METHOD OF PRODUCING REINFORCED, FORMED FABRICS

• US 20090140455A1
• Filed: 11/19/2008
• Published: 06/04/2009
• Est. Priority Date: 07/02/2002
• Status: Active Grant

• Current Assignee: North Sails Group, LLC (North Technology Group LLC)
• Original Assignee: Createx S.A.
• Inventors: Kessi, Edouard, Gautier, Gerard
• Granted Patent: US 8,709,186 B2
• Time in Patent Office: Days
• US Class Current: 264/241
• 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: B63H 9/0671 Moulded sails
• CPC Class Codes: B63H 9/0678 Laminated sails
• CPC Class Codes: Y10T 156/1043 Subsequent to assembly
• CPC Class Codes: Y10T 442/643 Including parallel strand or fiber material within the nonwoven fabric
• CPC Class Codes: Y10T 442/696 Including strand or fiber material which is stated to have specific attributes [e.g., heat or fire resistance, chemical or solvent resistance, high absorption for aqueous compositions, water solubility, heat shrinkability, etc.]

Abstract

The invention relates to a method of producing reinforced, formed fabrics, consisting in producing a continuous fabric alternated with a membrane (34) containing embedded reinforcing elements, which is prepared in overlapping portions on a conveyor belt (29) which passes over a preparation table (25). The membrane (34) and the reinforcing elements are then positioned under a press consisting of an upper air-filled chamber (1), the lower part thereof comprising a flexible element (4), and a lower water-filled chamber (14), the upper part thereof comprising a flexible element (17). According to the invention, a forming bar (10) is adjustably mounted in the upper chamber (1). When the aforementioned forming bar (10) is adjusted to adopt a particular shape, the different flexible elements can deform at the forming bar and the membrane and the reinforcing elements are hot pressed with a portion corresponding to the forming bar having a three dimensional shape, thereby defining the form of the fabric produced.

Claims

1. A method of manufacturing a fabric comprising:

selecting a plurality of reinforcing elements, wherein the reinforcing elements are formed from filaments which are aligned in strip form;

arranging the reinforcing elements to form a strip;

providing a resin in contact with the reinforcing elements;

positioning the strips so that at least some of the strips partially overlap adjacent strips; and

activating the resin to encase the reinforcing elements, thereby forming the fabric.

2. The method of claim 1, wherein positioning comprises:

positioning at least one additional strip along at least a portion of a predicted line of force to which the fabric will be subjected.

3. The method of claim 2, wherein the at least one additional strip is positioned substantially parallel to the predicted lines of force.

4. The method of claim 2, wherein the at least one additional strip is positioned substantially perpendicular to the predicted lines of force.

5. The method of claim 2, wherein the at least one additional strip is positioned substantially parallel and at least one additional strip is positioned substantially perpendicular to the predicted lines of force.

6. The method of claim 1, wherein positioning comprises:

positioning at least one additional strip in a location where the fabric will require reinforcement.

7. The method of claim 1, wherein the strips comprise reinforcing elements pre-impregnated with resin.

22. The method of claim 1, wherein positioning the strips comprises:

layering strips, one on top of the other, to provide a plurality of layers.

23. The method of claim 22, further comprising:

positioning the strips of a first layer at angles with the strips of a second layer.

24. The method of claim 1, wherein positioning the strips comprises:

positioning at least some of the strips to overlap substantially along a length of each strip.

25. The method of claim 1, wherein positioning comprises:

positioning at least some of the strips in parallel, such that a first end of one strip substantially overlaps a first end of a second strip.

8. A method of manufacturing a shaped fabric comprising:

selecting a plurality of reinforcing elements, wherein the reinforcing elements are formed from filaments which are aligned in strip form;

arranging the reinforcing elements to form a strip;

providing a resin in contact with the reinforcing elements;

arranging the strips so that at least some of the strips partially overlap adjacent strips;

placing the arranged strips on a surface having a three-dimensional shape; and

activating the resin to encase the reinforcing elements, thereby forming the shaped fabric.

9. The method of claim 8, wherein positioning comprises:

positioning at least one additional strip along at least a portion of a predicted line of force to which the fabric will be subjected.

10. The method of claim 9, wherein the at least one additional strip is positioned substantially parallel to the predicted lines of force.

11. The method of claim 9, wherein the at least one additional strip is positioned substantially perpendicular to the predicted lines of force.

12. The method of claim 9, wherein the at least one additional strip is positioned substantially parallel and at least one additional strip is positioned substantially perpendicular to the predicted lines of force.

13. The method of claim 8, wherein positioning comprises:

positioning at least one additional strip in a location where the fabric will require reinforcement.

14. The method of claim 8, wherein the strips comprise reinforcing elements pre-impregnated with resin.

26. The method of claim 8, wherein arranging the strips comprises:

layering strips, one on top of the other, to provide a plurality of layers.

27. The method of claim 26, further comprising:

positioning the strips of a first layer at angles with the strips of a second layer.

28. The method of claim 8, wherein arranging the strips comprises:

positioning at least some of the strips to overlap substantially along a length of each strip.

29. The method of claim 8, wherein arranging the strips comprises:

positioning at least some of the strips in parallel, such that a first end of one strip substantially overlaps a first end of a second strip.

15. A method of manufacturing a shaped fabric comprising:

selecting a plurality of reinforcing elements, wherein the reinforcing elements are formed from filaments which are aligned in strip form;

providing a resin in contact with the reinforcing elements;

arranging the reinforcing elements to form a strip;

arranging the strips on a surface having a three dimensional shape so that at least some of the strips partially overlap adjacent strips; and

activating the resin to encase the reinforcing elements, thereby forming the shaped fabric.

16. The method of claim 15, wherein positioning comprises:

positioning at least one additional strip along at least a portion of a predicted line of force to which the fabric will be subjected.

17. The method of claim 16, wherein the at least one additional strip is positioned substantially parallel to the predicted lines of force.

18. The method of claim 16, wherein the at least one additional strip is positioned substantially perpendicular to the predicted lines of force.

19. The method of claim 16, wherein the at least one additional strip is positioned substantially parallel and at least one additional strip is positioned substantially perpendicular to the predicted lines of force.

20. The method of claim 15, wherein positioning comprises:

positioning at least one additional strip in a location where the fabric will require reinforcement.

21. The method of claim 15, wherein the strips comprise reinforcing elements pre-impregnated with resin.

30. The method of claim 15, wherein arranging the strips comprises:

layering strips, one on top of the other, to provide a plurality of layers.

31. The method of claim 30, further comprising

positioning the strips of a first layer at angles with the strips of a second layer.

32. The method of claim 15, wherein arranging the strips comprises:

positioning at least some of the strips to overlap substantially along a length of each strip.

33. The method of claim 15, wherein arranging the strips comprises:

positioning at least some of the strips in parallel, such that a first end of one strip substantially overlaps a first end of a second strip.