Systems and method for producing three-dimensional articles from flexible composite materials

• US 10,189,209 B2
• Filed: 03/13/2014
• Issued: 01/29/2019
• Est. Priority Date: 03/13/2013
• Status: Expired due to Fees

• Current Assignee: DSM IP Assets BV (DSM-Firmenich AG)
• Original Assignee: DSM IP Assets BV (DSM-Firmenich AG)
• Inventors: Downs, Roland Joseph, Adams, Christopher Michael, Holweger, Jon Michael, Hatcher, Wesley Edward, McDaniels, Keith Joel, Meldner, Heiner
• Primary Examiner(s): Khare, Atul P.
• Application Number:
  US14/774,490
• Publication Number:
  US 20160031164A1
• Time in Patent Office: 1,783 Days
• Field of Search: 156289
• CPC Class Codes: A43B 23/0225 Composite materials, e.g. material with a matrix
• CPC Class Codes: A43B 23/0235 Different layers of different material
• CPC Class Codes: A43B 23/042 Uppers made of one piece one piece slippers A43B3/106; one piece sandals A43B3/124
• CPC Class Codes: A43B 7/12 Special watertight footwear overshoes A43B3/16
• CPC Class Codes: B29C 33/0016 Lost moulds, e.g. staying on the moulded object flexible bags without particular shape filled with expandable material B29C44/182; single use mandrels for winding and forming B29C53/822
• CPC Class Codes: B29C 33/52 soluble or fusible in particular used in injection moulding B29C45/4457
• CPC Class Codes: B29C 33/68 Release sheets
• CPC Class Codes: B29C 37/0075 using release sheets
• CPC Class Codes: B29C 66/004 Preventing sticking together, e.g. of some areas of the parts to be joined
• CPC Class Codes: B29C 66/4332 by folding a sheet over
• CPC Class Codes: B29C 66/438 Joining sheets for making hollow-walled, channelled structures or multi-tubular articles
• CPC Class Codes: B29C 66/439 Joining sheets for making inflated articles without using a mould
• CPC Class Codes: B29C 66/721 Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/72141 Fibres of continuous length
• CPC Class Codes: B29C 66/723 being multi-layered B29C66/7292, B29C66/72941 take precedence
• CPC Class Codes: B29C 70/342 using isostatic pressure
• CPC Class Codes: B29C 70/345 using matched moulds
• CPC Class Codes: B29C 70/44 using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
• CPC Class Codes: B29C 70/542 Placing or positioning the reinforcement in a covering or packaging element before or during moulding, e.g. drawing in a sleeve
• CPC Class Codes: B29D 22/02 Inflatable articles
• CPC Class Codes: B29D 35/06 : having soles or heels formed and joined on to preformed uppers using a moulding technique, e.g. by injection moulding, pressing and vulcanising
• CPC Class Codes: B29D 35/122 : Soles
• CPC Class Codes: B29K 2105/0881 : unidirectional
• CPC Class Codes: B29K 2995/0046 : Elastic
• CPC Class Codes: B29L 2022/027 : Air bags
• CPC Class Codes: B29L 2031/50 : Footwear, e.g. shoes or parts thereof

Abstract

The present disclosure encompasses three-dimensional articles comprising flexible composite materials and methods of manufacturing said three-dimensional articles. More particularly, the present system relates to methods for manufacturing seamless three dimensional-shaped articles usable for such finished products as airbags/inflatable structures, bags, shoes, and similar three-dimensional products. A preferred manufacturing process combines composite molding methods with specific precursor materials to form flexible fiber-reinforced continuous shaped articles.

Claims

1. A method comprising the steps of:

providing a female mold;

constructing a composite layup in the female mold by applying a first fiber-reinforced scrim layer in the female mold, applying a release liner over said first fiber-reinforced scrim layer, and applying a second fiber-reinforced scrim layer over said release liner such that the release liner is sandwiched between said first and second fiber-reinforced scrim layers in the female mold, wherein said first scrim layer extends beyond said second scrim layer so as to form peripherally extended first scrim layer material;

curing said composite layup;

cutting a hole into the cured composite layup up to the release liner;

inflating the composite layup through said hole;

applying a coating into the inflated layup through said hole;

displacing the coating by rotating the composite layup to coat the interior of the layup; and

drying or curing the displaced coating.

2. The method of claim 1, further comprising bonding a film or a surface layer on one or on both sides of said composite layup after said curing.

3. The method of claim 1, wherein each of the first and second fiber-reinforced scrim layers comprise two or more unidirectional tape layers, each unidirectional tape layer comprising reinforcing fibers in parallel alignment.

4. The method of claim 3, wherein said reinforcing fibers comprise ultra-high molecular weight polyethylene (UHMWPE).

5. The method of claim 3, wherein the first and second scrim layers further comprise an intervening film layer between each of the unidirectional tape layers thereof.

6. The method of claim 3, wherein different orientations are provided for each respective one of the unidirectional tape layers of each of the first and second scrims relative to an adjacent one of said unidirectional tape layers of that first or second scrim.

7. The method of claim 1, further comprising folding said peripherally extended material of said first scrim onto and over said second scrim prior to said curing.

8. The method of claim 1, further comprising removing the cured layup from the female mold.

9. The method of claim 1, further comprising removing the release liner through the hole.