US20100043689A1

US20100043689A1 - Apparatus And Method Of Producing Reinforced Laminated Panels As A Continuous Batch

Info

Publication number: US20100043689A1
Application number: US12/195,963
Authority: US
Inventors: Kenneth M. Madsen; John Gluek
Original assignee: DIMENSION-POLYANT Inc
Current assignee: DIMENSION-POLYANT Inc
Priority date: 2008-08-21
Filing date: 2008-08-21
Publication date: 2010-02-25
Also published as: WO2010021758A1

Abstract

An apparatus and method for producing multiple panels of a reinforced laminated membrane are provided. The apparatus and method utilize an accommodator between a yarn-laying station and a plotting and cutting station to allow these stations to operate simultaneously and without interruption on more than one part of a sheet of material. Reinforcing yarns are deposited on the sheet of material at the yarn-laying station in one or more patterns. Panels are cut at the cutting station after lamination. The accommodator accommodates material between these stations.

Description

FIELD OF THE INVENTION

The present invention relates to the manufacture of a reinforced laminated membrane. In particular, the present invention relates to the manufacture of reinforced laminated panels.

BACKGROUND OF THE INVENTION

It is well known that the demands of high performance sailing have driven important advances in sails and sailmaking technology in recent decades. In the past, all sails were constructed from woven fabrics. First, textile yarns made from organic fibers, such as cotton, were used. Eventually, textile yarns made from organic fibers were replaced by synthetic yarns, which were generally extruded multifilaments. Examples of such synthetic yarns are polyester, nylon, polyaramid, polyethylene naphthalate, polyphenulene benzo bisoxazole, and the like. Initially, these synthetic yarns were woven into cloths of varying weights and densities just as textile yarns had been for centuries prior. Today, synthetic yarns and materials have almost completely replaced organic yarns for use in sails of all types in all parts of the world.
Sails made from woven materials—whether synthetic or not—are known to possess serious shortcomings. For example, the 90 degree warp and fill orientation and the over and under shape of the warp yarns (called “crimp”) created by weaving make the sail highly susceptible to distortion of the sail's shape once it is exposed to the high loads associated with powering a sailboat. Because the warp and fill yarns are oriented at strictly a 90 degree angle to one another, the woven material has anisotropic properties when force is applied at angles other than 90 degrees to the warp or fill. Also, because of the “crimp,” the cloth is often woven so that it has better properties (for example less stretch) in only one of the warp or fill directions. This can result in uneven elongation of the material. The drawbacks of woven materials, while not overly worrisome for most recreational sailors, were a significant problem for high performance sailors.
In response, sailmakers made significant advances in high performance sailcloth over the past 30 years. Of these advances, the move to laminated “structural” sails has been the most significant. In summary, structural sails generally combine high strength and low-stretch synthetic films with high strength and low-stretch synthetic yarns that are placed along the anticipated load-paths of the sail. Synthetic yarns are placed along paths which the sailmaker has calculated the force to be following. This allows the sail to be extremely strong while also significantly lighter than woven materials, since the yarns are used much more efficiently. In essence, a structural sail is customized for a particular boat and a particular use: the sail provides optimum performance in its application as selected by the sailor.
FIG. 4 shows an exploded view of a sail panel 50 that is part of a structural sail. In general, the sail panel 50 is cut from a web of laminated membrane. The laminated membrane is formed of one or more layers 51 of reinforcing yarns 20 that are laminated between a top sheet 52 of film and a bottom sheet 53 of film. The reinforcing yarns 20 are disposed along the anticipated load paths of the sail panel 50. The reinforcing yarns 20 are preferably synthetic material having high strength, very low stretch, and light weight. The film used for top sheet 52 and bottom sheet 53 is also selected to have high strength, very low stretch, and light weight.
Structural sails provide many advantages over traditional woven sails, as described in the prior art. The two primary approaches to designing and making structural sails are represented by U.S. Pat. No. 4,708,080 to Conrad (and related patents to Conrad et al., collectively the “Conrad process”) and U.S. Pat. No. 5,097,784 to Baudet (the “3DL process”). Reference should be made to these documents for further details regarding the advantages of structural sails.
In a simple embodiment of the Conrad process, yarns are laid onto a film (such as Mylar) along the directions in which the principal forces run. This structure is then laminated with a second film to form a sail panel. A plurality of sail panels are constructed in this way and the plurality of panels are joined together to form a sail. The well-known technique of broadseaming is used to join the panels such that the resulting sail has a three-dimensional shape.
