cam 928 is an expanding'Archimedes'spiral (from Rl to R2), and for 1/3 of a revolution, the shaped cam is a receding'Archimedes'spiral (from R2 to R1).

[73] The cam following roller 928a is attached to the carriage block 929 and is constrained to a horizontal movement. When the shaped cam 928 turns 1 full turn, the cam following roller 928a and carriage block 929 complete a full stroke, back and forth, wherein the stroke length equals the difference between R2 and Rl. The re- ciprocating movement of the carriage block 929 is executed with a linear velocity pro- portional to the angular velocity of the shaped cam 928. The angular separation, 120° in this embodiment, between the expanding and receding spirals (the angular re- lationship between R1 and R2) can vary to change the velocity or acceleration of the portions of the stroke of the carriage block. In this embodiment, the portion of the stroke moving with the panel occurs at a velocity less than the portion of the stroke returning the carriage block to its initial position. The lengths of R1 and R2 may also change to modify the size of the stroke made by the carriage block. In the present embodiment, the rotation of the shaped cam is proportional or isokinetic to the linear movement of the panel. If the panel is moved through the pultrusion system at a faster rate, the shaped cam may be rotated at a higher speed to ensure the needles match the panel's movement. One skilled in the art will recognize the other changes that may be made to this tufting system to create panels in different ways or create different panels.

[74] The shaped cam 928 is driven by the motor 904 through the transmission 909, the shaft 910, the transmission 614, the clutch 926, and the shaft 927. The motor 904 speed is controlled by the controller (not shown), such that the linear velocity of the carriage block 929 when propelled by the expanding spiral part of shaped cam 928 exactly matches the linear velocity of the panel to be stitched 100. Thus, the panel may be stitched in a pultrusion process without stopping the linear movement of the pultruded panel. When the needles are inserted into the panel to place the roving, the carriage block 929, the stitching head 604, and the needles 800, all move, in the horizontal direction, at the very same speed as the panel 100. The controller (not shown) actuates the reciprocating clutch 926 for every new stitch. Thus, the controller can manipulate the stitch rate described earlier by changing the frequency of actuation of the reciprocating clutch.

Stitching Head Vertical Motion [75] The vertical motion of the stitching head occurs during the period when the needles 800 and the panel 100 are traveling at the same horizontal velocity. Referring to FIG.

9B and 9F, a crankshaft 918 is rigidly coupled to the stitching shaft 916. A link bar 920 is articulated with the crankshaft 918 at one end and with the stitching head 604 at the other end. The stitching head 604 rides on two vertical guide shafts 922a and 922b.

[76] The stitching shaft 916 and the crankshaft 918 execute 1 turn when the stitching clutch 912 is actuated by the controller. For one turn of the crankshaft 918, the stitching head 604 completes one stitching cycle (one down and up stroke). FIG. 9F shows the stitching head in the'up'position and FIG. 9B shows the stitching head 604 in the'down'position, with the needles 800 having pierced through panel 100.

Control and Synchronization of the Stitching Head's Horizontal and Vertical Motion [77] In the exemplary embodiment presented, the transmission 612 has a 1/1 ratio to the stitching shaft 916. Thus, the transmission 612 and the stitching shaft 916 turn at the same speed as the main shaft 910, when the clutch 912 is actuated. The transmission 614 has a 2/3 ratio to the reciprocating shaft 927 and turns at 2/3 the speed of the main shaft 910, when the clutch 926 is actuated. One skilled in the art will recognize that the 2/3 ratio for the transmission 614 corresponds to the 2/3 expanding spiral and 1/3 receding spiral of the shaped cam 928. One skilled in the art will also recognize that other transmission ratios and other cam angles are included in the present invention.

[78] The controller synchronizes the stitching head's horizontal and vertical motion by appropriately actuating clutches 912 and 926. Clutches 912 and 926, in the exemplary embodiment, are one-turn clutches. In other words, when triggered, the clutches rotate for one revolution only and stop precisely. The invention is not limited to this one embodiment and other clutch and brake combinations can achieve the same goal. In another embodiment, separate and independent motors can drive shafts 916 and 927 and can be synchronized by the controller.

