FR2866858A1 - Manufacturing procedure for sails, shells or envelopes from multilayer composition materials uses cushion of gas or particles to produce shape - Google Patents

Abstract

The method uses a multi-layer structure with its shape maintained by inflation or padding of a first layer (1) retained by an adjustable frame (2) that is integrated in the final product. (1) Is made from cut-out panels assembled by adhesion, sewing or thermo-forming. The final shape of the article is produced by the application of structural members or supplementary layers. The method uses a multi-layer structure with its shape maintained by inflation or padding of a first layer (1) retained by an adjustable frame (2) that is integrated in the final product. (1) Is made from cut-out panels assembled by adhesion, sewing or thermo-forming, and with its volume measured by sensors or electromagnetic scanning. The final shape of the article is produced by the application of structural members or supplementary layers.

Description

2866858 1 Title

  Method of manufacturing sails, hulls, and structural envelopes on air cushion or particles

Description

  State of the art Several manufactured products require the manufacture of multilayer envelopes of small thickness (from 0.1 mm to about 100 mm), having high mechanical characteristics in terms of resistance to effort and fatigue, non-deformation in the weather. Among this type of product, there are the sails of ships, which are subjected to particularly high demands on their operating environment, and also tents, tarpaulins, domes, hulls, aerostats ...

  To obtain the best possible performance on these criteria, the product called Structural Veil has been described in its structure and patented by ship sails specialists (Brevets Sobstad Sailmakers Inc n FR2574749, EP0191216 and US4831953). It is essentially skins, made from panels, covered with lattices and structural members connecting one point of concentration of load to another, and able to withstand the main efforts, the whole possibly being covered with layers or extra skin.

  Various methods are conventionally used to produce structural webs or envelopes: Patent Methods Sobstad Sailmakers Inc No. FR2574749, EP0191216 and US4831953, by Juxtaposition of Panels Made on Vacuum Tables or on Floors - Process of the North Salis Patent EPO475083, by Tension layers of multiple panels pre assembled on mold.

  2866858 2 - Process implemented by various companies including UK Sailmakers, reinforcement by adhesive strips laid on structural members, carried out on sailcloth floors.

  These various processes are characterized by the presence of an immobile solid physical surface extended for the development of the product. The present invention makes it possible to manufacture structural webs or envelopes without any solid physical support of this type in contact with the envelope, whether mold, vacuum table or floor. It makes it possible to produce products of larger and more variable dimensions, with increased facility and reduced investments.

  The shaping is performed by inflation, padding or powering up, a production solution described corresponding to a pressurizing process.

  A sail or thin envelope may have a complex structure formed mainly of elongate elements arranged along the lines of efforts. This structure is coated with adhesive and sandwiched between several layers forming the outer skins of the product.

  The described method makes it possible to create complex reinforced surfaces, to do so with a reduced hardware investment and dimensional possibilities only limited by the production room.

  The first phase is preferably the computer-based creation of the volumes and diagrams of forces that will determine the structure. From these drawings are drawn the outer skins which are created according to the classic processes of the sailcloth.

  One of these skins is preferably shaped by air pressure for example and receives in this position the structural elements through an automated device. A second skin can be positioned, vacuum-plated to the structure and bonded by activating the glues thus forming one of the desired products.

General description

  To manufacture sails, shells or composite shells, the overall shape is obtained without mold, by pressurization or depression, and / or tensioning, and / or padding of an enclosure, one of whose walls is a first flexible layer, retained by an adjustable frame (continuous or discontinuous or consisting of a set of attachment points) and integrated into the final product, which is obtained preferably by the application of flexible or rigid structural members and / or additional flexible or rigid layers on said first layer thus shaped.

  The shape of the first layer is determined by cutting and joining panels, glued or sewn, and / or thermoforming.

  The first layer thus volume can be measured by probes or electromagnetic scanning, compared to the expected volumes, and readjusted by changing the pressure and / or dimensions of the frame before application of the successive elements on this layer.

  Then this first layer is modified while possibly remaining under pressure, by sampling or addition of surface elements, followed by gluing. Corrections of this type may represent most or all of the formatting of the first layer.