The 3DL process differs slightly in that an entire three-dimensional sail is made in one piece. In the 3DL process, sections of film are broadseamed together and placed on a mold. The mold has a three-dimensional shape corresponding to the desired shape of the sail. A gantry deposits yarns on the film in continuous trajectories from one edge of the sail to another. The yarns are oriented, as in the Conrad process, along the principal load-paths. After the yarns are deposited, an outer layer of film may be applied on top of the fiber layer. The arrangement is laminated using heat or light and/or vacuum pressure.
Both of the foregoing processes have been used with great success by sailmakers to create high-performance sails used by the best sailors in the world. The customized, structural laminated sails have effectively become required equipment for serious sailboat racing.
While the high-performance, customized structural sails are typically well within the budget of sponsored sailboat racing teams and organizations, other sailors often struggle to justify the expense of these high-performance sails. Over the past decade, sailmakers have labored to reduce the cost of these high-performance sails to make them more accessible to recreational sailors, high-performance cruising sailors, and sailors that are beginning a racing career.
The current method for making sails according to the Conrad process is commonly known as the “D4 process.” In the D4 process, a sail is designed using a computer, which can provide models of expected load-paths for the sail. The sails are designed to include a plurality of sections or panels—typically five to seven. The computer model of the sail is used by the sailmaker to undertake the following steps to create a sail. First, a film layer is placed on the construction floor and secured in place. Next, a computer driven overhead gantry system lays out a yarn matrix on the film. The gantry system lays out the yarn according to the computer models. After the yarns are laid, a top film is placed on top of the yarns and bottom layer and the components are laminated using pressure rollers.
As is well-known, additional components have often been incorporated into sail panels made by the D4 process. For example, laminates made under U.S. Pat. No. 5,403,641 to Linville et al (often marketed under the trademark “X-Ply”) or similar laminated membranes are often used in addition to or instead of the top film.
Unfortunately, the D4 process, while significantly more efficient that the 3DL process, still leaves room for improvement in cost savings. Primarily, the traditional D4 process is more labor intensive than desired, as human intervention is required at numerous steps in the process. For example, the first film layer must be manually drawn and laid out for each and every panel. Second, each and every laminated structure must be manually moved after lamination. Thus, manual labor and material handling is relatively high in known methods for producing customized, laminated panels.
It is also known that laminate structures similar to those used in structural sails have a wide variety of applications in a wide variety of industries. For example, laminated membranes that are reinforced by load-bearing yarns are used in parachutes, reinforced bags, air bags, tents, awnings, etc. A more efficient and cost effective means of manufacturing these membranes is also desired.
What is desired, therefore, is a method and apparatus for producing custom panels of a reinforced laminated membrane that significantly minimizes manual labor and includes improved automation. A method and apparatus that produces custom panels of a reinforced laminated membrane in rapid succession is also desired.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a method and apparatus for producing custom panels of a reinforced laminated membrane that minimizes manual labor.
It is a further object of the present invention to provide a method and apparatus for producing custom panels of a reinforced laminated membrane with a high degree of automation.
It is yet a further object of the present invention to provide a method and apparatus for producing custom panels of a reinforced laminated membrane in rapid succession.
These and other objects are achieved according to a first embodiment of the present invention by provision of a method of continuously producing multiple sail panels for sails having one or more patterns of reinforcing yarns, comprising the steps of: providing a sheet of sail panel material; adding first reinforcing yarns to a first portion of the sheet in a first pattern; laminating the first reinforcing yarns to the first portion of the sheet to form a first reinforced laminated sail cloth; advancing the first reinforced laminated sailcloth through an accommodating station to a cutting station; fixing the first reinforced laminated sailcloth in place at the cutting station; cutting the first reinforced laminated sailcloth into a first sail panel; while cutting the first sail panel, adding second reinforcing yarns to a second portion of the sheet in a second pattern; laminating the second reinforcing yarns to the second portion of the sheet to form a second reinforced laminated sail cloth; accommodating the second reinforced laminated sailcloth in the accommodating station until cutting of the first sail panel from the first reinforced laminated sailcloth complete.
