METHOD OF PRODUCING REINFORCED, FORMED FABRICS
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.
1 . A method of manufacturing shaped and reinforced fabrics comprising reinforcing elements and a resin, the method comprising:
positioning the reinforcing elements and the resin on a surface, wherein the reinforcing elements and the resin are in contact with each other;
shaping at least a portion of the reinforcing elements and at least a portion of the resin in a three-dimensional shape;
applying pressure and heat to the reinforcing elements and the resin;
activating and polymerizing the resin to encase the reinforcing elements, thereby forming the fabric, and
removing the fabric from the surface.
2 . The method of claim 1 , wherein positioning comprises:
forming the reinforcing elements and the resin into strips; and
positioning the strips on the surface.
3 . The method of claim 2 , wherein shaping is performed substantially simultaneously with applying pressure and heat.
4 . The method of claim 3 , wherein shaping comprises:
providing a press having an upper chamber with an elastically flexible lower element and a lower chamber with an elastically flexible upper element;
positioning the reinforcing elements and resin 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 reinforcing elements and the portion of the resin in contact with the portion of the flexible upper element and the portion of the flexible lower element in a three-dimensional shape.
5 . The method of claim 4 , wherein the upper chamber comprises a shaping bar, and wherein deforming comprises:
adjusting the shape of the shaping bar; and
contacting the lower flexible element with the adjusted shaping bar to deform the portion of the flexible lower element, the portion of the flexible upper element, the portion of the reinforcing elements, and the portion of the resin, in a three-dimensional shape.
6 . The method of claim 5 , wherein the surface comprises a preparation table, wherein the preparation table is separate from the press.
7 . The method of claim 6 , wherein activating the resin or polymerizing the resin comprises heating the preparation table.
8 . The method of claim 5 , wherein the surface comprises the elastically flexible upper element of the lower chamber of the press.
9 . The method of claim 5 , wherein activating the resin comprises heating the preparation table, and polymerizing the resin comprises heating the upper chamber or heating the lower chamber.
10 . The method of claim 5 , wherein activating the resin or polymerizing the resin comprises heating the press.
11 . The method of claim 1 , wherein positioning comprises:
positioning the reinforcing elements to partially overlap one another.
12 . The method of claim 11 , wherein positioning comprises:
positioning at least one reinforcing element along at least a portion of a predicted line of force to which the fabric will be subjected.
13 . The method of claim 11 , wherein positioning comprises:
positioning at least one reinforcing element in a location where the fabric will require reinforcement.
14 . The method of claim 2 , wherein positioning comprises:
positioning the strips to partially overlap one another.
15 . The method of claim 14 , wherein positioning comprises:
positioning at least one strip along at least a portion of a predicted line of force to which the fabric will be subjected.
16 . The method of claim 14 , wherein positioning comprises:
positioning at least one strip in a location where the fabric will require reinforcement.
17 . The method of claim 1 , wherein the reinforcing elements are pre-impregnated with resin.
18 . The method of claim 2 , wherein the strips comprise reinforcing elements pre-impregnated with resin.
19 . The method of claim 2 , wherein positioning further comprises:
positioning strips in contact with at least a portion of a first fabric comprising a first reinforcing elements and a first resin;
and wherein the method further comprises:
joining the strips to the first fabric by applying pressure and heat to the first fabric and the strips which are in contact with the first fabric.
20 . The method of claim 1 , wherein the reinforcing elements comprise filaments, the method comprising:
distributing the filaments throughout fabric.
21 . The method of claim 14 , wherein the reinforcing element comprise filaments, and wherein the filaments are distributed throughout the strips.
22 . The method of claim 1 , wherein the fabric is formed primarily of reinforcing elements and resin.
23 . The method of claim 1 , wherein the fabric consists essentially of reinforcing elements and resin.
24 . A method of manufacturing shaped and reinforced fabrics comprising reinforcing elements and a resin, the method comprising:
positioning the reinforcing elements and the resin on a surface, wherein the reinforcing elements and the resin are in contact with each other;
shaping at least a portion of the reinforcing elements and at least a portion of the resin in a three-dimensional shape;
applying pressure and heat to the reinforcing elements and the resin;
activating and polymerizing the resin to encase the reinforcing elements, thereby forming the fabric,
wherein the fabric comprises a first surface and an opposing second surface, and wherein both the first surface and the second surface are free of a separate polymerized plastic sheet; and
removing the fabric from the surface.
25 . The method of claim 22 , wherein positioning comprises:
layering strips, one on top of the other, to provide a plurality of layers.
26 . The method of claim 25 , further comprising
positioning the strips of a first layer at angles with the strips of a second layer.
27 . The method of claim 11 , wherein positioning comprises:
positioning at least some of the strips to overlap substantially along a length of each strip.
28 . The method of claim 11 , wherein positioning comprises:
positioning at least some of the strips in parallel, such that a first end of one strip substantially overlaps a first end of a second strip.