Apparatus And Method Of Producing Reinforced Laminated Panels As A Continuous Batch

• US 20100043689A1
• Filed: 08/21/2008
• Published: 02/25/2010
• Est. Priority Date: 08/21/2008
• Status: Abandoned Application

• Current Assignee: Dimension-Polyant Incorporated (Sioen Family)
• Original Assignee: Dimension-Polyant Incorporated (Sioen Family)
• Inventors: Madsen, Kenneth M., Gluek, John
• Application Number:
  US12/195,963
• Publication Number:
  US 20100043689A1
• Time in Patent Office: Days
• US Class Current: 114/102.290
• CPC Class Codes: B26D 7/018 Holding the work by suction
• CPC Class Codes: B26D 7/27 Means for performing other operations combined with cutting B26D9/00 takes precedence
• CPC Class Codes: B26F 1/3813 wherein the tool head is moved in a plane parallel to the work in a coordinate system fixed with respect to the work
• CPC Class Codes: B32B 2605/12 Ships
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 3/08 characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B63H 9/067 Sails characterised by their construction or manufacturing process

Abstract

An apparatus and method for producing multiple panels of a reinforced laminated membrane are provided. The apparatus and method utilize an accommodator between a yarn-laying station and a plotting and cutting station to allow these stations to operate simultaneously and without interruption on more than one part of a sheet of material. Reinforcing yarns are deposited on the sheet of material at the yarn-laying station in one or more patterns. Panels are cut at the cutting station after lamination. The accommodator accommodates material between these stations.

Claims

1. A method of continuously producing multiple sail panels for sails having one or more patterns of reinforcing yarns, comprising the steps of:

providing a sheet of sail panel material;

adding first reinforcing yarns to a first portion of the sheet in a first pattern;

laminating the first reinforcing yarns to the first portion of the sheet to form a first reinforced laminated sailcloth;

advancing the first reinforced laminated sailcloth through an accommodating station to a cutting station;

fixing the first reinforced laminated sailcloth in place at the cutting station;

cutting the first reinforced laminated sailcloth into a first sail panel;

while cutting the first sail panel, adding second reinforcing yarns to a second portion of the sheet in a second pattern;

laminating the second reinforcing yarns to the second portion of the sheet to form a second reinforced laminated sail cloth;

accommodating the second reinforced laminated sailcloth in the accommodating station until cutting of the first sail panel from the first reinforced laminated sailcloth complete.

2. The method of claim 1, wherein the first pattern and the second pattern are the same.

3. The method of claim 1, wherein the first pattern and the second pattern are different.

4. The method of claim 3, further comprising the steps of:

advancing the second reinforced laminated sailcloth to the cutting station;

fixing the second reinforced laminated sailcloth in place at the cutting station; and

cutting the second reinforced laminated sailcloth into a second sail panel, where the second sail panel and the first sail panel are intended to form parts of a sail.

5. The method of claim 4, wherein the second panel is cut to a different shape than the first panel.

6. The method of claim 1, wherein the steps of laminating comprise laminating the first and second reinforcing yarns and the first and second portions of the sheet of sail panel material to a previously laminated material.

7. The method of claim 6, wherein the previously laminated material comprises reinforced sailcloth.

8. The method of claim 1, wherein the step of accommodating comprises translating at least one roller to vary the distance to be travelled by the second reinforced laminated sailcloth to arrive at the cutting station.

9. The method of claim 1, wherein the steps of laminating comprise advancing the first and second reinforcing yarns and the first and second portions of the sheet of sail panel material between a heated metal roll and a flexible counter roll.

10. The method of claim 1, wherein the step of adding first reinforcing yarns to a sheet of sail panel material comprises adding first reinforcing yarns along expected load-paths in a sail panel.

11. An apparatus for continuously producing multiple panels of a laminated membrane having one or more patterns of reinforcing yarn, comprising:

a yarn-laying head for adding first reinforcing yarn to a first portion of a sheet of material in a first pattern and second reinforcing yarn to a second portion of the sheet of material in a second pattern;

a laminator for laminating the first reinforcing yarn to the first portion of the sheet to form a first portion of reinforced laminated membrane and the second reinforcing yarn to the second portion of the sheet to form a second portion of reinforced laminated membrane;

a cutting device for cutting panels from the first and second portions of reinforced laminated membrane; and

an accommodator disposed between the yarn-laying head and the cutting device for accommodating the second portion of the sheet of material until the cutting of a first panel from the first portion of reinforced laminated membrane is completed by the cutting device.

12. The apparatus of claim 11, further comprising a cutting table on which the first portion of reinforced laminated membrane is fixed while panels are cut by the cutting device.

13. The apparatus of claim 12, wherein the cutting table includes a vacuum surface.

14. The apparatus of claim 11, wherein the first pattern and the second pattern are different.

15. The apparatus of claim 11, wherein the first pattern and the second pattern are the same.

16. The apparatus of claim 11, wherein the accommodator comprises a plurality of translatable rollers for varying the distance travelled by the second reinforced laminated membrane between the laminator and the cutting device.

17. The apparatus of claim 11, wherein the laminator comprises a heated metal roll and a flexible counter roll.

18. The apparatus of claim 11, wherein the laminator laminates the first and second reinforcing yarns and the first and second portions of the sheet of material to a previously laminated membrane.

19. The apparatus of claim 11, further comprising a yarn-laying table on which the sheet of material is secured while the yarn-laying head adds the first reinforcing yarn to the sheet.

20. The apparatus of claim 11, wherein the yarn-laying head adds the first reinforcing yarns to the sheet of material along expected load-paths in the panel.

21. The apparatus of claim 11, wherein the laminator is disposed between the yarn-laying head and the cutting device and the accommodator is disposed between the yarn-laying head and the laminator.

22. The apparatus of claim 11, wherein the laminator is disposed between the yarn-laying head and the cutting device and the accommodator is disposed between the cutting device and the laminator.