  Structural members are preferably applied to the first layer, possibly previously covered with other layers, continuously connecting charge concentration points and able to withstand the majority of the efforts of the end product in its use. These structural members may consist for example of Aramid fibers, carbon fibers, composite slats or metal reinforcements and may comply with the specifications relating to structural webs, and in particular covered with other flexible or rigid layers, continuous or in part. mesh.

  These structural members are generally coated with cold or hot glues and / or applied to surfaces themselves coated with glue.

  The laying of the structural members is preferably carried out by means of one or more groups of two motorized mechanical devices, called effectors, moving on either side of the first layer, remaining opposite, one serving support and the other deposit system of the aforementioned structural members.

  These effectors can be supported by trolleys connected to gantries with rails.

  Alternatively one of the two effectors of one group may also be supported through the first layer by the other effector, or suspended therefrom, by means of contact, pressure or electromagnetic forces with position control through said first layer. One of the effectors is mechanically linked for example to a mobile telescopic terminal.

  In an alternative embodiment, these effectors are guided optically along curves drawn on the layer receiving the structural members.

  Then the adhesion of the materials is generally favored by the vacuum between layers and preferably activated by controlled increase in the temperature of the gas of the enclosure, or alternatively by circulation of radiative panels.

  The enclosure maintained under pressure may not be completely closed but traversed by a dynamic flow of gas.

  Different shaping variants are as follows: The frame may in certain cases be mainly constituted by a ship rigging. The shaping of the first layer may be obtained by localized traction possibly in addition to the pressurization. or depression of the enclosure.

  The shaping of the first layer can be carried out by filling particles or padding, filling associated or substituted with a fluid pressure in the general chamber and / or pressurizing secondary enclosures located within said general enclosure. These particles may consist of balls, balls, grains, bubbles, balloons, flakes or fibers, made of polystyrene, polyester, polyethylene, polypropylene, plastic foam, cork and other synthetic or natural materials. In this method it is possible to obtain an increased local support of the first layer for depositing the structural members by means of a single effector instead of two.

  The shaping of the first layer can be carried out mainly by gravity and adjustment of the frame, associated or substituted for a pressure or vacuum of fluid in the general enclosure.

  The flexible or rigid layers or the lattices and structural members used are for example made using one or more of the following materials: Concretes, Metals, Fiberglass, Polyester, Polystyrene, Polymers, Foams, Vegetable Fibers, Aramids, Carbon , Nanotubes and various other materials which are applied in film, tissue or projection form.

  Illustrations FIG. 1 Perspective view of the realization of a FIG tent. 2 Perspective view of the realization of a mainsail FIG. 3 Sectional view of the realization of an envelope

  7 Description of an exemplary embodiment

  In the exemplary embodiment chosen, the first step consists of cutting Mylar (trade mark) film panels coated with glue based on heat activatable and / or ultra violet polymers and protected by teflon paper. This cutting is done by means of plotters or conventional cutting in the craft of sail. The cutting forms were previously defined in view of the experience accumulated by comparison of forecasts and realizations, using specialized CAD software, which decomposes the overall surface area into juxtaposition of developable surfaces in the mathematical sense of the term. The panels are assembled on the floor by superimposing their edges about 2 cm, with local activation of the coating glue.

  This first skin (1) thus obtained is transported on the frame (2) to which it is fixed by continuous clamping after being released from its protective paper. A flexible skirt (3) goes around the frame and connects it to the building wall or the floor, thus ensuring the required seal.

  Still in the embodiment chosen, the enclosure (4) is pressurized with air by a compressor (5) slaved to a pressure sensor for regulation. The filling can also be carried out using balls of tyrene polys of caliber about 1 cm, by blowing them under the skin until agglomeration. The envelope then takes an inflated initial form close to the theoretical form.

  After resuming the games by traction on the retaining cables (6) 2866858 8 of the frame, a measurement of the surface is performed by moving probes, and compared computeratically to planned surfaces. The arrangement is readjusted by changing the pressure and / or dimensions of the frame. Successive measurements and corrections may be necessary before volume validation. All this phase is carried out in a room devoid of substantial air movement so that the measurements are not disturbed.

  As the form is thus established, the process of laying structural limbs can begin. This is in the case of realization selected, ribbons or Kevlar fiber yarns (registered trademark). The patterns described by the structural members are normally chosen by the master sailboat or the technician responsible for calculating the structure. In some cases they continuously connect charge concentration points and are able to withstand the majority of the end product's efforts in its use.