In some embodiments, the first pattern and the second pattern are different. In some embodiments, the first pattern and the second pattern are the same. In some embodiments, the method further comprises the steps of: advancing the second reinforced laminated sailcloth to the cutting station; fixing the second reinforced laminated sailcloth in place at the cutting station; and cutting the second reinforced laminated sailcloth into a second sail panel, where the second sail panel and the first sail panel are intended to form parts of a sail.
In some embodiments, the second panel is cut to a different shape than the first panel. In some embodiments, the steps of laminating comprise laminating the first and second reinforcing yarns and the first and second portions of the sheet of sail panel material to a previously laminated material. In some embodiments, the previously laminated material comprises reinforced sailcloth.
In some embodiments, the step of accommodating comprises translating at least one roller to vary the distance to be travelled by the second reinforced laminated sailcloth to arrive at the cutting station. In some embodiments, the steps of laminating comprise advancing the first and second reinforcing yarns and the first and second portions of the sheet of sail panel material between a heated metal roll and a flexible counter roll. In some embodiments, the step of adding first reinforcing yarns to a sheet of sail panel material comprises adding first reinforcing yarns along expected load-paths in a sail panel.
According to a second exemplary embodiment of the present invention, an apparatus for continuously producing multiple panels of a laminated membrane having one or more patterns of reinforcing yarn is provided. The apparatus comprises: a yarn-laying head for adding first reinforcing yarn to a first portion of a sheet of material in a first pattern and second reinforcing yarn to a second portion of the sheet of material in a second pattern; a laminator for laminating the first reinforcing yarn to the first portion of the sheet to form a first portion of reinforced laminated membrane and the second reinforcing yarn to the second portion of the sheet to form a second portion of reinforced laminated membrane; a cutting device for cutting panels from the first and second portions of reinforced laminated membrane; and an accommodator disposed between the yarn-laying head and the cutting device for accommodating the second portion of the sheet of material until the cutting of a first panel from the first portion of reinforced laminated membrane is completed by the cutting device.
In some embodiments, the apparatus further comprises a cutting table on which the first portion of reinforced laminated membrane is fixed while panels are cut by the cutting device. In some embodiments, the cutting table includes a vacuum surface. In some embodiments, the first pattern and the second pattern are different. In some embodiments, the first pattern and the second pattern are the same.
In some embodiments, the accommodator comprises a plurality of translatable rollers for varying the distance travelled by the second reinforced laminated membrane between the laminator and the cutting device. In some embodiments, the laminator comprises a heated metal roll and a flexible counter roll. In some embodiments, the laminator laminates the first and second reinforcing yarns and the first and second portions of the sheet of material to a previously laminated membrane.
In some embodiments, the apparatus further comprises a yarn-laying table on which the sheet of material is secured while the yarn-laying head adds the first reinforcing yarn to the sheet. In some embodiments, the yarn-laying head adds the first reinforcing yarns to the sheet of material along expected load-paths in the panel.
In some embodiments, the laminator is disposed between the yarn-laying head and the cutting device and the accommodator is disposed between the yarn-laying head and the laminator. In some embodiments, the laminator is disposed between the yarn-laying head and the cutting device and the accommodator is disposed between the cutting device and the laminator.
Thus, the present invention provides a method and apparatus for producing multiple panels of a reinforced laminated membrane efficiently and cost-effectively. The accommodator allows the sail panel material (often a film or sheet) to be stationary so that reinforcing yarns may be deposited thereon and stationary at the cutting station for plotting and cutting, even though these tasks may require different lengths of time to complete. In some embodiments, human intervention is not required to move the laminated membrane from the laminator to the cutting table, as this is taken care of by a driven rewind roll at the end of the cutting table, and thus, the end of the apparatus. A large number of panels having various lengths and yarn patterns may be produced in rapid succession without stopping any part of the apparatus for an extended period of time.
The particular details and benefits of the present invention will be apparent to those of skill in the art based on the following description with reference to the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an apparatus for producing sail panels according to the present invention.

