Abstract:
A method of producing, for example, handles for using in rolling stock or other transport situations, employs a flexible core mould that is coated with an impregnated glass fibre. The coated core mould is placed into a tool for curing, whereupon the rubber core is pulled out of the center of the resulting handle member after curing. The method helps create 3D shapes of any form and cross section in a cost effective manner and using a standardized methodology and process. Further, the method enables creation of a hollow and lightweight part. The method allows use of standard glass fiber instead of more specialized braided fibre of the prior art.

Description:
BACKGROUND 
       [0001]    This disclosure relates to the process of manufacturing hollow seamless handles made of glass reinforced fibre material and the handles made thereby. 
         [0002]    Handles, such as those used in rail or bus or other transportation applications, for passengers to grasp, are traditionally made in metal or are nylon based. 
         [0003]    Fibre reinforced plastic (FRP) handles typically have to be made with a core inside as it is difficult to process and retain the shape of the handle without a core. Such handles are therefore heavier and difficult to process. Use of solid retained cores is especially difficult for complex 3D shapes, wherein the core has also to be manufactured to match the profile of the desired geometry, requiring an extra operation, time &amp; cost. 
         [0004]    Typically FRP industry has used special braided fibres for preparing any hollow sections. This braided fibre is then ‘put onto’ a mandrel to form the shape &amp; wet out with resin. The facility to produce braided fibre is limited to a few manufacturers and needs a special type of machinery. Further, this material is only available in certain standard diameters and weight. This would limit the product thickness that can be offered and reduce the weight benefits that go along with the end product. 
         [0005]    It is desirable to find a better way to make such handles in a variety of shapes. 
       SUMMARY 
       [0006]    In accordance with the disclosure, a method of making hollow lightweight fibre reinforced plastic handles and the handles made thereby are provided. The new process allows the flexibility of use of more commonly available glass fabrics and the possibility of manufacturing the end product in a range of diameters and optimized weights. 
         [0007]    Accordingly, it is an advantage of the present disclosure to provide an improved method of making handles. 
         [0008]    It is a further advantage of the present disclosure to provide an improved method of producing hollow lightweight fibre reinforced plastic handles in a variety of configurations. 
         [0009]    It is yet another advantage of the present disclosure to provide improved hollow lightweight fibre reinforced plastic handles in a variety of shapes and configurations. 
         [0010]    The subject matter of the present technology is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation, together with further advantages and embodiments thereof, may best be understood by reference to the following description taken in connection with accompanying drawings wherein like reference characters refer to like elements. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  is a perspective view of the mould/tooling used in the process; 
           [0012]      FIG. 2  is a view of the steps of beginning to apply glass fibre to the flexible core; 
           [0013]      FIG. 3  is a view of the completed step of rolling the fibre onto the flexible core; 
           [0014]      FIG. 4  illustrates the placement of the rolled fibre/flexible core into the tool; 
           [0015]      FIG. 5  illustrates the closure of the counter tool and clamping of the tools together as well as later removal of the core; 
           [0016]      FIGS. 6-8  are examples of handle shapes that may be manufactured in accordance with the process; 
           [0017]      FIG. 9  illustrates a handle configuration for which strength testing results are provided; 
           [0018]      FIG. 10  illustrates one example of mounting a handle to a wall, etc.; 
           [0019]      FIG. 11  illustrates another example of mounting a handle; and 
           [0020]      FIGS. 12 and 13  illustrate mounting configurations. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    The system according to a preferred embodiment of the present disclosure provides a process that results in a handle that is seamless, lightweight and strong. 
         [0022]    The process employs a flexible core made of material that can be removed from within the interior of the part after manufacture. 
         [0023]    The process also allows for a method by which complex 3D shapes can be moulded, to the same level of accuracy every time. The same construction in metal would be done by heat treatment, welding, bending, etc., which would reduce the accuracy of the individual parts. 
         [0024]    The selection of the raw materials and the fibre weave gives the part great rigidity &amp; strength. Different resin matrices can be selected to offer a great level of fire retardancy, that is a must in transport applications, or other desired properties. 
         [0025]    The handles so produced are corrosion resistance, having a very low thermal co-efficient as compared to metal handles. 
         [0026]    They can be offered in all colours and a variety of finishes to suite the customer requirements. They can also be chrome finished to replicate the metal sheen produced by Stainless steel handles. 
         [0027]    While the examples illustrated herein are circular in cross-section, it is also possible to create handles in other cross sectional shapes, such as rectangular, oval, half round, triangular, etc. 
         [0028]    Joining of various 3D shapes to shapes to create one integrated structure is also possible while moulding. 
