Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Patent
1997-02-18
1999-10-26
Aftergut, Jeff H.
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
156229, 156292, 156324, 156494, 156543, 156547, 156148, 139384R, 139410, B29D 2400, B29C 7024, B29C 7052
Patent
active
059721464
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a continuous forming method and device for a composite structure, in particular a composite structure featuring a three-dimensional intermediate fabric composed of two sheets of fabric facing each other and connected by a number of yarns extending from the adjacent walls of the two sheets.
2. Description of the Related Art
Composite structures, e.g. of the type described in Italian Patent Application n. TO91A000397 filed on May 29, 1991 by the present Applicant and entitled "Process for producing a composite structure with three-dimensional intermediate fabric, and structure produced thereby", are known to be produced using a forming device (e.g. a press) onto which the three-dimensional fabric impregnated with thermosetting or thermoplastic resin is fed.
The device provides for setting the resin and forming the three-dimensional fabric into a rigid panel in which the yarns are completely hardened and extend perpendicularly between the sheets for rigidly connecting them.
Known devices provide for forming panels of substantially the same size (width and length) as the three-dimensional fabric fed onto the press.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method and device for continuously forming a composite structure, of the type described above, of substantially unlimited length.
According to the present invention, there is provided a method of continuously forming a composite structure comprising at least a three-dimensional fabric composed of a first and second sheet of fabric facing each other and connected by intermediate yarns, characterized in that it comprises stages consisting in:
providing a continuous supply of three-dimensional fabric;
impregnating said three-dimensional fabric with thermoreactive resin;
mating said three-dimensional fabric with a first outer strip contacting said first sheet of fabric, and a second outer strip contacting said second sheet of fabric, to form a stratified structure containing the impregnated three-dimensional fabric;
heating said stratified structure to at least partially polymerize the resin between said outer strips and said first and second sheets of fabric, while the resin impregnating the yarns remains substantially in the plastic state; said first and second sheets of fabric adhering to said outer strips;
parting said outer strips as said stratified structure is fed in said direction, to at least partially distend said yarns; and
fully solidifying the resin impregnating said three-dimensional fabric.
The present invention also relates to a device for continuously forming a composite structure comprising at least a three-dimensional fabric composed of a first and second sheet of fabric facing each other and connected by intermediate yarns, characterized in that it comprises:
first and second container means for providing a continuous supply of a first and second strip;
dispensing means for providing a continuous supply of three-dimensional fabric;
impregnating means for applying thermoreactive resin to at least said three-dimensional fabric;
combining means for mating said three-dimensional fabric with said first and second strips, so that said first and second strips contact said first and second sheets of fabric to form a continuous stratified structure containing said impregnated three-dimensional fabric;
feed means for feeding said three-dimensional fabric in a straight direction;
forming means for heating said stratified structure as it is fed along, to at least partially polymerize the resin between said outer strips and said first and second sheets of fabric, while the resin impregnating said yarns remains substantially in the plastic state;
said forming means also parting said outer strips as said stratified structure is fed in said direction, to at least partially distend said yarns; and
final polymerizing means for fully solidifying the resin impregnating said three-dimensional fabric.
BRIEF DESCRIPTION OF THE DRAWING
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patent: 3234972 (1966-02-01), Koppelman et al.
patent: 5166480 (1992-11-01), Bottger
patent: 5188555 (1993-02-01), Horovitz
patent: 5580412 (1996-12-01), Fantino
patent: 5630897 (1997-05-01), Branca et al.
Aftergut Jeff H.
Metalleido S.r.l.
Spencer George H.
Wells Ashley J.
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