FIG. 2 is a perspective view of an embodiment of an apparatus for producing sail panels as shown schematically in FIG. 1.

FIG. 3 is a perspective view of a sail constructed of sail panels made using the apparatus shown in FIG. 2.

FIG. 4 is an exploded view of a panel made using the apparatus shown in FIG. 2.

FIG. 5 shows a method of producing panels according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention will now be described with reference to the drawings. FIG. 1 shows a schematic view of an apparatus 10 for producing sail panels according to the present invention. In general, the apparatus 10 is used to create a reinforced laminated membrane from which a series of panels may be cut. In some embodiments, the panels are designed to be sail panels that form part of a structural sail. The apparatus 10 deposits yarns on a bottom sheet of material that is often provided in a roll. Sheets of material used in the present invention may be most any type of sheet, film, or substrate, including, in some embodiments, tafetta or other cloth. The type of material used will vary depending on the intended use of the panels to be constructed, as will be recognized by those of skill in the art. The yarn is deposited in a series of desired patterns corresponding to the patterns desired for each individual panel. For example, the yarns are deposited along the expected load lines in a sail panel. The apparatus 10 advances the bottom sheet carrying the yarn through a laminating station, in which the bottom sheet and yarns are laminated to a top sheet to form a laminated membrane or sail cloth. The top sheet may be a previously laminated component. The completed laminated membrane or sailcloth is then advanced to the plotting and cutting table so that a sail panel may be cut and removed from the membrane. A material accommodator is used to accommodate the laminated membrane or sail cloth, as necessary, between the laminator and the plotting and cutting table.
The present invention is particularly suited for the manufacture of sail panels used to create three-dimensional structural sails, but many other reinforced laminated products are advantageously produced in accordance with the invention. For example, reinforced laminated membrane panels made according to the present invention are used for such products as tents, awnings, parachutes, air bags, various construction materials, and the like.
More particularly, the apparatus 10 has four primary stations: a yarn-laying station 11, a laminator or laminating station 12, an accommodating station, accumulator, or accommodator 13, and a plotting/cutting station 14. A sheet 17 is provided on a roll 15, which is located at one end of a yarn-laying table 16 and is arranged so that the sheet 17 may be advanced over the table 16. In situations where the sheet 17 is provided on a liner, a rewind roll 18 is also provided to collect the liner as the sheet 17 is unwound from the roll 15. The sheet 17 is advanced over the table 16—and through the entire apparatus 10—via one or more driven rollers located in the apparatus. The table 16 includes, in some embodiments, a vacuum system as is well-known in the art to hold the sheet 17 in place. Driven rollers may be located in the laminating station 12, in the accommodator 13, and/or at the end of the apparatus 10 opposite to the roll 15. The operation of such driven rollers to advance the sheet 17 is well-known to those of skill in the art.
A yarn-laying head 18 is also part of the yarn-laying station 11. Yarn-laying head 18 draws one or more yarns 20 from one or more spools 19 and applies the yarns 20 to the sheet 17. In the embodiment shown in FIG. 1, four spools 19 and four individual yarns 20 are shown. The yarns 20 are run through two ceiling supports 30 and 31. In some embodiments, more than two ceiling supports are used. The yarns 20 are, in some embodiments, pre-coated with and adhesive so that they will adhere to the sheet 17. The yarn-laying head 18 includes a heating element in order to heat the pre-coated adhesive for application of the yarns 20 to the sheet 17. In other embodiments, the yarns 20 are adhered to the sheet 17 by an adhesive that is heated in the yarn-laying head 18 and applied to the yarns 20 as they are drawn onto the sheet 17. The yarn-laying head 18 can lay yarns in substantially any pattern selected by the operator of the apparatus 10. The yarn-laying head 18 can make multiple passes over the sheet 17 to lay yarns 20 in multiple layers, as desired. After the yarns 20 are deposited on the sheet 17, the adhesive cools and hardens such that the yarns are secured to the sheet 17. Yarn-laying head 18 also includes, in some embodiments, a marker (such as a pen, pencil, or the like) that is used to create marks on the sheet 17 to assist the plotter/cutter 29 in discerning features to be plotted and cut from the finished membrane.
After the yarns 20 have been laid on the sheet 17, the sheet is advanced to the laminating station 12. The laminating station 12 utilizes roll goods lamination technology and comprises, in the embodiment represented in FIG. 1, a heated metal roll 21 and a flexible counter roll 22. The flexible counter roll 22 is made, in many embodiments, of silicone rubber. The flexible counter roll 22 ensures uniform pressure across the sheet 17 as the sheet 17 passes through the laminating station 12 despite the changes in thicknesses due to the varying density of yarns across the sheet 17. As those of skill in the art will appreciate, uniform lamination is critical to a durable sail that performs consistently. For this reason, the speed of the laminator can be varied according to the density of yarns laid on the sheet 17. For higher yarn densities, the laminator is often run more slowly so that the yarns and the sheet are sufficiently heated by the heated metal roll 21.
In some embodiments, a “flat-bed” laminator may be used instead of roll goods lamination technology. Flat-bed laminators are well known in the art, and generally include a heated metal press under which the components of the panel are pressed for lamination.
