DE202011000326U1 - Reinforced canvas with UHMWP strands - Google Patents

Abstract

A reinforced laminated canvas with outer layers of material with reinforcing material layered and bonded in between, the reinforcing material comprising: strands composed of UHMWP fibers, without fibers of any other material.

Description

Technical area

The present invention relates to reinforced canvas, especially laminated canvas.

Background of the invention

Maintaining the shape of the airfoil is critical to sailing performance, and conventional woven, knit or knitted canvas of natural or synthetic fibers is prone to undesirable deformations caused by non-linear forces on the pull-up canvas. A variety of advances have been made in the design of sails, in the use of various materials, and in methods of constructing sails, all of which have the purpose of restricting canvas deformation under load. Despite continued improvements that enable ever denser constructions, woven canvas has directional stretch properties. For example, the loom practically curves the warp threads around the weft threads that are being held. The result is a fabric of low extensibility in the direction of the weft yarn, but less stiff in the direction of the warp under tension because the added length of corrugation is pulled out of the fibers under load.

DE4010086 describes laminated canvas having outer layers sandwiching therebetween a woven fabric reinforcing layer and second and third layers of parallel, separate reinforcing strands of stretch resistant material. The warp and weft yarn of the woven fabric are aligned lengthwise and transversely, while the strands of the second and third layers are oriented obliquely, at an acute angle to a longitudinal axis of the interwoven fabric. Such canvas has satisfactory deformation behavior, with the reinforcing fabric and strands also imparting to the layers tear resistance properties. However, the reinforcing plane of woven fabric is relatively thick and has directional elongation properties. It is an object of the present invention to overcome or substantially ameliorate these disadvantages or, more generally, provide an improved canvas.

The yarns used to reinforce the laminated sailcloth should have high toughness, high modulus, low density, and good ultraviolet resistance. One such material is Ultra High Molecular Weight Polyethylene (UHMWP); however, because this material has self-lubricating properties, it has not hitherto been suitable to be satisfactorily adhered. One solution that made use of UHMWP involved forming a composite yarn of UHMWP fibers blended with fibers of a material having better bonding properties, such as polyester or carbon. However, this makes the yarns and canvas thicker than they would otherwise because these composite yarns have lower toughness, lower modulus of elasticity, and higher density than yarns consisting of only UHMWP for a given nominal yarn diameter.

Description of the invention

According to a first aspect of the invention, there is provided a reinforced laminated canvas comprising outer layers of material having reinforcing material interposed therebetween and joined, said reinforcing material comprising strands composed of UHMWP fibers without fibers of any other material ,

Preferably, the strands are connected by a polymer resin.

Preferably, the polymer resin has a water-based polyurethane emulsion coating.

According to a second aspect of the invention there is provided a reinforced laminated canvas having outer layers of material with reinforcing material layered and joined between the outer layers, the reinforcing material having at least one layer of substantially parallel strands made of UHMWP fibers made without fibers of any other material.

Preferably, the UHMWP fibers are bonded by a polymeric resin.

Preferably, the polymer resin has a water-based polyurethane emulsion coating.

Preferably, the one layer has a first layer of substantially parallel strands that are substantially parallel to an axis of the outer layers of material, and further comprises:
a second layer of substantially parallel strands that are stretched substantially transverse to the longitudinal axis, wherein the strands of the first and second layers are not interwoven and unlinked
a third layer of substantially parallel strands elongated at a first acute angle to the longitudinal axis, and
a fourth layer of substantially parallel strands which are stretched at a second acute angle to the longitudinal axis,
wherein the strands of at least two of these layers of UHMWP fibers are made without fibers of any other material.

Preferably, the UHMWP fibers are bonded by a polymeric resin.

Preferably, the polymer resin has a water-based polyurethane emulsion coating.

Preferably, the outer layers are formed from: either layer or fabric or at least two fabrics or reinforced laminated cloth.

Preferably, the strands in the third layer are disposed in an angle opposite the axis of the strands in the fourth layer.

Preferably, the first acute angle is between about 10 ° and about 60 °.

Preferably, the first acute angle is between 20 ° and 40 °.

Preferably, one of the outer layers is formed from a layer of dimensionally stable resin.

This invention provides reinforced laminated canvas that not only can be made thinner and lighter, but also provides improved directional stretch properties.

Other aspects of the invention will be apparent from the drawings and the description which follows, which is given by way of example only.

Brief description of the drawings

Preferred embodiments of the present invention will now be described by way of example with reference to the accompanying drawings, in which:

1 an exploded view of an embodiment of a laminated cloth in accordance with the invention;

2 a schematic side view of an apparatus for continuous production of the laminated cloth according to 1 is;

3 a schematic plan view of the device according to 2 is and

4 a schematic representation of the feeder for oblique strands after 2 and 3 is.

