METHOD OF MANUFACTURING A FIBROUS STRUCTURE AND AN APPARATUS THEREFOR

• US 20110081816A1
• Filed: 11/14/2008
• Published: 04/07/2011
• Est. Priority Date: 11/16/2007
• Status: Active Grant

• Current Assignee: Mr. Richard Allen
• Original Assignee: Mr. Richard Allen
• Inventors: Halstead, Tom Lloyd, Allen, Richard
• Granted Patent: US 8,381,376 B2
• Time in Patent Office: Days
• US Class Current: 442/388
• CPC Class Codes: D04H 1/4242 Carbon fibres
• CPC Class Codes: D04H 1/46 by needling or like operations to cause entanglement of fibres D04H1/45 takes precedence; needling machines D04H18/00
• CPC Class Codes: D04H 1/492 by fluid jet D04H1/49 takes precedence
• CPC Class Codes: D04H 13/00 Other non-woven fabrics
• CPC Class Codes: D04H 18/02 with needles
• CPC Class Codes: Y10T 442/667 Needled

Abstract

A method of manufacturing a fibrous structure is particularly, though not exclusively, applicable to the manufacture of friction products such as preform discs. The method comprises mounting a former on a shaft. First feeds of fibrous material are spaced along the shaft and applied to the former in a direction tangential to the shaft as the shaft is rotated. A second feed is also applied to the former in a direction substantially parallel to the longitudinal axis of the shaft. The fibrous materials in the feeds overlie as the shaft rotates and the thickness of the material applied to the former increases to form the fibrous structure. Lengths of the first and/or second feeds are then inserted into the fibrous structure body in a radial direction with respect to the shaft as the shaft is rotated to interconnect the overlying layers and hold the structure together.

Claims

1. A method of manufacturing a fibrous structure comprising the steps of

fixedly mounting a former on a shaft;

rotating the shaft about its longitudinal axis;

providing a plurality of first feeds of fibrous material spaced along the length of the shaft;

providing a second feed of fibrous material;

applying the first feeds of fibrous material to the former in a direction tangential to the shaft as the shaft is rotated;

applying the second feed of fibrous material to the former in a direction substantially parallel to the longitudinal axis of the shaft, the fibrous materials in the first feed and the second feed overlying one another as the shaft rotates and the thickness of the fibrous material applied to the former increases to form the fibrous structure; and

causing selected lengths of the first and/or second feeds to be inserted into the body of the fibrous structure in a radial direction with respect to the shaft as the shaft is rotated to interconnect the overlying layers formed by the first and second feeds and thereby hold the fibrous structure together.

2. A method as claimed in claim 1, wherein the first feeds of fibrous material are continuously applied to the former.

5. A method as claimed in claim 1, wherein the speed of rotation of the shaft is varied as the thickness of the fibrous material applied to the former increases and wherein the first feeds of fibrous material are pulled on to the former in the direction tangential to the shaft as the shaft rotates.

6. A method as claimed any of claims 1 to 5, wherein the first feeds of fibrous material are pulled on to the former in the direction tangential to the shaft as the shaft rotates.

7. A method as claimed in claim 1, wherein the shaft is moved linearly away from the point of insertion of the selected lengths of the first and/or second feeds as the thickness of the fibrous material applied to the former increases to ensure a constant insertion depth.

8. A method as claimed in claim 1, wherein the shaft is vertically movable in a frame.

9. A method as claimed in claim 1, wherein the selected lengths of the first and/or second feeds are inserted into the body of the fibrous structure in a radial direction by one of needle-punching and high pressure gas jets, and wherein in the case of needle-punching the shape of the needling head follows the underlying contour of the former.

10. A method as claimed in claim 9, wherein the shape of the needling head follows the underlying contour of the former.

11. A method as claimed in any of claims 1 to 10, wherein the first and/or second feeds are entangled within the body of the fibrous structure in a radial direction by high pressure gas jets.

12. A method as claimed in any of claims 1 to 11, wherein the shaft is orientated in a substantially horizontal direction.

13. A method as claimed in claim 1, wherein the angle of the shaft to the vertical is varied during production of the structure in order that a substantially flat surface is always presented to the needling area.

14. A method as claimed in claim 1, wherein the former is located on the shaft between containment shields which hold the fibrous material in place on the former as the fibrous structure is being formed.

