Method of producing reinforced, formed fabrics

• US 8,709,186 B2
• Filed: 11/19/2008
• Issued: 04/29/2014
• 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, Grard, Kessi, Edouard
• Primary Examiner(s): Musser, Barbara J
• Application Number:
  US12/274,307
• Publication Number:
  US 20090140455A1
• Time in Patent Office: 1,987 Days
• Field of Search: 156/583.3
• US Class Current: 156/182
• 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:

providing reinforcement elements comprising filaments;

providing a resin in contact with the reinforcing elements;

arranging the reinforcement elements and the resin into a plurality of first strips and into a plurality of second strips;

positioning the plurality of first strips to partially overlap adjacent first strips to form a sheet;

positioning the plurality of second strips on the first strips only along a predicted line of force to which the sail will be subjected, wherein the second strips do not extend to or beyond the outer dimension of the sheet; and

forming a fabric of the sail by curing the resin of the first and second strips such that the cured resin encases the reinforcing elements, wherein the fabric is without exterior layers of polymerized plastic sheets,

wherein the sail includes at least a leech and a foot.

2. The method of claim 1, wherein at least one additional second strip is positioned substantially parallel to the predicted line of force.

3. The method of claim 1, wherein at least one additional second strip is positioned substantially perpendicular to the predicted line of force.

4. The method of claim 1, wherein at least one additional second strip is positioned substantially parallel and at least another additional second strip is positioned substantially perpendicular to the predicted line of force.

5. The method of claim 1, wherein positioning comprises:

positioning at least one additional second strip in a location where the fabric will require reinforcement.

6. The method of claim 1, wherein the first and second strips comprise reinforcing elements pre-impregnated with the resin.

7. The method of claim 1, wherein positioning the first strips comprises:

positioning at least some of the first strips to overlap substantially along a length of each first strip.

8. The method of claim 1, wherein positioning the first strips comprises:

positioning at least some of the first strips in parallel, such that a first end of one first strip substantially overlaps a first end of a second first strip.

9. The method of claim 1, wherein, during the curing step, the filaments of partially overlapping first and second strips intermix with one another.

10. The method of claim 1, wherein the reinforcing elements comprise thousands of filaments that are distributed over the width of each first and second strip.

11. The method of claim 10, wherein the first strips are positioned such that the fabric comprises the thousands of filaments disposed unidirectionally in the sheet.

12. The method of claim 11, wherein the second strips are positioned such that the thousands of filaments in the second strips are disposed in a different direction relative to the filaments of the first strips.

13. The method of claim 1, wherein the sail further comprises at least one eyelet configured to operatively connect the sail to a wind-powered sailing vessel.

14. A method of manufacturing a sail, comprising:

providing a plurality of reinforcing elements, wherein the reinforcing elements are formed from filaments which are aligned;

providing a resin in contact with the reinforcing elements;

arranging the reinforcing elements and the resin to form a plurality of first strips and to form a plurality of second strips;

arranging the plurality of first strips to partially overlap adjacent first strips, the plurality of first strips defining a sheet with an outer dimension;

positioning the plurality of second strips on the sheet of first strips along a predicted line of force to which the sail will be subjected, wherein the second strips do not extend to or beyond the outer dimension of the sheet of first strips;

placing the arranged strips on a surface; and

forming a fabric of the sail by curing the resin of the strips such that the cured resin encases the reinforcing elements, wherein the fabric is without exterior layers of polymerized plastic sheets,

wherein the sail includes at least a leech and a foot.

15. The method of claim 14, wherein at least one additional second strip is positioned substantially parallel to the predicted line of force.

16. The method of claim 14, wherein at least one additional second strip is positioned substantially perpendicular to the predicted line of force.

17. The method of claim 14, wherein at least one additional second strip is positioned substantially parallel and at least another additional second strip is positioned substantially perpendicular to the predicted line of force.

18. The method of claim 14, wherein positioning the plurality of second strips comprises:

positioning at least one additional second strip in a location where the fabric will require reinforcement.

19. The method of claim 14, wherein the first and second strips comprise reinforcing elements pre-impregnated with the resin.

20. The method of claim 14, wherein arranging the first strips comprises:

positioning at least some of the first strips to overlap substantially along a length of each first strip.

21. The method of claim 14, wherein arranging the first strips comprises:

positioning at least some of the first strips in parallel, such that a first end of one first strip substantially overlaps a first end of a second first strip.

22. The method of claim 14, wherein the sail further comprises at least one eyelet configured to operatively connect the sail to a wind-powered sailing vessel.

23. A method of manufacturing a sail, comprising:

providing reinforcement elements comprising filaments;

providing a resin in contact with the reinforcing elements;

arranging the reinforcement elements and the resin into a plurality of first strips, a second strip, and a third strip;

arranging the plurality of first strips on a surface so that at least some of the first strips partially overlap adjacent first strips, the plurality of first strips defining an outer dimension;

positioning the second strip and the third strip along only a predicted line of force to which the sail will be subjected, and such that the second strip and the third strip do not extend to or beyond the outer dimension; and

forming a fabric of the sail by curing the resin of the strips such that the cured resin encases the reinforcing elements,

wherein the fabric of the sail consists essentially of the cured resin and the reinforcing elements, and wherein the sail includes at least a leech and a foot.

24. The method of claim 23, further comprising arranging the reinforcement elements and the resin into a fourth strip, wherein the fourth strip is positioned substantially parallel to the predicted line of force.

25. The method of claim 23, further comprising arranging the reinforcement elements and the resin into a fourth strip, wherein the fourth strip is positioned substantially perpendicular to the predicted line of force.

26. The method of claim 23, further comprising arranging the reinforcement elements and the resin into a fourth strip and a fifth strip, wherein the fourth strip is positioned substantially parallel and the fifth strip is positioned substantially perpendicular to the predicted line of force.

27. The method of claim 23, further comprising arranging the reinforcement elements and the resin into a fourth strip, and positioning the fourth strip in a location where the fabric will require reinforcement.

28. The method of claim 23, wherein the first, second, and third strips comprise reinforcing elements pre-impregnated with the resin.

29. The method of claim 23, wherein arranging the first strips comprises:

positioning at least some of the first strips to overlap substantially along a length of each first strip.

30. The method of claim 23, wherein arranging the first strips comprises:

positioning at least some of the first strips in parallel, such that a first end of one first strip substantially overlaps a first end of a second first strip.

31. The method of claim 23, wherein the sail further comprises at least one eyelet configured to operatively connect the sail to a wind-powered sailing vessel.