Description of the Preferred Embodiments

With reference to the drawings shows 1 a reinforced laminated cloth 10 in accordance with the invention, the outer layers 11 and 12 with reinforcing material 13 which is stratified in between.

The outer layers 11 . 12 each have a same layer of dimensionally stable resin with high elongation resistance. Alternatively, the outer layers 11 . 12 comprise: the same or other woven, non-woven, tricot-like or scrim-like fabrics; a combination of at least two layers, fabrics or both; or a reinforced laminated cloth. Various outer layer combinations may be used to tailor the performance characteristics according to a given application, and those skilled in the art will be aware of a variety of suitable materials for these layers.

The reinforcing material 13 has a first, second, third and fourth position 21 - 24 of strands 14 - 17 from yarn having many fibers of any suitable synthetic material having high elongation resistance. In the preferred embodiment, the strands are those that are made from ultra-high-molecular-weight polyethylenes, such as UHMWP which is available under the trademark Dyneema ^® from Royal DSM NV. Each of the layers 21 - 24 has coplanar single strands 14 - 17 from essentially parallel yarn on.

When UHMWP strands are used without any other material, the UHMWP forms weak bonds to the outer layers using conventional lamination techniques 11 . 12 out. However, according to one embodiment of the invention, UHMWP strands, without any other material, can be used to form strong bonds with outer layers 11 . 12 of the sailcloth when the UHMWP strands are first coated or impregnated with a resin, such as a water-based polyurethane emulsion coating. The reinforcing material 13 Preferably, therefore, it has yarn that is impregnated with a water-based polyurethane emulsion coating. In a preferred embodiment, the emulsion comprises a composition comprising the lower two components:
Ico-Thane 10 : which is a polyester-based aqueous aliphatic polyurethane dispersion compound, and
Lago 45 : which is a synthetic polymer-based anionic polyurethane specially developed for the impregnation of UHMWPE fibers.

The strands 14 in the first position 21 are warp threads, all parallel to a longitudinal axis 18 the outer layers 11 . 12 are aligned while the strands 15 in the second position 22 Weft threads are all transverse to the longitudinal axis 18 aligned so that the strands 15 in the second position 22 at an angle of about 90 degrees to the strands 14 in the first position 21 are aligned. Unlike the prior art, the strands of the first and second layers are not interwoven and unlinked. Untwisted or unlinked means that the strands in adjacent layers overlap and are not interwoven. Furthermore, the strands 16 in the third position 23 all aligned in one direction, making an acute angle 19 with reference to the long axis 18 describes while the strands 17 in the fourth position 24 all aligned in one direction, the one at an acute angle 20 with reference to the long axis 18 describes. The angles 19 . 20 advantageously have a value which is in the range of about 2 ° to about 88 °, preferably in the range of about 10 ° to about 60 °, and most preferably in the range of 20 ° to 40 °. Basically, only the strands of the first and second layers are not interwoven and unlinked, but preferably none of the strands in any of the four plies are interwoven or interlinked with strands of another of the layer (that is, all layers are not interwoven).

2 and 3 FIG. 3 schematically illustrates a process and apparatus for the continuous production of laminates in accordance with the invention. Continuous layers covering the outer layers 11 . 12 are output from respective rollers (not shown) and via guide rollers 33 (etc) to opposite sides of a pair of nip rollers 30 . 31 fed, wherein at least one of the opposite surfaces of the layers is coated with adhesive. At least one of the rollers 30 . 31 can be heated to soften the adhesive. The pressure rollers 30 . 31 are driven so that their outsides move synchronously by a motor (not shown) and around the layers 11 . 12 and the strands 14 - 17 follow through. The distance between the rollers 30 . 31 is set to provide sufficient pressure to bond the various layers together, around the reinforced laminated cloth 10 manufacture. A cutter (not shown) may be the edges of the newly formed laminated cloth 10 which is ultimately cut into suitable lengths and structures to be formed into a finished article such as a sail.

The longitudinal feeder 35 leads the longitudinal strands 14 the rollers 30 . 31 to and includes a plurality of transversely spaced guides (not shown), each of which has a corresponding strand 14 in cooperation with the roller 36 and associated coils (not shown) from which the strands are output and tensioners (not shown).