A roll 23 is also present in the laminating section 12, which holds an additional component 24 to be laminated with the sheet 17 and yarns 20. In some embodiments, the roll 23 holds a second sheet identical or similar to the sheet 17. In other embodiments, the roll 23 will include synthetic fabric or taffeta that is often used to make laminated sails. In still other embodiments, the roll 23 will include a previously laminated web of, for example, sailcloth made according to U.S. Pat. No. 5,403,641 to Linville et al. Selection of the component 24 on roll 23 is crucial to the performance of the panel that will eventually result from the process described herein and will depend on the intended use of the panel. The component 24 is often a “top” sheet to compliment the “bottom” sheet 17 and sandwich the yarns 20.
After the sheet 17, the yarns 20, and the component 24 are laminated, they form a reinforced laminated sailcloth or membrane 25. The reinforced laminated membrane 25 is then advanced through the accommodator 13 to the plotting and cutting station 14. FIG. 1 shows the accommodator 13 represented schematically as an accumulator made up of a plurality of rollers, including translatable rollers 26 and stationary rollers 27. The accommodator 13, as shown in FIG. 1 (and FIG. 2), can accommodate the reinforced laminated membrane 25 by increasing the distance between one or more of the translatable rollers 26 and the stationary rollers 27, by the vertical movement of the translatable rollers 26. In this way, a longer length of the membrane 25 can be present between the laminating station 12 and the plotting and cutting table 14 within the rollers 26 and 27 of the accommodator 13. Effectively, the accommodator 13 increases the distance that the reinforced laminated membrane 25 must travel between the laminating station 12 and the cutting station 14.
The accommodator 13 can take numerous forms without departing from the spirit of the present invention. In some embodiments, the accommodator 13 has translatable rollers that move in a horizontal direction. In another embodiment, the accommodator 13 is a table having an extended length on which the reinforced laminated membrane 25 is deposited after lamination. In such an embodiment, the length of the accommodating table is such that numerous sections or portions of the reinforced laminated membrane 25 may rest there before being processed by the plotting/cutting station 14. In yet another embodiment, the accommodator 13 is in the form of a box in which the reinforced laminated membrane 25 may be loosely folded while it awaits processing by the plotting/cutting station 14. Each type of accommodator is able to effectively increase the distance that the reinforced laminated membrane 25 must travel between the laminating station 12 and the cutting station 14.
The first section of reinforced laminated membrane 25 to be advanced to the plotting/cutting station 14 will not, in most cases, be accommodated but will simply pass directly through the accommodator 13. A “section” or “portion” of the sheet 17 or reinforced laminated membrane 25 is used to refer loosely to a length of the sheet 17 or reinforced laminated membrane 25 in which a pattern of yarns 20 has been deposited that is intended to become an individual panel. The accommodator 13 is most often used to accommodate subsequent portions reinforced laminated membrane 25.
The plotting/cutting station 14 includes a plotting and cutting table 28 and a plotter/cutter 29. The table 28 includes, in some embodiments, a vacuum system for sucking the reinforced laminated membrane 25 against the table so that it cannot be moved by the plotter/cutter 29 while plotting and cutting is taking place. Other securing mechanisms are employed in other embodiments, including clamps, weights, hooks and the like. The plotter/cutter 29 utilizes marks on the reinforced laminated membrane 25 and information from the computer models to accurately map and then cut a sail panel to its desired shape and size. The panel is then removed from the table 28 and taken to a curing station and eventually in some cases to a finishing station.
As the first panel is being cut from the reinforced laminated membrane 25, the other sections of the apparatus 10 are performing work on other sections of the sheet 17. The sheet 17, which originates from roll 15, runs through the apparatus 10 substantially from one end of the apparatus 10 (i.e., the yarn-laying station 11 ) to the other end of the apparatus 10 (i.e., the plotting and cutting station 14). In some embodiments, a final rewind roll is provided after the plotting and cutting table to draw the laminated sailcloth 25 and sheet 17 and to collect the unused portions of the laminated sailcloth 25. The accommodator 13 allows the various stations of the apparatus 10 to operate continuously and in a substantially uninterrupted fashion.
FIG. 2 shows a perspective view of the apparatus 10, which is an embodiment of the present invention. FIG. 2 shows a gantry 33 that carries the yarn-laying head 18. The gantry 33 runs along the length of the yarn-laying table 16 in the directions of arrows 34. The yarn-laying head 18 is able to move across the width of the yarn-laying table 16 along a top portion of the gantry 33 in the directions of arrows 35. The yarn-laying head 18, or components thereof, are also capable of rotation about a vertical axis that is perpendicular to the plane of the table 16. The movement of the gantry 33 on the table and the yarn-laying head 18 on the gantry permit yarns 20 to be deposited, even along curved paths, over substantially all of the surface area of the sheet 17 that is laid on the table 16. The construction and operation of a gantry and yarn-laying head which may be used in an apparatus according to the present invention is well known to those of skill in the art. One example of such a gantry and yarn-laying head is found in U.S. Pat. No. 5,355,820 to Conrad.