[79] In the exemplary embodiment, one stitching cycle includes both vertical and horizontal motion that is in concert and synchronized. This cycle starts with the crankshaft in its initial position, as shown in FIG. 9F, and the reciprocating spiral cam 928 in its initial position, as shown in FIG. 9E, which corresponds to the carriage block 929 and the needles 800 being in their rightmost position. The stitching cycle begins with the actuation of clutches 926 and 912. The needles 800 move horizontally forward at the same speed as the panel 100 being stitched and pultruded. Simul- taneously, the needles 800 move down and then up. The clutch 912 finishes one turn and un-clutches. The needles 800 move backward to the reset position. Finally, the clutch 926 finishes one turn and un-clutches, and the stitching system waits for the next stitching cycle.

Looper Motion [80] Referring to FIG. 9D, on the opposite side of the panel 100 (not shown), there is a looper module 906, fixed in position relative to tufting head 602 (both 602 and 906 being fastened to a common supporting structure not shown). The looper module 906 has an input shaft 952 that is driven from shaft 916, through transmission 962, shaft 926, and transmission 951. The looper shaft 952 and the stitching shaft 916 are syn- chronized. Now referring to FIG. 9G, the looper shaft 952 is connected to an eccentric cam 938 that contacts a looper cam following roller 939. The roller 939 is attached to a hook pivot arm 940. On one side, the pivot arm 940 is connected to a pivot 942, which is set in a hook plate 944. At the other end of the pivot am 940, the hook head 946 is set with an array of hooks 814. The cam 938 can drive the hook head 946 through an arc of motion, which is generally horizontal in orientation. Referring again to FIG. 8C, the hooks 814 can proceed to engage the needles 800 during the needles 800 downward motion. As the needles retract, the hook head 946 reaches the end of its forward motion and begins to also retract. Retracting the hook head 946 disengages the loops 803 at the bottom of the panel 100 and prepares the hook head 946 to retain the next group of loops 803. The gears, belts, drives, axles, and other mechanical pieces are designed to create synchronous motion in the stitching head 604 and the hook head 946.

[81] The following is an improvement of the tufting head 602 previously described and shown in FIG. 9A to FIG. 9G demonstrating the addition of a roving feeding module 1302 and a roving foot lock 1304. Referring to FIG. 13,14, 15, and 16, this embodiment of the tufting head 1300 is illustrated. In particular, FIG. 13 shows the tufting head 1300 with an additional feeding module 1302 and a foot lock 1304. FIG.

14 shows the feeding module 1302 and foot lock 1304 removed from the tufting head assembly 1300. FIG. 15 shows the foot lock 1304 installed over the needle block 1308.

FIG. 16 shows one phase of the tufting sequence.

[82] The tufting head comprises a feeding module 1302 and a tufting module 1306. The feeding module comprises rollers 1310, a transmission 1312 and gears 1314 to turn the rollers 1310, a mobile dancer assembly 1316, a needle block 1308 connected to the dancer 1316, a foot lock 1304 and springs 1320. Fibers are threaded through holes 1322 in the fixed frame and in the mobile dancer 1316, and around the feeding rollers 1310. There are several rovings 1324 installed, one for each needle 1326 of the tufting frame.

[83] The tufting head 1300 comprises a plurality of needles 1326 used to puncture the outer skin, drive through the inner core, and puncture the inner skin. The needle 1326 has a fiber bundle threaded through a hole in the neck of the needle 1326. The fiber bundle is drawn through the hole created by the needle 1326. A hook or retention device 1328 on the other side of the panel can retain the fiber bundle as a loop, while the needle is retracted. The number of needles 1326 on each tufting head 1300 may vary. The pitch of the stitch density is determined by the number of needles in the stitching head for the amount of space covered by the tufting head. In the embodiment shown, there are 27 needles set at a 1/2 pitch. In other words, there is a needle in the tufting head every 1/2 inch across the length of the tufting head. The pitch can be any amount of needles depending on the desired qualities of the final panel. In addition, each separate injection device can have a different and unique pitch.

[84] An example of one phase of the stitching process is illustrated in FIG. 16. In this embodiment, the dancer 1316 includes a lower bar 1316a, two rods 1316c and an upper bar 1316b. The sequence begins with needle block 1308 in the fully down position the needle 1326 piercing the substrate 1334. Hooks 1328 are engaged between needle 1326 and fiber roving 1324. Dancer 1316 comprises a lower bar 1316a, two rods 1316c and an upper bar 1316b. During the process, the needle block 1308, drives the dancer 1316 up and down through pin 3114. Concurrently, the foot lock 1304 is pressed down by springs 1320 and presses roving 1324 against substrate 1334.

