Textiles: weaving – Bias fabric digest
Reexamination Certificate
1997-12-01
2001-12-04
Calvert, John J. (Department: 3741)
Textiles: weaving
Bias fabric digest
C139S011000, C139S016000, C442S205000, C442S206000
Reexamination Certificate
active
06325109
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates to a method of producing a continuous-thread disk element from which to form composite materials.
In British Patent Application n. 2 168 032 filed on Oct. 2, 1985, composite materials are produced by forming a number of disks, each obtained by winding a continuous reinforcing thread about an axis to form a flat coil; stacking the disks with a matrix spacer sheet between each disk and the next; and axially compacting the stack so formed to obtain a matrix in which the various coils of reinforcing thread are embedded.
The physical characteristics of the composite materials obtained as described above mainly depend on the distribution of the reinforcing threads inside the matrix; and homogeneous distribution of the threads depends on the extent to which the turns in each disk are equally spaced, and the extent to which the freedom of movement of the various turns is limited, especially during compression.
In British Patent Application n. 2 168 032, the turns in each disk are spaced and locked with respect to one another by interposing between each turn and the next a continuous spacer bead, which is wound simultaneously with the reinforcing thread about the axis of the disk, and is connected to the reinforcing thread by means of a binding material, preferably an acrylic resin.
In the above method, the mutual position of the turns of reinforcing thread, i.e. the distance between one turn and the next, depends on the geometric characteristics of the spacer bead, which must be sized in each case according to the desired distribution of the reinforcing thread inside the matrix, and must be made of different materials, depending on the matrix involved, so that production time and cost are obviously fairly high.
Moreover, the above method is also unsatisfactory by failing to allow a reduction, below a relatively high minimum threshold value, in the spacing or distance between the turns in each disk, and in the thickness of the reinforcing thread disks themselves. In fact, the materials and known techniques normally used to form the beads impose a minimum transverse dimension of the beads, which is normally always greater than the minimum transverse dimension of the reinforcing threads, so that the above known method fails to provide for producing composite materials with any reinforcing thread distribution or density.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a straightforward, low-cost method of producing a continuous-thread disk element, designed to eliminate the aforementioned drawbacks.
According to the present invention, there is provided a method of producing a continuous-thread disk element from which to produce composite materials, the method comprising the steps of feeding a continuous first thread to a winding station; winding the continuous first thread about an axis to form a flat first coil comprising a number of first turns; and locking the first turns in fixed positions with respect to one another; characterized in that locking the first turns with respect to one another comprises the steps of inserting removable spacer elements between each first turn and the adjacent first turn; winding binding thread elements about at least an intermediate portion of each first turn to form a binding solely surrounding the intermediate portions of said first turns; and removing said spacer elements from said first coil.
The present invention also relates to a machine for producing a continuous-thread disk element from which to produce composite materials.
According to the present invention, there is also provided a machine for producing a continuous-thread disk element from which to produce composite materials, the machine comprising a winding station; supply means for feeding a continuous first thread to the winding station; first winding means for winding said first thread about an axis to form a flat first coil comprising a number of first turns; and connecting means for locking said first turns in fixed positions with respect to one another; characterized in that said connecting means comprise feeding and positioning means for inserting removable spacer elements between each first turn and the adjacent first turn; and manipulating means for winding thread elements about at least an intermediate portion of each first turn to form a binding solely surrounding the intermediate portions of said first turns; gripping means being provided for removing said spacer elements from said first coil.
The present invention also relates to a continuous-thread disk element from which to produce composite materials, preferably rotary bodies of machines and/or aerospace engine parts.
According to the present invention, there is provided a continuous-thread disk element from which to produce composite materials, and comprising a continuous-thread flat coil having a respective axis and a number of turns; and locking means for locking the turns in fixed mutual positions; characterized in that said locking means solely comprise binding thread means extending crosswise to said turns and surrounding the turns at least partially.
REFERENCES:
patent: 2624367 (1953-01-01), Dunod
patent: 2690194 (1954-09-01), Latieyle
patent: 3750714 (1973-08-01), Holman, Jr. et al.
patent: 4260441 (1981-04-01), Prewo
patent: 4490201 (1984-12-01), Leeds
patent: 5070914 (1991-12-01), Fukuta et al.
patent: 5091246 (1992-02-01), Yasui et al.
patent: 5130188 (1992-07-01), Anahara et al.
patent: 0 710 728 (1996-08-01), None
patent: 2 168 032 (1986-06-01), None
patent: 01201550 (1989-08-01), None
Patent Abstracts of Japan, vol. 14, No. 548, Dec. 5, 1990, and JP 02 234944 A (Ashimori Ind. Co. Ltd.).
Calvert John J.
Fiatavio S.p.A.
Muromoto Jr. Robert H.
Shlesinger & Arkwright & Garvey LLP
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