FIG. 2 also shows the laminating station 12 and the accommodator 13. The reinforced laminated membrane 25 is shown being advanced through the accommodator 13 to the plotting and cutting table 28 in plotting and cutting station 14. The plotter/cutter 29, like the yarn-laying head 18, rides on a gantry 36 up and down the table 28 in the directions of the arrows 37. The plotter/cutter 29 moves on the gantry 36 in the directions of the arrows 38. The plotter/cutter 29, or components thereof, is also capable to rotation about a vertical axis that is perpendicular to the plane of the table 28. This allows the plotter/cutter 29 to move, even along curved paths, over the entire portion of reinforced laminated membrane 25 to be plotted and cut. Vacuum system 42 is shown schematically under the table 28. In some embodiments, the yarn-laying table 16 also includes a similar vacuum system 72 (also shown in FIG. 2).
The accommodator 13 is again shown having three translatable rollers 26 and four stationary rollers 27. The three translatable rollers 26 are capable of being translated vertically. In some embodiments, the translatable rollers 26 move independently of one another and in some embodiments the rollers 26 move in unison. The number of translatable rollers and the distance that they are permitted to travel determines the amount of reinforced laminated membrane 25 that may be accommodated. The accommodator may be operated manually by a person monitoring the apparatus 10, or automatically. In automatic operation, the accommodator will respond to information and commands from the yarn-laying station 11 and the plotting and cutting station 14. Again, other types of accommodators are employed in other embodiments of the present invention.
FIG. 2 illustrates an important aspect of the present invention. A first portion 39 of the reinforced laminated membrane 25 is shown undergoing plotting/cutting operations on the plotting and cutting table 28. At the same time, a second portion 40 is being created in the yarn-laying station 11 by the yarn-laying head 18 depositing reinforcing yarns on the sheet 17. A third (and even a fourth) portion is accommodated in the accommodator 13, waiting to be advanced to the plotting and cutting station 14.
In the embodiment shown, first portion 39 and second portion 40 (and any portions in the accommodator 13) are each intended to be a panel of a structural sail and the yarns 20 are deposited along expected load paths. Second portion 40 is shown to be slightly larger than first portion 39 and has a different pattern of reinforcing yarns 20 deposited thereon. In such a situation, the time required for the yarn-laying head 18 to deposit the desired pattern of reinforcing yarns 20 on the second portion 40 may be different than the time required by the plotter/cutter 29 to cut out the panel from first portion 39. In particular, the time required by yarn-laying station 11 may be more than that required by the plotting and cutting station 14, so that a second portion 40 will not be ready to be advanced through the laminating station 12 when the first portion 39 is ready to be removed from the table 28. A similar situation arises when the patterns of yarns differ from one portion to the next. It is also true of some embodiments that, even for a series of portions having identical size, shape, and yarn patterns, the yarn-laying head 18 simply takes longer than the plotter/cutter 29 (or vice versa).
In general, the step of yarn-laying takes the most time, even when the panels are of substantially the same size with substantially the same pattern of yarns. In order to further speed the overall process, in some embodiments, two, three, or more yarn-laying heads 18 are arranged on the table 16 and all operate simultaneously so that multiple panels may be advanced through the machine in a more rapid fashion. In other embodiments, multiple yarn-laying heads 18 are position over multiple tables, all in line, operating simultaneously, and all feeding the laminating station.
In these situations, the accommodator allows the plotting and cutting station 14 and the yarn-laying station 11 to operate substantially continuously despite the foregoing differences in time required at each station. The accommodator allows second portion 40 (or a third portion, fourth portion, etc.) to be advanced through the laminating station 12 so that the yarn-laying station 11 can begin work on additional portions before the first portion 39 is ready to be removed from the plotting and cutting station 14. In this way, the apparatus 10 can rapidly create and process a series of portions, sections, or intended panels of reinforced laminated membrane 25 substantially without interruption or human intervention.
In some embodiments, “frames” of multiple panels are created in series. A “frame” includes multiple panels that are separated by at most a very small distance on the sheet. The yarn-laying head 18 lays yarn patterns for all of the multiple panels while the sheet is stationary on the yarn-laying table 16. Once a “frame” of multiple panels has been laminated, each of the multiple panels is plotted and cut at the plotting and cutting station 14. Meanwhile, a second “frame” of multiple panels is being worked on by the yarn-laying station 11 and/or the laminating station 12.
One of skill in the art will recognize that the particular arrangement of the accommodator between the laminating station and the plotting/cutting station is not necessary. The accommodator may be disposed at other locations between the yarn-laying station and the plotting/cutting station. For example, in some embodiments, the accommodator is disposed between the yarn-laying station and the laminating station. In these embodiments, the reinforced laminated membrane will often have to be cooled before it is sent to the plotting/cutting station.
Once a panel has been cut from the reinforced laminated membrane 25, a completed panel may require time for curing before it is finished. The amount of time required for curing will depend on the materials used. For example, many panels require overnight (roughly 12 hour) curing.
