METHOD OF PRODUCING SAILS USING REINFORCED, FORMED FABRICS

• US 20090133818A1
• Filed: 12/02/2008
• Published: 05/28/2009
• Est. Priority Date: 07/02/2002
• Status: Active Grant

• Current Assignee: Createx S.A.
• Original Assignee: Createx S.A.
• Inventors: Gautier, Gerard, Kessi, Edouard
• Granted Patent: US 8,506,739 B2
• Time in Patent Office: Days
• US Class Current: 156/245
• CPC Class Codes: B29C 51/085 with at least one of the shaping surfaces being made of resilien material, e.g. rubber
• CPC Class Codes: B29C 51/145 having at least one layer of textile or fibrous material combined with at least one plastics layer
• CPC Class Codes: B29C 51/28 for applying pressure through the wall of an inflated bag or diaphragm
• 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: B29L 2031/52 Sports equipment ; Games; Articles for amusement; Toys B29L2031/54 takes precedence
• CPC Class Codes: B63H 9/0671 Moulded sails
• CPC Class Codes: B63H 9/0678 Laminated sails
• CPC Class Codes: Y10T 156/1043 Subsequent to assembly

Abstract

The present disclosure relates to methods and compositions useful for the manufacture of sails. Particularly, the present disclosure relates to shaped, reinforced fabrics that can be used to make high-performance, shaped, reinforced sails.

Claims

1. A method of manufacturing a sail comprising:

positioning strips, comprising filaments and resin, onto a first surface to form panels,

positioning the panels onto a shaped mold, wherein adjacent panels overlap;

applying pressure and heat to the panels on the mold thereby joining the panels to form a shaped fabric; and

forming a sail from the shaped fabric.

2. The method of claim 1, wherein the filaments comprise carbon.

3. The method of claim 1, wherein the filaments comprise aramid.

4. The method of claim 1, wherein applying pressure comprises applying a vacuum.

5. The method of claim 1, wherein the pressure is applied from about 1700 to about 1900 pounds per square foot.

6. The method of claim 1, wherein the pressure is applied to about 1800 pounds per square foot.

7. The method of claim 1, wherein applying pressure comprises subjecting the panels on the mold to a vacuum.

8. The method of claim 1, wherein the heat is applied with a heat blanket.

9. The method of claim 1, wherein positioning the strips comprises positioning a strip such that the filaments of the strip are generally parallel to a line of force to which the sail will be subjected.

10. The method of claim 9, wherein the sail has at least one corner, and the filaments of at least some of the positioned strips extend outwardly from the corner in a non-parallel orientation.

11. The method of claim 1, wherein positioning the strips comprises positioning a strip in a location on the sail that is predicted to require reinforcement.

12. The method of claim 11, wherein the location on the sail predicted to require reinforcement comprises a corner.

13. A method of manufacturing a sail comprising:

positioning strips, comprising filaments and resin, onto a shaped mold;

applying pressure and heat to the strips on the mold, thereby joining the strips to form a shaped fabric; and

forming a sail from the shaped fabric.

14. The method of claim 13, wherein the filaments comprise carbon.

15. The method of claim 13, wherein the filaments comprise aramid.

16. The method of claim 13, wherein applying pressure comprises applying a vacuum.

17. The method of claim 13, wherein the pressure is applied from about 1700 to about 1900 pounds per square foot.

18. The method of claim 13, wherein the pressure is applied to about 1800 pounds per square foot

19. The method of claim 13, wherein applying pressure comprises forming a vacuum bag over the panels on the mold.

20. The method of claim 13, wherein the heat is applied with a heat blanket.

21. The method of claim 13, wherein positioning the strips comprises positioning a strip such that the filaments of the strip is generally parallel to a line of force to which the sail will be subjected.

22. The method of claim 21, wherein the sail has at least one corner, and the filaments of at least some of the positioned strips extend outwardly from the corner in a non-parallel orientation.

23. The method of claim 22, wherein positioning the strips comprises positioning a strip in a location on the sail that is predicted to require reinforcement.