Process for producing a convex sail or a tensile structure

• US 6,230,641 B1
• Filed: 05/15/2000
• Issued: 05/15/2001
• Est. Priority Date: 11/13/1997
• Status: Expired due to Term

• Current Assignee: North Sails Group, LLC (North Technology Group LLC)
• Original Assignee: Filatura Super Geelong - S.R.L.
• Inventors: Savelli, Marco
• Primary Examiner(s): Avila, Stephen
• Application Number:
  US09/554,399
• Time in Patent Office: 365 Days
• Field of Search: 114/102.1, 114/102.29, 114/102.31
• US Class Current: 114/102.29
• CPC Class Codes: B29C 33/0011 thin-walled moulds
• CPC Class Codes: B29C 70/30 Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
• CPC Class Codes: B32B 2038/1891 Using a robot for handling the layers
• CPC Class Codes: B32B 38/1866 conforming the layers or laminate to a convex or concave profile
• CPC Class Codes: B63H 9/067 Sails characterised by their construction or manufacturing process
• CPC Class Codes: B63H 9/0671 Moulded sails
• CPC Class Codes: B63H 9/0678 Laminated sails

Abstract

A process for modelling a sail with a sandwich configuration and a three-dimensional convex shape, wherein the “mould” is formed by a semirigid film material which has a shape identical to that of the sail to be produced. On this kind of “parent sail”, a cloth is prepared by adhering, by means of a removable adhesive, synthetic weft (1) and warp (2) filaments onto the “parent sail”. This cloth will form the inner layer of the final “sandwich”. Two thin external plastic laminates are applied on the cloth, one on each side, after removal of the cloth from the “parent sail”. The thin external plastic laminates are applied in individual pieces adapted to follow the convexity of the cloth. The application of the external laminates is performed on a plane support.

Claims

1. A process for producing a sail or a cover element of a tensile structure having a triangular or trapezoidal form, characterized in that on a parent sail consisting of a semirigid film material of the same shape and size as that of the desired product, a thick cloth of synthetic filaments is formed, including horizontal weft filaments (1) and vertical warp filaments (2), the said cloth being made to adhere to the parent sail by means of a removable adhesive and being used for applying thereon two external plastic laminates, after the said cloth has been removed from the parent sail, wherein the external plastic laminates are applied in individual pieces on both sides of the cloth, in such a way as to adapt themselves and follow the local convexity of the cloth, and this operation is carried out on a plane support.

2. A process for producing a sail or an element of a tensile structure according to claim 1,

characterized in that the distance between the synthetic weft filaments (1) is less than 1 cm, and that between the synthetic warp filaments (2) is also less than 1 cm.

3. A process according to claim 2 characterized in that the thickness of the parent sail is about 250 micron (10 mils).

4. A process according to claim 1, characterized in that the height of the pieces which form each external plastic laminate is equal to about 1 m.

5. A sail or element of a tensile structure, having a polygonal form, produced according to the process of claim 1, comprising two external plastic laminates, which are formed by a plurality of pieces, wherein said pieces are joined to each other at their edges, and comprising also an inner convex-shaped cloth, which is flexible and has the same form and size of the sail to be realized;

the said cloth including horizontal synthetic weft filaments (1) and vertical synthetic warp filaments (2), arranged in such a way as to form a homogeneous cloth.

6. A sail or an element of a tensile structure, according to claim 5, characterized in that the mutual distance between the weft filaments (1) is less than 1 cm, and the distance between the warp filaments (2) is also less than 1 cm.

7. A sail according to claim 6, characterized in that the pieces which form the external plastic laminates of the sail'"'"'s “

sandwich”

, have a size allowing them to follow the curvature of the flexible internal cloth without folds and crease.