After curing, the individual panels are moved to a finishing station 41 and may be joined to form, for example, a structural sail. When forming a structural sail, the panels are joined using a broadseam technique so that the finished sail has a three-dimensional shape. The panels may be joined by stitching, adhesive bonding, or the like. Preferably, the panels are joined using high pressure lamination of two panels and an adhesive strip (one such process is marketed under the trademark Q-Bond).
FIG. 3 shows the assembly of a sail 60 from four completed panels 61, 62, 63, and 64 on a finishing station 41. The three-dimensional shape of the sail 60 is apparent from FIG. 3. Each of the four completed panels 61, 62, 63, and 64 has a different size, shape, and reinforcing yarn pattern, as is typical of structural sails.
FIG. 4 shows the structure of a panel 50, including two sheet layers 52 and 53. A reinforcing layer 51 is composed of the yarns 20 and is disposed between the top sheet 52 and the bottom sheet 53.
FIG. 5 depicts an exemplary method 100 of continuously producing multiple sail panels for sails having one or more patterns of reinforcing yarns. First, a bottom sheet of sail panel material is provided 101. Then, first reinforcing yarns are added 102 to a first portion of the bottom sheet in a first pattern. The first reinforcing yarns are laminated 103 to the first portion of the bottom sheet and to a top sheet to form a first reinforced laminated sail cloth. This first reinforced laminated sailcloth is advanced 104 through an accommodating station to a cutting station and then the first reinforced laminated sailcloth is fixed 105 in place at the cutting station. A first sail panel is cut 106 from the first reinforced laminated sail cloth.
As the first reinforced laminated sailcloth is being fixed 105 at the cutting table and the first sail panel is being cut 106, second reinforcing yarns are added 107 to a second portion of the bottom sheet of sail panel material. These second reinforcing yarns are laminated 108 to the second portion of the bottom sheet and to a top sheet to form a second reinforced laminated sail cloth. These steps (adding yarns 107 and laminating 108) take place while the first sail panel is being cut 106. The second reinforced laminated sailcloth is accommodated 109 in the accommodating station until the cutting 106 of the first sail panel is complete. Once the cutting 106 of the first sail panel is complete, the second reinforced laminated sailcloth is advanced 110 to the cutting station, where it is fixed 111 in place while a second sail panel is cut 112 from the second reinforced laminated sail cloth.
This process is repeated to form a third sail panel. Even as early as when the second reinforced sailcloth is being accommodated 109, third reinforcing yarns are added 113 to a third portion of the bottom sheet in a third pattern. The third reinforcing yarns are laminated 114 to the third portion of the bottom sheet and to a top sheet to form a third reinforced laminated sail cloth. The third reinforced laminated sailcloth is then accommodated 115 until the cutting 112 of the second sail panel is complete. Once the cutting 112 of the second sail panel is complete, the third reinforced laminated sailcloth is advanced 116 to the cutting station, fixed 117 in place, and a third sail panel is cut 118. Box 119 signifies that the process is repeated and ongoing so that as many sail panels as desired can be created in rapid succession.
The use of the accommodator allows the process to continue with no substantial interruption. After the first reinforced laminated sailcloth is fixed 105 in place at the cutting station, the other stations begin work on a second section of the sail panel material. In essence, each station may perform its function in a repeated fashion on a series of panels despite the fact that the time required for each station to perform its function on any given section of the material may be different than the time required for any other station to perform its function on a different section of the material. Thus, while the first sail panel is being cut 106, yarns are being added 107 to the sheet of material in a second, different part of the sheet. Whenever the steps of adding yarns (101, 107, 113) and cutting panels (106, 112, 118) require different lengths of time to complete, material will be accommodated (109, 115) as necessary ahead of the cutting station so that all stations may operate continuously.
The laminating steps 103, 108, 114 include, in some embodiments, laminating the reinforcing yarns and the sheet of sail panel material to a second sheet of sail panel material. This second sheet of sail panel material, as described above, is often a previously laminated membrane or sailcloth that may include reinforcing yarns laminated to a sheet in a regular or irregular pattern.
The steps of accommodating 109, 115 include, in some embodiments, translating at least one roller so that the distance to be travelled by the reinforced laminated sailcloth between where the reinforcing yarns are added 102, 107, 113 and the cutting station is increased. The steps of laminating 103, 108, 114 include, in some embodiments, the use of roll-goods lamination. That is, the reinforcing yarns and the sheet of sail panel material are advanced between a heated metal roll and a flexible counter roll.
Of course, as with structural sail panels made according to the methods of the prior art, the reinforcing yarns are added 102, 107, 113 along expected load-paths in the sail panel. The locations of the load-paths are often predicted using computer simulations.
Thus, the present invention provides a method and apparatus for more efficiently and cost-effectively producing multiple panels of a reinforced laminated membrane having one or more patterns of yarns. The required amount of human intervention is minimized and the various machines or parts of the apparatus are able to operate at a much higher capacity.
Although the invention has been described with reference to several embodiments with certain constructions, structures, ingredients and formulations and the like, these are not intended to exhaust all possible arrangements or features, and indeed many other modifications and variations will be ascertainable to those of skill in the art.

