SYSTEMS AND METHOD FOR PRODUCING THREE-DIMENSIONAL ARTICLES FROM FLEXIBLE COMPOSITE MATERIALS

• US 20140134378A1
• Filed: 11/09/2013
• Published: 05/15/2014
• Est. Priority Date: 11/09/2012
• Status: Active Grant

• Current Assignee: Cubic Tech Corporation (DSM-Firmenich AG)
• Original Assignee: Cubic Tech Corporation (DSM-Firmenich AG)
• Inventors: Downs, Roland Joseph, Adams, Christopher Michael, Holweger, Jon Michael
• Granted Patent: US 9,114,570 B2
• Time in Patent Office: Days
• US Class Current: 428/57
• 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: B29C 33/505 cores or mandrels, e.g. inflatable B29C33/0016 takes precedence; for winding and joining B29C53/824; for supporting articles during joining B29C66/634; flexible cores for vulcanizing tyres B29D30/0654
• CPC Class Codes: B29C 33/76 Cores B29C33/02 - B29C33/70, B29C41/40, B29C53/74, B29C53/82 take precedence
• CPC Class Codes: B29C 35/02 Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mouldcold vulcanisation B29C35/18 ; vulcanising tyres, presses therefor B29D30/0601
• CPC Class Codes: B29C 37/0078 Measures or configurations for obtaining anchoring effects in the contact areas between layers surface shaping B29C59/00; B29C66/02 takes precedence
• CPC Class Codes: B29C 43/003 characterised by the choice of material
• CPC Class Codes: B29C 43/12 using bags surrounding the moulding material or using membranes contacting the moulding material
• CPC Class Codes: B29C 43/203 Making multilayered articles
• CPC Class Codes: B29C 53/60 using internal forming surfaces, e.g. mandrels
• CPC Class Codes: B29C 55/023 using multilayered plates or sheets
• CPC Class Codes: B29C 65/7832 by setting the overlap between the parts to be joined, e.g. the overlap between sheets, plates or web-like materials
• CPC Class Codes: B29C 66/004 Preventing sticking together, e.g. of some areas of the parts to be joined
• CPC Class Codes: B29C 66/022 Mechanical pre-treatments, e.g. reshaping
• CPC Class Codes: B29C 66/432 for making tubular articles or closed loops, e.g. by joining several sheets B29C66/547 takes precedence; bending and joining sheets at right angles to the longitudinal axis of the article being formed and joining the edges B29C53/38; for making hollow articles or hollow preforms
• CPC Class Codes: B29C 66/547 Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles, e.g. endless tubes
• CPC Class Codes: B29C 70/20 oriented in a single direction, e.g. roofing or other parallel fibres B29C70/083, B29C70/226 take precedence
• CPC Class Codes: B29C 70/202 arranged in parallel planes or structures of fibres crossing at substantial angles, e.g. cross-moulding compound [XMC] B29C70/207 takes precedence
• CPC Class Codes: B29C 70/205 the structure being shaped to form a three-dimensional configuration
• CPC Class Codes: B29C 70/345 : using matched moulds
• CPC Class Codes: B29D 35/00 : Producing footwear
• CPC Class Codes: B29D 35/0054 : by compression moulding, vulcanising or the like; Apparatus therefor
• CPC Class Codes: B29D 35/0063 : Moulds
• CPC Class Codes: B29D 35/146 : Uppers
• CPC Class Codes: B29K 2105/12 : of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B29K 2105/256 : Sheets, plates, blanks or films
• CPC Class Codes: B29L 2031/30 : Vehicles, e.g. ships or aircraft, or body parts thereof vanes or blades B29L2031/08, air bags B29L2022/027
• CPC Class Codes: B29L 2031/505 : Uppers
• CPC Class Codes: B29L 2031/768 : Protective equipment B29L2031/4821 takes precedence
• CPC Class Codes: B32B 1/00 : Layered products having a non-planar shape
• CPC Class Codes: B32B 2260/023 : Two or more layers
• CPC Class Codes: B32B 2260/046 : Synthetic resin
• CPC Class Codes: B32B 2262/0269 : Aromatic polyamide fibres
• CPC Class Codes: B32B 2262/103 : Metal fibres
• CPC Class Codes: B32B 2262/106 : Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2307/734 : Dimensional stability
• CPC Class Codes: B32B 2307/748 : Releasability
• CPC Class Codes: B32B 2437/02 : Gloves, shoes
• CPC Class Codes: B32B 2571/00 : Protective equipment
• CPC Class Codes: B32B 2605/00 : Vehicles
• CPC Class Codes: B32B 37/18 : involving the assembly of discrete sheets or panels only
• CPC Class Codes: B32B 38/0012 : Mechanical treatment, e.g. roughening, deforming, stretching
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/028 : Net structure, e.g. spaced apart filaments bonded at the crossing points
• CPC Class Codes: B32B 5/04 : characterised by a layer being specifically extensible by reason of its structure or arrangement , e.g. by reason of the chemical nature of the fibres or filaments
• CPC Class Codes: B32B 5/12 : characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: Y10T 156/1002 : with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 156/1051 : by folding
• CPC Class Codes: Y10T 156/14 : Surface bonding means and/or assembly means with shaping, scarifying, or cleaning joining surface only
• CPC Class Codes: Y10T 428/19 : Sheets or webs edge spliced or joined
• CPC Class Codes: Y10T 428/24074 : Strand or strand-portions
• CPC Class Codes: Y10T 428/24628 : Nonplanar uniform thickness material
• CPC Class Codes: Y10T 442/614 : Strand or fiber material specified as having microdimensions [i.e., microfiber]

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 fiber-reinforced continuous shaped articles that are flexible and collapsible.

