Method of producing reinforced, formed fabrics

• US 7,479,200 B2
• Filed: 06/25/2003
• Issued: 01/20/2009
• 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: Gautier, Gérard, Kessi, Edouard
• Primary Examiner(s): Crispino; Richard
• Assistant Examiner(s): Musser; Barbara J.
• Application Number:
  US10/521,160
• Publication Number:
  US 20060157189A1
• Time in Patent Office: 2,036 Days
• Field of Search: 156/221, 156/382, 156/443, 156/580, 156/307.1, 156/307.3, 156/307.7
• US Class Current: 156/221
• 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 sail comprising reinforcing elements and a resin, comprising:

forming the reinforcing elements and the resin into strips;

positioning the strips on a surface, and wherein the strips are positioned to partially overlap one another;

shaping at least a portion of the strips in a three-dimensional shape, by

providing a press having an upper chamber with an elastically flexible lower element and a lower chamber with an elastically flexible upper element;

transferring the positioned strips from the surface and positioning the strips between, and in contact with, the elastically flexible upper element and the elastically flexible lower element;

deforming at least a portion of the flexible upper element and at least a portion of the flexible lower element in a three-dimensional shape, thereby deforming the portion of the strips in contact with the portion of the flexible upper element and the portion of the flexible lower element in a three-dimensional shape;

applying pressure and heat to the strips;

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

2. The method of claim 1, wherein the reinforcing elements comprise filaments, and wherein the filaments are distributed throughout the strip.

3. The method of claim 1, wherein positioning comprises providing one or more additional strips along at least a portion of a predicted line of force to which the fabric will be subjected.

4. The method of claim 1, wherein positioning comprises providing one or more additional strips in a location where the fabric will require reinforcement.

5. A method of manufacturing shaped and reinforced fabrics, wherein the fabric comprises a membrane which encases reinforcing elements, the method comprising:

providing a press which comprises an upper chamber whose lower part is constituted by a flexible element and a lower chamber whose upper part is constituted by a flexible element, the upper chamber comprising a shaping bar whose shape can be adjusted by adjustment rods and whose adjusted shape causes the elastic deformation in three dimensions of the flexible elements and consequently of the membrane and the reinforcing elements which are in the press, wherein the shaping bar has an active position in which the shaping bar deforms the membrane and reinforcing elements, and an inactive position in which the shaping bar is inactive and there is no deformation of the membrane and the reinforcing elements, preparing portions of membrane and reinforcing elements before pressing on a conveyor belt which is put on a preparation table which then places these portions under the press which provides pressure and heating, and by the fact that the portions of the membrane and reinforcing elements are overlapped during the preparation so as to constitute at the output of the press a homogeneous fabric which comprises flat portions and portions shaped in three dimensions according to multiple shapes determined by the adjustment of the shaping bar during the pressing of each portion of membrane and reinforcing elements whose length is determined by the width of the press and of the preparation table.

6. A manufacturing method according to claim 5, characterized by the fact that the upper chamber of the press is filled with air whose pressure is adjustable and controlled by a manometer, the pressing pressure being provided by the compressed air contained in the upper chamber.

7. A manufacturing method according to claim 5, characterized by the fact that the lower chamber is filled with water whose level is maintained by the communicating vessels principally by linking of the water supply and outlet which is connected to a tank, and whose pressure is maintained during pressing by closure of the valve.

8. A manufacturing method according to claim 5, characterized by the fact that polymerization or activation of the resin constituting the membrane is obtained by heating the preparation table.

9. A manufacturing method according to claim 5, characterized by the fact that activation of the resin is obtained by heating the preparation table and that polymerization is obtained by heating on or other of the chambers.

10. A manufacturing method according to claim 5, characterized by the fact that activation or polymerization of the resin is obtained by heating the press.

11. A manufacturing method according to claim 5, characterized by the fact that the portions of membrane and reinforcing elements are placed partially overlapping one another so as to guarantee the homogeneity of the fabric.

12. A manufacturing method according to claim 5, characterized by the fact that the portions of membrane and reinforcing elements can be disposed in all directions and also one upon another by crossing according to the direction of the forces to which the fabric is subjected and according to the locations where the fabric has to comprise particular reinforcements.

13. A manufacturing method according to claim 5, characterized by the fact that an element for immobilizing the fabric is activated during the pressing.