  The effectors can deposit several ribbons in parallel while moving at the speed of unwinding of the ribbon itself. They are preferably driven by software similar to 5-axis milling drivers thus allowing tangential tracking of the surface at each point.

  The upper effector (7) is supported through the first layer by the other effector (8), by means of contact forces, and electromagnetic with position control through said first layer by registration with sensors capacitive. the lower effector (8) thus makes it possible to apply sufficient pressure to the surface so that the deposited elements (also coated with glue or not) remain in place during the entire process. In an alternative embodiment, the adhesive coating the structural fibers has its modified temperature 2866858 9 before installation to facilitate the holding in place of the assembly before the final connection.

  The lower effector is, in the example supported by a mobile telescopic terminal (9) on the flat surface of the floor of the enclosure. In an alternative embodiment, each effector is supported by a carriage connected to a gantry (10) having rails.

  As in a machining process, the effectors are preferably positioned at a suitable origin so as to begin the work process in opposite.

  Once the removal work of the structure is completed, a negative twin layer of the first can be adjusted on all before vacuuming the product using suitable pumps.

  The following phase consists in the selected embodiment, to trigger the final polymerization of the adhesives taken between the two films; this is done in the example by a controlled and homogeneous elevation of the air temperature of the empty enclosure of any material, the heat, by convection and conduction, propagating in the material.

  According to one variant, the polymerization is obtained by ultraviolet or thermal radiation from specialized effectors moving along the surface.

  After cooling if necessary, the enclosure is brought back or maintained at the external pressure, the product can be extracted from the frame, and transported to the finishing shop.

Claims (8)

claims   1 / A process for manufacturing sails, shells or composite shells, characterized in that the overall shape is obtained without a mold, by pressurization or depression, tensioning, and / or padding of an enclosure, one of which walls is a first flexible layer, retained by an adjustable frame (continuous or discontinuous or consisting of a set of attachment points) and integrated into the final product, which is obtained by the application of flexible or rigid structural members and / or additional flexible or rigid layers on said first layer thus shaped.   2 / A method according to claim 1 characterized in that the first layer is modified while optionally remaining in pressure, by sampling or addition of surface elements and bonding followed, the corrections of this type representing a part or all of the shaping of the first layer.   3 / A method according to claim 1 characterized in that the laying of the structural members is effected by means of one or more groups of two motorized mechanical devices, called effectors, moving on either side of the first layer, remaining in opposite, one serving as a support and the other as a system for removing the aforementioned structural members, said effectors being supported by carriages connected to gantries comprising rails or alternatively one of the two effectors of a group being supported through, or being suspended from, the first layer by the other end effector by means of contact, pressure or electromagnetic forces with position feedback through said first layer.   4 / A method according to claim 1 characterized in that the adhesion of the materials is promoted by the vacuum between layers and activated by controlled increase in the temperature of the gas of the enclosure, or alternatively by circulation of radiative panels.   5 / A method according to claim 1 characterized in that the chamber maintained under pressure is not completely closed but traversed by a dynamic flow of gas.   6 / A method according to claim 1 characterized in that said frame is mainly made of a ship rigging.   7 / A method according to claim 1 characterized in that the overall shape of the first layer is obtained by localized traction on the first layer possibly additional to the pressurization or depression of the enclosure.   8 / A method according to claim 1 characterized in that the shaping of the first layer is performed by filling particles or padding, filling associated or substituted for a fluid pressure in the general chamber and / or pressurizing secondary speakers located inside said general enclosure. These particles may consist of balls, balls, grains, bubbles, balloons, flakes or fibers, made of polystyrene, polyester, polyethylene, polypropylene, plastic foam, cork and other synthetic or natural materials. In this method it is possible to obtain an increased local support of the first layer for depositing the structural members by means of a single effector instead of two.   28. The method as claimed in claim 1, characterized in that the shaping of the first layer is carried out mainly by gravity and adjustment of the frame, associated or substituted for a fluid pressure or vacuum in the general enclosure.   10 / A method according to claim 1 characterized in that the additional layers are made by spraying materials. 15 20 25