Claims

1. A laminate comprising:

reinforcing elements comprising at least one unidirectional tape; and

monofilaments disposed within said unidirectional tape,

wherein all of said monofilaments are situated in a predetermined direction within said tape;

wherein said monofilaments have diameters less than 40 microns; and

wherein individual monofilaments abut adjacent monofilaments or wherein spacing between individual monofilaments within an adjoining strengthening group of monofilaments is within a gap distance in the range between non-abutting monofilaments up to fifty times the monofilament major diameter.

2. The laminate according to claim 1, wherein said monofilaments are extruded, pull-truded or converted into monofilaments coated and embedded within an adhesive resin.

3. The laminate according to claim 1, wherein said reinforcing elements comprise at least two unidirectional tapes.

4. The laminate according to claim 3, wherein a first one of said at least two unidirectional tapes includes monofilaments lying in a different predetermined direction than the monofilaments within a second one of said at least two unidirectional tapes.

5. The laminate according to claim 3, wherein each of said at least two unidirectional tapes includes larger areas without monofilaments therein, and wherein said larger areas comprise a set of laminar overlays comprising smaller areas without monofilaments.

6. The laminate according to claim 5, wherein said smaller areas comprise user-planned arrangements.

7. The laminate according to claim 5, further comprising a set of waterproof/breathable elements comprising laminar overlays of said smaller areas.

8. The laminate according to claim 7, further comprising at least one additional set of laminar overlays.

9. The laminate according to claim 4, wherein a combination of said different predetermined directions of said at least two unidirectional tapes is user-selected to achieve a planned directional rigidity/flexibility.

10. The laminate according to claim 1, wherein said laminate comprises a three-dimensional shaped, flexible composite product.

11. The laminate according to claim 10, further comprising multiple laminate segments joined along peripheral edges.

12. The laminate according to claim 11, comprising at least one laminate segment joined along peripheral edges to at least one non-laminate segment.

13. The laminate according to claim 11, comprising multiple laminate segments joined along peripheral edges.

14. The laminate according to claim 13, comprising at least one laminate segment along peripheral edges to at least one non-laminate segment.

15. The laminate according to claim 13, comprising at least one laminate segment along peripheral edges to at least one unitape segment.

16. The laminate according to claim 13, comprising at least one laminate segment along peripheral edges to at least one monofilament segment.

17. The laminate according to claim 1, further comprising at least one rigid element.

18. A three-dimensionally shaped article comprising the laminate of claim 1, wherein said at least one unidirectional tape is attached to said article.

19. The article according to claim 18, further comprising integrated structural reinforcements for attachment points, through holes, and reinforcing straps.

20. A method of producing three-dimensionally shaped, flexible composite parts, said method comprising the steps of:

a. providing at least one male mold and at least one female mold having compatible configurations;

b. constructing a first composite layup by applying at least one fiber-reinforced scrim and optional first surface layer over the male mold, said fiber-reinforced scrim comprising two or more layers of unidirectional fibers placed at different orientations;

c. removing the first composite layup from the male mold and placing said first composite layup within said female mold;

d. optionally placing at least one release liner within the female mold over said first composite layup;

e. constructing a second composite layup by applying at least one fiber-reinforced scrim and optional second surface layer over the male mold, said fiber-reinforced scrim comprising two or more layers of unidirectional fibers placed at different orientations;

f. removing said second composite layup from the male mold and placing said second composite layup in said female mold over the first composite layup;

g. joining peripherally such first composite layup and such second composite layup; and

h. curing the first composite layup and second composite layup to form at least one three-dimensional shaped article.

21. The method according to claim 20, further comprising the step of forming at least one opening into such at least one three-dimensional shaped article.

22. The method according to claim 21, further comprising the step of removing such optional release liner through such at least one opening.

23. The method according to claim 20 further comprising the step of adding at least one reinforcing structure to such at least one three-dimensional shaped article.

24. The method according to claim 20, wherein such at least one three-dimensional shaped article is integrated within a shoe.

25. The method according to claim 20, wherein such at least one three-dimensional shaped article is integrated within a bag.

26. The method according to claim 20 wherein such at least one three-dimensional shaped article is gas impermeable.

27. The method according to claim 20 wherein such at least one three-dimensional shaped article is configured to be gas inflatable.

31. A three-dimensionally shaped, flexible composite part produced by the method of claim 20.

28. A method of producing three-dimensionally shaped, flexible composite parts, said method comprising the steps of:

a) joining two symmetrical flexible composite parts by folding peripheral material from a first part side over a second part side to form a two dimensional flexible composite part having a region of overlap seam; and

b) curing such two symmetrical flexible composite part to form a unitary three-dimensionally shaped flexible composite part having a hollow interior.

29. A system for producing three-dimensionally shaped, flexible composite parts, said system comprising:

a design phase usable to arrive at a design for said composite part; and

a fabrication phase comprising the execution of a composite-material layup, said composite-material layup comprising at least one mold wherein said composite material is consolidated and cured.

30. The system of claim 29, wherein said three-dimensionally shaped, flexible composite part comprises a C-staged or B-staged composite footwear upper.