[85] The first step in the stitching process is dancer pre-feeding. During this process, the dancer 1316 moves up, pulling from upstream the length of roving 1324 necessary for the next stitch. Needle block 1308 is moving up, driven by camshaft 1330 and rod 1332. The needle block 1308 drives dancer 1316 up by means of pin 1336. Hooks 1328 remain engaged into roving 1344 loop, thus preventing downstream roving 1324 to be pulled back. Additionally, foot lock 1304 also locks downstream roving by pressing it against substrate 1334. Thus, the upward movement of dancer 1316 can only draw roving 1324 from upstream. The rollers 1310 are coupled to shafts 1338 by uni-directional clutches, allowing freedom to over-rotate when roving 1324 is pulled by dancer 1316.

[86] Once dancer 1316 has reach its uppermost position, the roving 1324 necessary for the next tufting has been drawn from upstream and is accumulated between last roller 1310 and dancer upper bar 1316a. When reaching its uppermost position, needle block 1308 has compressed spring 1320 and pushed foot lock 1304 upwards. Foot lock 1304 thus stops pressing roving 1324 against substrate 1334. However, hooks 1328 are still engaged into roving loop 1344.

[87] Once the stitch is accomplished, the substrate moves forward to receive the next stitch. During this step, the needles 1326 and the foot lock 1304 remain fully retracted in their uppermost position, substrate 1334 moves forward between 2 stitches. During this step, feeding rollers 1310 are feeding a length of roving 1324 equal to the substrate forward stroke.

[88] Generally, the stitching process can be broken into three steps. During the first step, the camshaft 1330 and rod 1332 drive needle block 1308 downward. Needles 1326 pierce substrate 1334 and drive down roving 1324 loop. The roving length necessary to form the needle loop comes from dancer 1316 driven downward by block 1308.

Needle block 1308 downward movement frees spring 1320 and foot-lock 1304 presses roving 1324 downstream lead against substrate 1334. Hooks 1328 remain engaged during the first part of the needles downward stroke. While the needles 1326 are driven further down, cam 1340 forces hooks 1328 to swing back and free roving 1324 previous downstream loop. Needles 1326 have reached their lowermost position.

Spring 1342, in combination with cam 1340 rotation made hook block swing back. At this point in the process, the hooks 1328 are engaged between roving 1324 and needle 1326.

[89] In the exemplary embodiment, the stitching needles 800 create holes in the panel (through both skins and the core) that are larger than the diameter of the bundles of fibers placed into the holes. One skilled in the art will recognize other mechanical structures that may be used in the tufting device 602. The preceding description provides only an exemplary device and other modifications and changes are con- templated and included in the invention.

[90] After the stitching operation, the pultrusion system includes a wet out system and die 204. The wet out system 204 may be any process or device that can wet or impregnate the fibers 108, and skins 102 and 106, the fibers 108 with resin. Wet out systems 204 may include incorporating the resin in a solid form that will be liquefied during later heating. For instance, a thermoplastic resin may be formed as several fibers. These fibers may be interspersed within the fibrous skins 102 and 106 and the rovings 108. When heat is applied to the bundle of fibers, the thermoplastic fibers liquefy or melt and impregnate or wet the carbon and glass fibers. In another embodiment, the carbon and glass fibers may have a bark or skin surrounding the fiber rovings or fibrous skins; the bark holds or contains a thermoplastic or other type resin in a powder form. When heat is applied to the fibers, the bark melts or evaporates, the powdered resin melts, and the melted resin wets the fibers. In another embodiment, the resin is a film applied to the fibers or skins and then melted to wet the fibers. In still another embodiment, the fibers or skins are already impregnated with a resin-these fibers and skins are known in the art as pre-preg tows and pre-preg fabrics. If the pre- preg fibers and skins are used, no wet out tank or device is used.

[91] An embodiment of the wet out system is a resin injection chamber 1002.