         [0029]    Embedding of inserts in fixed locations to assist assembly/mounting operations is also feasible. 
         [0030]    In accordance with the disclosure, production of lightweight, strong, hollow, easy to process and manufacture FRP handles for rolling stock applications (vehicles that move on a railway, wheeled vehicles used by businesses on roadways, etc.), is provided. 
         [0031]    Referring to  FIG. 1 , a view of the tooling used in the process, for a particular elongate C-shaped handle, a standard closed mould tool  12  with two mould halves ( 12 ,  12 ′), offset based on part thickness, is provided. The mould tool portions have registration pins  14  and corresponding registration pin receiving openings  16  to provide for proper alignment of the two tool faces in use. Multiple fastener receiving holes  18  are provided in the tools to allow bolting or other fasteners to secure the mould portions together during a curing phase. 
         [0032]    Referring to  FIGS. 1-4  together, the inner faces  20  of the mould tool portions are gel coated and a layer of low density glass fibre is impregnated with resin onto the gel coated surfaces. 
         [0033]    Next, a pre-made cast flexible core representation  22  of the handle is provided. The casted material part can be substantially straight, for example, and does not need to follow the 3D profile of the tool or of the ultimate part to be constructed, as the shape of the tool will determine the end part configuration and the flexible casting will conform to the tool&#39;s shape. The cast will preferably be of cross sectional profile of the desired cross sectional profile of the finished handle, circular in the illustrated embodiment, and of slightly less diameter than the finished product&#39;s desired diameter as defined by the diameter of the space defined in the tools. The flexible core representation  22  is placed onto an impregnated glass fibre  24 , and the impregnated glass fibre is then wrapped onto the flexible core ( FIGS. 2, 3 ), for example by rolling the flexible core  22  so as to wrap the fibre around the mould, in the illustrated embodiment (alternatively the flexible core can be held stationary and the fibre wrapped around the mould), producing an impregnated fibre/flexible core combination  26 . 
         [0034]    The type of glass fibre used is such that it imparts structural properties &amp; stiffness uniformly and is easy to drape around a small diameter core. This gives equalized strength in all directions and produces the seamless effect. Requirement of traditionally used braided fibre only is thus eliminated. Part thickness can be modified depending on the number of windings, which is also considered a limitation when using braided fibre in accordance with traditional processes. 
         [0035]    The rolled fibre/flexible core combination  26  is lifted and placed in the coated tool cavity  20  ( FIG. 4 ) of one of the tool portions  12 , the counter tool portion  12 ′ is moved (arrow  28 ) to close the two mould pieces together. Fasteners  30  may be installed in ones of the fastener receiving holes  18  ( FIG. 5 ) to secure and hold the mould portions together and the part is left to cure. 
         [0036]    Once cured, either before or after demoulding, the flexible core is pulled/stretched physically and pulled out, for example in the direction of arrow  32 , from inside the cured moulded fibre handle part, leaving a hollow interior  33  to the handle. Being elastomer based in the particular embodiment, the core has self-release properties making its removal from the interior of the moulded fibre handle possible. 
         [0037]    The moulded fibre handle part may then be trimmed, as the end portions may be uneven, finished for joint line marking and painted as required for the particular application. 
         [0038]      FIGS. 6-8  are examples of particular handle shapes that have been constructed using the process, such as elongate C-shape  34  ( FIG. 6 ), straight  36  ( FIG. 7 ), and elongate S-curve  38  ( FIG. 8 ). Of course, additional configurations are possible, and the illustrations are not meant to be exhaustive of the possible shapes. 
         [0039]      FIG. 9  illustrates a handle  34  mounted to a surface such as a wall  40 , wherein escutcheons  42  are provided to conceal fasteners  44  (visible in  FIG. 10 , where the escutcheon is removed) that secure the handle to the wall via mounting plate  46 . 
         [0040]      FIGS. 12 and 13  are cross sectional views of example mounting configurations, wherein in  FIG. 12 , mounting plate  46  includes an extending center pin member  48  and a mounting member  50  of approximate diameter of the inner diameter of the handle  34  has a corresponding receiving portion for the center pin. A cross pin  52  extends through the handle, the mounting member and a portion of the center pin  48  to lock the handle to the mounting member. 
         [0041]    In  FIG. 13 , mounting plate  46 ′ carries an extension member  54  (for example a tubular shape corresponding to the inner profile of the handle  34 ) that extends inwardly to the handle interior. Mounting can be accomplished by adhesive engagement between the handle and the extension member, or by fasteners extending through the handle and the extension member. 
         [0042]      FIG. 11  illustrates a different mounting configuration, wherein mounting pins  56 ,  56 ′ are carried by base plates  58 ,  58 ′. An opening  60 ,  60 ′ in the handle  34  (formed for example by embedded inserts mentioned hereinabove) receives the mounting pins  56 ,  56 ′ to hold the handle in position. 
       ILLUSTRATIVE COMPARATIVE EXAMPLE 
       [0043]    Table 1 shows comparison of weight per linear meter of a handle having a 33 mm outer diameter, for a handle made by the present process, a prior art nylon coated handle, and a prior art mild steel handle. As illustrated by the table, the prior art handles were 1.2 and 6 times heavier than the handle manufactured in accordance with the present disclosure. 
         [0000]    
       
