Method of producing reinforced, formed fabrics

• US 8,181,587 B2
• Filed: 11/19/2008
• Issued: 05/22/2012
• 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): AVILA, STEPHEN P
• Application Number:
  US12/274,214
• Publication Number:
  US 20090173267A1
• Time in Patent Office: 1,280 Days
• Field of Search: 114/102.31, 114/102.33
• US Class Current: 114/102.31
• 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 sail, comprising:

a plurality of strips, each of the strips comprising;

reinforcing elements comprising substantially parallel filaments; and

an activated resin encasing the filaments;

wherein at least some of the plurality of strips partially overlap adjacent strips;

wherein the strips are arranged to form a fabric of the sail that accommodates expected forces in the sail; and

wherein the substantially parallel filaments of a first of the strips are oriented in a first direction and the substantially parallel filaments of a second of the strips are oriented in a second direction that is different than the first direction.

3. The sail of claim 1, wherein at least some of the strips overlap substantially along a length of each strip.

4. The sail of claim 1, wherein at least some of the strips are positioned in parallel, such that a first end of one strip substantially overlaps a first end of a second strip.

30. The sail of claim 1, wherein the fabric of the sail has outermost layers that are free of a separate polymerized plastic sheet.

2. A sail, comprising:

a first strip; and

a second strip, wherein each of the strips consists essentially of;

reinforcing elements comprising substantially parallel filaments; and

an activated resin encasing the filaments;

wherein the first strip partially overlaps the second strip and wherein the strips are arranged in a predetermined, three-dimensional fashion to form a fabric of the sail that accommodates expected forces in the sail.

31. The sail of claim 2, wherein the fabric of the sail has outermost layers that are free of a separate polymerized plastic sheet.

5. A sail, comprising:

a plurality of strips, each of the strips consists essentially of;

reinforcing elements comprising substantially parallel filaments; and

an activated resin encasing the filaments;

wherein at least some of the plurality of strips partially overlap adjacent strips to form a fabric of the sail.

6. The sail of claim 5, wherein the fabric of the sail has outermost layers that are free of a separate polymerized plastic sheet.

7. The sail of claim 6, wherein at least one additional strip is present along predicted lines of force to which the sail will be subjected.

8. The sail of claim 7, wherein at least one additional strip is present in a region of the sail that is predicted to be subject to higher forces.

9. The sail of claim 7, wherein at least one additional strip is positioned substantially parallel to the predicted lines of force.

10. The sail of claim 7, wherein at least one additional strip is positioned substantially perpendicular to the predicted lines of force.

11. The sail of claim 7, wherein at least one additional strip is positioned substantially parallel and at least one additional strip is positioned substantially perpendicular to the predicted lines of force.

12. A sail, comprising:

a plurality of strips, each of the strips comprising;

reinforcing elements comprising substantially parallel filaments; and

an activated resin encasing the filaments;

wherein at least some of the plurality of strips partially overlap adjacent strips and wherein the filaments of overlapping strips are intermixed so as to constitute a fabric of the sail that is impervious to wind and has outermost layers free of a separate polymerized plastic sheet.

13. The sail of claim 12, wherein at least one additional strip is present along predicted lines of force to which the sail will be subjected.

14. The sail of claim 12, wherein at least one additional strip is present in a region of the sail that is predicted to be subject to higher forces.

15. The sail of claim 13, wherein at least one additional strip is positioned substantially parallel to the predicted lines of force.

16. The sail of claim 13, wherein at least one additional strip is positioned substantially perpendicular to the predicted lines of force.

17. The sail of claim 13, wherein at least one additional strip is positioned substantially parallel and at least one additional strip is positioned substantially perpendicular to the predicted lines of force.

18. The sail of claim 12, wherein the strips are layered, one on top of the other, to provide a plurality of layers.

19. The sail of claim 18, wherein the strips of a first layer are at angles with the strips of a second layer.

20. The sail of claim 12, wherein at least some of the strips overlap substantially along a length of each strip.

21. The sail of claim 12, wherein at least some of the strips are positioned in parallel, such that a first end of one strip substantially overlaps a first end of a second strip.

22. A sail, comprising:

a plurality of strips, each of the strips comprising;

reinforcing elements comprising substantially parallel filaments; and

an activated resin encasing the reinforcing elements individually;

wherein at least some of the plurality of strips partially overlap adjacent strips, and wherein the filaments of the overlapping strips are intermixed so as to constitute a fabric of the sail substantially homogeneous, having no creases.

23. The sail of claim 22, wherein the fabric of the sail has outermost layers that are free of a separate polymerized plastic sheet.

24. The sail of claim 23, wherein at least one additional strip is present along predicted lines of force to which the sail will be subjected.

25. The sail of claim 23, wherein at least one additional strip is present in a region of the sail that is predicted to be subject to higher forces.

26. The sail of claim 23, wherein at least one additional strip is positioned substantially parallel to the predicted lines of force.

27. The sail of claim 23, wherein at least one additional strip is positioned substantially perpendicular to the predicted lines of force.

28. The sail of claim 23, wherein at least one additional strip is positioned substantially parallel and at least one additional strip is positioned substantially perpendicular to the predicted lines of force.

29. A sail, comprising:

a plurality of strips, each of the strips comprising;

reinforcing elements of thousands of filaments and are distributed uni-directionally over the width of each strip; and

an activated resin encasing the filaments;

wherein at least some of the plurality of strips partially overlap adjacent strips, and wherein the strips are layered to form a fabric of the sail, which comprises thousands of the filaments disposed uni-directionally in a first layer, and wherein the fabric further comprises a second layer of thousands of the filaments disposed in another direction relative to the filaments of the first layer.