Hereinafter, a resin injection chamber 1002 will be used in the description, but the present invention is not meant to be limited to that embodiment. Rather, the wet out system 204 may be any device to wet the fibers. The resin injection chamber 1002 is shown in a side view in FIG. 10A and an end view in FIG. 10B. The preform enters the chamber 1002 through a first opening 1004. A resin tank 1006 contains resin under pressure. Resin enters the tank 1006 in the upper section 1006a and exits through the lower section 1006b. Excess resin is recycled into the upper section 1006a via a recycle port 1009. Using gravity and pressure, the resin is squeezed through the holes created during the stitching operation (which can be larger in diameter than the bundle of fibers in the hole), wets the tufted rovings 108 in the interior of the panel 100, and is exuded out the other side of the panel 100. At the other side of the panel 100, the resin impregnates the opposite side skins. In this manner, all parts of the panel 100 are assured wet-out including the rovings 108. In addition, the fabric that creates the female couple 802a is also impregnated with special injectors 1008.

[92] Various alternative techniques well known in the art can be employed to apply or impregnate the preform with resin. Such techniques include for example, spraying, dipping, reverse coating, brushing, and resin injection. In an alternate embodiment, ultrasonic activation uses vibrations to improve the wetting of the preform. In another embodiment, a dip tank may be used to wet out the preform. A dip tank has the preform enter a tank filled with resin. When the preform panel emerges from the tank filled with resin, the fibers and skins are wetted.

[93] Generally, any of the various known resin compositions can be used with the invention. In an exemplary embodiment, a heat curable thermosetting polymeric may be used. The resin may be for example, PEAR (PolyEther Amide Resin), Bis- maleimide, Polyimide, liquid-crystal polymer (LCP), vinyl ester, high temperature epoxy based on liquid crystal technology, or similar resin materials. One skilled in the art will recognize other resins that may be used in the present invention. Resins are selected based on the process and the physical characteristics desired in the composite core.

[94] Preferably, a recycle conduit 1009 on the bottom of a pressurized tank can catch overflow resin. More preferably, the wet out tank 1002 has an auxiliary tank with overflow capability. Overflow resin is returned to the auxiliary tank by gravity and pressure through the piping. Alternatively, tank overflow can be captured by an overflow channel and returned to the tank by gravity or pressure. In a further alternate, the process can use a drain pump system to recycle the resin back from the auxiliary tank and into the wet out tank. Preferably, a computer system controls the level of resin within the tank. Sensors detect low resin levels and activate a pump to pump resin into the tank from the auxiliary mixing tank into the processing tank. More preferably, there is a mixing tank located within the area of the wet out tank 1002. The resin is mixed in the mixing tank and pumped into the resin wet out tank 1002.

[95] The impregnated panel 100 is then pulled into a pultrusion die and oven 1010. The die and oven 1010 heat the resin to a temperature changing the liquid stage of resin to a cured stage. In addition, the fabric on the sides of the panel 100 are formed into the female coupling structure 802a. Also, the shape of the male coupling structure 802b is also formed in the die 1010. In the exemplary embodiment, the panel 100 is given the shape similar to the opening 1004. However, the shape of the panel 100 may be changed by changing the shape of the die 1010. One skilled in the art will recognize the other systems and methods of forming the panel using the heated die 1010.

[96] A cooling zone 206 follows the formation die 1010. The cooling zone 206 is simply a period of space where the cured resin has time to cool. The zone may have a mandrel to support the cured panel 100. In other embodiments, the panel 100 may roll along on a set of rollers or conveyors. The cooling zone may also include fans or refrigeration systems to more rapidly cool the cured panel 100. One skilled in the art will recognize different devices and methods that can be used in the cooling zone 206 to cool the cured panel 100.

[97] Referring to FIG. 11, a puller zone 208 follows the cooling zone 206. The puller zone 208 may comprise one or more pulling devices. A reciprocation pulling apparatus is shown in FIG. 11 and FIG. 2. In the embodiment shown, the device 1102 is a traditional reciprocating device with two pulling devices 1102a and 1102b that move at the same speed but their period of movement is opposed. As one pulling device, which has grabbed the panel 100 and is pulling the panel 100, nears the end of its path of movement, the second pulling device grabs the panel 100 and begins to move with the first pulling device. The second pulling device continues to pull the panel 100 after the first pulling device loosens its grip and moves to its starting position. Generally, the pulling apparatus 1102 has one or more clamps 1104. The clamps 1104 hold the panel 100 as the pulling apparatus moves. Preferably, the panel 100 is held on all sides to prevent undue stress on one side of the panel 100 versus another. This type of pulling apparatuses is well known in the art and will not be explained further. Al- ternatives are available to the reciprocating system including but not limited to a caterpuller system as described in US CIP Patent Application 2002/10/691447, in- corporated by reference herein.