         
               
             
               
               
               
               
               
             
               
               
               
               
               
             
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Weight comparisons 
               
             
          
           
               
                   
                   
                   
                 Weight/linear m - 
                   
               
               
                   
                 TYPE 
                   
                 OD 33 mm 
                 Weight Comparison 
               
               
                   
                   
               
             
          
           
               
                   
                 FRP handle of 
                 600 
                 grams 
                 Baseline 
               
             
          
           
               
                   
                 present method 
                   
                   
                   
                   
               
               
                   
                 Fire retardant 
               
               
                   
                 grade - 2.5~3 
               
               
                   
                 mm skin thickness 
               
               
                   
                 Nylon coated 
                 700 
                 grams 
                 1.2 
                 times heavier 
               
               
                   
                 handle 
               
               
                   
                 Mild steel handle - 
                 2.5 
                 kilograms 
                 6 
                 times heavier 
               
               
                   
                 3 mm skin 
               
               
                   
                 thickness 
               
               
                   
                   
               
             
          
         
       
     
       Fire Specification 
       [0044]    Testing of example handles had the following results related to fire specification standards. 
         [0000]    
       
         
               
             
               
               
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                 Fire Specification 
               
             
          
           
               
                   
                 Compliance 
                 Standard 
                 Rating Achieved 
               
               
                   
                   
               
               
                   
                 German 
                 DIN 5510 
                 S4/SR2/ST2 
               
               
                   
                 German/European 
                 EN ISO 5659 (as 
                 FED at 30 min &lt; 1 
               
               
                   
                   
                 per DIN 5510 - 
               
               
                   
                   
                 2009) 
               
               
                   
                 French 
                 NFF 16101 
                 M1 F3 
               
               
                   
                 US 
                 ASTM E 162 
                 FSI &lt; 25 
               
               
                   
                   
                 ASTM E 662 
                 Ds (1.5) &lt; 100 
               
               
                   
                   
                   
                 Ds (4) &lt; 200 
               
               
                   
                   
               
             
          
         
       
     
       Mechanical Strengths 
       [0045]    Table 3 illustrates mechanical strength specifications. 
         [0000]    
       
         
               
             
               
               
               
               
             
               
               
               
               
               
             
           
               
                 TABLE 3 
               
             
             
               
                   
               
               
                 Mechanical Strengths 
               
             
          
           
               
                   
                 Parameter 
                 Standard 
                 Specification 
               
               
                   
                   
               
               
                   
                 Product Thickness 
                 NA 
                 2.5 +/− 0.5 mm 
               
             
          
           
               
                   
                 Tensile Strength 
                 ASTM D 3039 
                 &gt;150 
                 MPa 
               
               
                   
                 Tensile Modulus 
                 ASTM D 3039 
                 8 
                 Gpa 
               
               
                   
                 Flexural Strength 
                 ASTM D 790 
                 &gt;175 
                 Mpa 
               
               
                   
                 Flexural Modulus 
                 ASTM D 790 
                 8 
                 Gpa 
               
               
                   
                   
               
             
          
         
       
     
       Strength Testing 
       [0046]    Referring again to  FIG. 9 , a constructed handle  34  having a circular cross section, 33 mm outer diameter, was tested for strength properties, both for vertical  62  and horizontal  64  loads. Table 4 illustrates the results of strength testing performed on the test handle constructed by the method. 
         [0000]    
       
         
               
             
               
               
               
               
             
           
               
                 TABLE 4 
               
             
             
               
                   
               
               
                 Strength Testing 
               
             
          
           
               
                   
                 Load 
                 Target 
                 Actual 
               
               
                   
                   
               
               
                   
                 Vertical loading 
                 150 kgs 
                 &gt;200 kgs 
               
               
                   
                 Horizontal 
                 100 kgs 
                 &gt;250 kgs 
               
               
                   
                 loading 
               
               
                   
                   
               
             
          
         
       
     
         [0047]    In accordance with the process/methods described herein, an improved handle construction method is provided, and the improved handle. The handle produced has many advantages over other handle types, such as being warm to the touch, having good abrasion resistance, and being very light and strong. The handle is fire retardant, corrosion resistant Handles and other parts can be moulded to complex 3D profiles, providing consistent dimensional profiles since the handles are moulded instead of being bent as with prior art. Handles can be manufactured in all colours with painted, smooth, matt and/or texture finish. The hollow profile handle is very light and strong. 
         [0048]    While a preferred embodiment of the technology has been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the broader aspects. The appended claims are therefore intended to cover all such changes and modifications as fall within the true spirit and scope of the technology.