15. A method as claimed in any of claims 1 to 14, wherein the former comprises a resilient support.

16. A method as claimed in any of claims 1 to 15, wherein the former is made from a resilient foam.

34. A fibrous structure manufactured in accordance with the method as claimed in claim 1.

3. A method as claimed in claim, wherein the second feed of fibrous material is applied in discrete lengths along a predetermined length of the former, said predetermined length being inclusive of the whole length of the former.

4. A method as claimed in claim 3, wherein the predetermined length comprises the whole length of the former.

17. An apparatus for of manufacturing a fibrous structure comprising

a former fixedly mounted on a shaft adapted to be rotatably driven about its longitudinal axis;

a plurality of first feeds of fibrous material spaced along the length of the shaft to apply fibrous material to the former in a direction tangential to the shaft as the shaft is rotated;

a second feed of fibrous material adapted to apply fibrous material to the former in a direction substantially parallel to the longitudinal axis of the shaft, whereby the fibrous materials in the first feed and the second feed overlying one another as the shaft rotates and the thickness of the fibrous material applied to the former increases to form the fibrous structure; and

insertion means for causing selected lengths of the first and/or second feeds to be inserted into the body of the fibrous structure in a radial direction with respect to the shaft as the shaft is rotated to interconnect the overlying layers formed by the first and second feeds and thereby hold the fibrous structure together.

18. An apparatus as claimed in claim 17, wherein the plurality of first feeds of fibrous material are pulled onto and wound around the former as the shaft rotates.

19. An apparatus as claimed in claim 18, wherein the plurality of first feeds of fibrous material are supplied to the former from a substantially horizontal grooved platen.

20. An apparatus as claimed in claim 17, wherein the second feed of fibrous material is applied to the former from a carrier mounted above the shaft and adapted to apply discrete lengths of feed to the former in a direction substantially parallel to the longitudinal axis of the shaft.

21. An apparatus as claimed in claim 20, wherein the carrier comprises a pair of endless chains or belts that are each driven around a pair of sprockets or pulleys located at each end of the shaft with their axes of rotation parallel to the longitudinal axis of the shaft;

wherein spaced along each endless chain or belt is a series of hooks around which the feed of fibrous material is wound cross-wise between the chains or belts by a traversing carriage; and

wherein the carrier feeds the fibrous material under the insertion means where the fibrous material is pulled off the carrying hooks and deposited longitudinally along the length of the structure.

22. An apparatus as claimed in claim 20 or claim 21, wherein spaced along each endless chain or belt is a series of hooks around which the feed of fibrous material is wound cross-wise between the chains or belts by a traversing carriage.

23. An apparatus as claimed in any of claims 20 to 22, wherein the carrier feeds the fibrous material under the insertion means where the fibrous material is pulled off the carrying hooks and deposited longitudinally along the length of the structure.

24. An apparatus as claimed in claim 17, wherein the second feed of fibrous material is applied to the former from a carriage mounted above the shaft and adapted to traverse the former in a direction at 90°

to the direction of the first feed of fibrous material.

25. An apparatus as claimed in claim 24, wherein the carriage comprises at least one feed tube through which the fibrous material is fed by infinitely variable feed rollers.

26. An apparatus as claimed in claim 25, wherein air is blown down each feed tube to assist passage of the fibrous material through the tube.

27. An apparatus as claimed in claim 26, wherein each feed tube comprises a venturi where the fibrous material enters the tube in order to accelerate the air flow thereby to assist passage of the fibrous material through the tube.

28. An apparatus as claimed in claim 24, wherein the feed tube can swing relative to the former in a controlled manner to allow the lay pattern of the fibrous material on the former to be varied.

29. An apparatus as claimed in claim 17, wherein the shaft is movable vertically up and down within a frame between roll containment shields that are located at the ends of the shaft.

30. An apparatus as claimed in claim 17, wherein the insertion means comprises a needling head that extends along the full length of the former and high pressure gas jets.

31. An apparatus as claimed in claim 30, wherein the needling head comprises a needle holder that has a graduated depth along its transverse profile so that needles along each of these profiles are arranged so to be substantially the same distance from the former.

32. An apparatus as claimed in any of claims 17 to 31, wherein the insertion means comprises high pressure gas jets.

33. An apparatus as claimed in any of claims 17 to 32, wherein the former comprises a resilient support made of foam.