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Abstract

A process for manufacturing a composite rod assembly that may be used, for example, as a tool handle includes the steps of feeding a core into a pultrusion die tube and surrounding the core with resin coated fibers. At least one external mold member having a mold face defining an irregular profile shape is inserted into a space between the resin coated fibers and the die tube. The core is pulled through the pultrusion die tube and the at least one external mold member is drawn through the die tube with the resin coated fibers and the core. The resin coated fibers are cured around the core to form a fiber-resin jacket having an outer surface conforming to the irregular profile shape of the mold face. The core itself may have an irregular profile shape so that an inner surface of the fiber-resin jacket conforms thereto to key-lock the fiber-resin jacket to the core. A secondary jacket may be molded over at least a portion of the outer surface of the fiber-resin jacket so that an inner surface of the secondary jacket conforms to the outer surface of the fiber-resin jacket to key-lock the secondary jacket to the fiber-resin jacket. The at least one external mold member may be removably attached to a belt that is guided through a track within the die tube.

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First Claim