[98] The system 200 may further comprise some type of milling zone 210 that may further comprise saws, routers, drills, or CNC machines. The machines within this zone 210 may be computer controlled or controlled by a human operator. The machines may also include any hand-operated tool or machine needed to form or finish the panel. An example of one embodiment of a sawing station for a four sided panel is illustrated in FIG. 12. In the exemplary embodiment, the sawing station comprises an encoder and wheel 1202, a saw motor 1204, a carriage 1220, a carriage return air cylinder 1208, carriage end of stroke sensors 1206, a saw head gear motor 1210, an upper clamp 1216, a lower clamp 1218, a clamp air cylinder 1214 and end of stroke sensors 1212. The station may further comprise a vacuum system for collection of saw dust.

[99] The saw head motor 1204 drives the saw through a shaft and timing belt transmission. The saw head gearmotor 1210 drives the sawing head in a circular pattern. The carriage return air cylinder 1208 carries the panel through the process and returns to starting position once the panel is cut to a predetermined length. The clamping air cylinder 1214. The clamping air cylinder 1214 close the clamps 1216 and 1218 thus coupling the saw assembly to the panel 100.

[100] The sawing process can be broken into several steps timed to operate syn- chronously. First, the saw blade motor 1204 is turned on and the pultrusion process paused as the clamps 1216 and 1218 close onto the panel. During this step the carriage 1220 is now coupled to the panel. At this stage the pultrusion process is re-started, saw rotation and vacuum is started and the saw blade moves in synchronism with the panel.

Sawing speed depends on the speed of pultrusion and the speed of sawing and carriage return. In other words, the sawing head cycle time closely matches the carriage stroke time and consequently the pultrusion line speed. In one embodiment, the sawing head circular motion is driven by a DCPM motor, so that motor speed can be adjusted to match the carriage stroke time. Once the panel is cut to a predetermined length, the saw blade, the vacuum and the sawing head rotation is turned off. The clamps 1216 and 1218 are released and the air cylinder 1208 brings back the carriage 1220 to the initial position.

[101] In various embodiments, the invention further comprises a plurality of alarms that function to effect the flow of the process. For example, the milling zone 210 may further comprise a saw alarm to detect a stalled blade or motor, a carriage alarm to detect if the sawing carriage does not follow the panel or does not return at the end of the sequence, a clamp alarm to detect whether the clamp clamps on at the beginning of the sequence or whether the clamp does not release at the end of the sequence. The saw head gearmotor drives the sawing head in a circular pattern, wherein the speed can be adjusted by an operator or a logic controller, a mobile saw can saw the panel at the desired length. For instance, the panel may be used in a 45'pole and the saw would be programmed to slice the continuous panel 100 after 45'of the panel 100 has been pultruded. A mobile saw may be a reciprocating saw, a band saw, or a circular saw.

The saw can be placed on a sled or other moving platform such that the saw moves in conjunction with the pultruded panel 100. In this way, binding or other problems are avoided between the panel 100 and the saw. Other cutting devices may include routers, lasers, water jet, or other devices that can mill the panel 100. Other tools may drill holes in the panel 100 for rivets or bolts used in later assembly. One skilled in the art will recognize other tools that are contemplated for inclusion in the milling zone 210.

[102] A part take-off zone 212 may finish the pultrusion system 200. The part take off zone 212 can include any storage or assembly areas needed to form structures from the panels 100. If poles are being built from the panels 100, the part take off zone 212 may be used to connect one or more panels using the coupling structures. The panels may be adhesively attached in addition to mechanically coupled. Rivets and bolts may also be used to attach the panels. Also, the bottom sleeves, top caps, or collars may be placed on the constructed poles in the assembly area 212. These different parts may also be adhesively attached or mechanical attached. The pole sections can then be stored for later use and transport.

Industrial Applicability [103] Composite panels may be specifically designed to enable construction of composite poles and towers that are lightweight, environmentally resistant and are capable of meeting strength requirements. A fast and continuous panel forming process enables such poles to be an economically viable solution to current poles. In addition, various embodiments of the invention enable increased strengthening of panel elements.