Claims

1. A method of continuously producing multiple sail panels for sails having one or more patterns of reinforcing yarns, comprising the steps of:

providing a sheet of sail panel material;

adding first reinforcing yarns to a first portion of the sheet in a first pattern;

laminating the first reinforcing yarns to the first portion of the sheet to form a first reinforced laminated sailcloth;

advancing the first reinforced laminated sailcloth through an accommodating station to a cutting station;

fixing the first reinforced laminated sailcloth in place at the cutting station;

cutting the first reinforced laminated sailcloth into a first sail panel;

while cutting the first sail panel, adding second reinforcing yarns to a second portion of the sheet in a second pattern;

laminating the second reinforcing yarns to the second portion of the sheet to form a second reinforced laminated sail cloth;

accommodating the second reinforced laminated sailcloth in the accommodating station until cutting of the first sail panel from the first reinforced laminated sailcloth complete.

2. The method of claim 1, wherein the first pattern and the second pattern are the same.

3. The method of claim 1, wherein the first pattern and the second pattern are different.

4. The method of claim 3, further comprising the steps of:

advancing the second reinforced laminated sailcloth to the cutting station;

fixing the second reinforced laminated sailcloth in place at the cutting station; and

cutting the second reinforced laminated sailcloth into a second sail panel, where the second sail panel and the first sail panel are intended to form parts of a sail.

5. The method of claim 4, wherein the second panel is cut to a different shape than the first panel.

6. The method of claim 1, wherein the steps of laminating comprise laminating the first and second reinforcing yarns and the first and second portions of the sheet of sail panel material to a previously laminated material.

7. The method of claim 6, wherein the previously laminated material comprises reinforced sailcloth.

8. The method of claim 1, wherein the step of accommodating comprises translating at least one roller to vary the distance to be travelled by the second reinforced laminated sailcloth to arrive at the cutting station.

9. The method of claim 1, wherein the steps of laminating comprise advancing the first and second reinforcing yarns and the first and second portions of the sheet of sail panel material between a heated metal roll and a flexible counter roll.

10. The method of claim 1, wherein the step of adding first reinforcing yarns to a sheet of sail panel material comprises adding first reinforcing yarns along expected load-paths in a sail panel.

11. An apparatus for continuously producing multiple panels of a laminated membrane having one or more patterns of reinforcing yarn, comprising:

a yarn-laying head for adding first reinforcing yarn to a first portion of a sheet of material in a first pattern and second reinforcing yarn to a second portion of the sheet of material in a second pattern;

a laminator for laminating the first reinforcing yarn to the first portion of the sheet to form a first portion of reinforced laminated membrane and the second reinforcing yarn to the second portion of the sheet to form a second portion of reinforced laminated membrane;

a cutting device for cutting panels from the first and second portions of reinforced laminated membrane; and

an accommodator disposed between the yarn-laying head and the cutting device for accommodating the second portion of the sheet of material until the cutting of a first panel from the first portion of reinforced laminated membrane is completed by the cutting device.

12. The apparatus of claim 11, further comprising a cutting table on which the first portion of reinforced laminated membrane is fixed while panels are cut by the cutting device.

13. The apparatus of claim 12, wherein the cutting table includes a vacuum surface.

14. The apparatus of claim 11, wherein the first pattern and the second pattern are different.

15. The apparatus of claim 11, wherein the first pattern and the second pattern are the same.

16. The apparatus of claim 11, wherein the accommodator comprises a plurality of translatable rollers for varying the distance travelled by the second reinforced laminated membrane between the laminator and the cutting device.

17. The apparatus of claim 11, wherein the laminator comprises a heated metal roll and a flexible counter roll.

18. The apparatus of claim 11, wherein the laminator laminates the first and second reinforcing yarns and the first and second portions of the sheet of material to a previously laminated membrane.

19. The apparatus of claim 11, further comprising a yarn-laying table on which the sheet of material is secured while the yarn-laying head adds the first reinforcing yarn to the sheet.

20. The apparatus of claim 11, wherein the yarn-laying head adds the first reinforcing yarns to the sheet of material along expected load-paths in the panel.

21. The apparatus of claim 11, wherein the laminator is disposed between the yarn-laying head and the cutting device and the accommodator is disposed between the yarn-laying head and the laminator.

22. The apparatus of claim 11, wherein the laminator is disposed between the yarn-laying head and the cutting device and the accommodator is disposed between the cutting device and the laminator.