The cross feeder 38 leads the cross strands 15 the rollers 30 . 31 to and includes a pair of longitudinal conveyors 39 . 40 on opposite sides of the device. The strands 15 extend over between the conveyors 39 . 40 that are driven synchronously to the strands 15 to keep parallel. The strands 15 extend around pegs (not shown) on the conveyors 39 . 40 who are constantly back on themselves, about every peg, back and forth between the sponsors 39 . 40 extend. A charging device 41 has a rotor that rotates about an upright axis around the strands via the conveyors 39 . 40 and associated coils (not shown) from which the strands are dispensed and tensioners (not shown). The loops that extend around the pegs are beyond the edges of the outer layers 11 . 12 arranged and are trimmed away by the cutter.

Another set of collars will be between the rollers 30 . 31 through a feeder 45 fed, the direction in which each strand with respect to the rolls 30 . 31 is curious, aligns. The feeder 45 generally moves the strands horizontally across from the left longitudinal edge 46 the outer layers 11 . 12 to the right edge 47 so the strands 16 the situation 23 be formed while he then strands across from the right edge 47 to the left edge 46 moved, so the strands 17 the situation 24 to form, repeating this movement to the laminated cloth 10 manufacture.

4 shows a circuit diagram of the feeder 45 for the oblique strands, which is a guide arrangement 46 which is driven to engage with a feed spindle 47 to turn. The strands are fed by individual coils (not shown) on the feed spindle 47 attached, along with thread tensioners (not shown) through which the strands pass. The leadership arrangement 46 can under the cross feeder 38 be attached and includes an endless belt 49 that on the pinions 51 . 52 is attached to the parallel axes 50 turn upwards to the rollers 30 . 31 are inclined. The strands coming from the feed spindle 47 are discharged, run by coupling with corresponding guide openings 48 on the tape 49 are arranged before going to the rollers 30 . 31 to run. The ribbon 49 is with the feed spindle 47 synchronized so that both complete a turn at the same time. The guide openings 48 move transversely in opposite directions on the plan upper and lower parts of the tape 49 in which at one time a single line is one of the strands 16 forms before then one of the strands 17 forms. The angle 19 . 20 that in the finished laminate form the unidirectional strands with those aligned in the other, can be varied in any desired manner by adjusting the rate at which the tape 49 with respect to the speed of the rollers 30 . 31 is driven.

The canvas 10 includes four or more superimposed or non-interwoven layers of strands. The superimposed layers of strands can form a pattern that is symmetrical or asymmetrical. The strands may differ or have the same denier. Every strand situation 21 - 24 is placed under train in its own plane while being between the rollers 30 . 31 be performed so that the wave deformation of the strands is eliminated. In addition to the fact that they are not interwoven, it adds that the layers of strands need no further stitches or strands to hold the different layers together.

Aspects of the present invention have been described by way of example only, and it should be understood that changes and additions may be made without departing from the scope thereof.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 4010086 [0003]

Claims (15)

A reinforced laminated canvas having outer layers of material with reinforcing material layered and bonded therebetween, said reinforcing material comprising strands composed of UHMWP fibers without fibers of any other material. The reinforced laminated cloth according to claim 1, wherein the strands are coated or impregnated with a polymer resin. The reinforced laminated fabric of claim 2, wherein the polymer resin comprises a water-based polyurethane emulsion coating. The reinforced laminated fabric of claim 2, wherein said reinforcing material comprises at least one layer of substantially parallel strands made of UHMWP fibers without any fibers of other material. The reinforced laminated canvas of claim 4, wherein the UHMWP fibers are coated or impregnated with a polymeric resin. The reinforced laminated canvas of claim 5, wherein the polymer resin comprises a water-based polyurethane emulsion coating. The reinforced laminated canvas of claim 4, wherein the one layer has a first layer of substantially parallel strands that are stretched substantially parallel to an axis of the outer layers of material, and further comprises: a second layer of substantially parallel strands which are elongated substantially transverse to the longitudinal axis, wherein the strands of the first and second layers are not interwoven and unlinked a third layer of substantially parallel strands elongated at a first acute angle to the longitudinal axis, and a fourth layer of substantially parallel strands which are stretched at a second acute angle to the longitudinal axis, wherein the strands of at least two of these layers of UHMWP fibers are made without fibers of any other material. The reinforced laminated fabric of claim 7, wherein none of the first, second, third or fourth layers of strands is interwoven with an adjacent other of the layers The reinforced laminated canvas of claim 7 or 8, wherein the UHMWP fibers are coated or impregnated with a polymeric resin. The reinforced laminated canvas of claim 9, wherein the polymer resin comprises a water-based polyurethane emulsion coating. The reinforced laminated canvas of claim 1 or 7, wherein the outer layers are formed of: either layer or fabric or at least two fabrics or reinforced laminated cloth. The reinforced laminated canvas of claim 7, wherein the strands in the third ply are disposed in an angle opposite the axis of the strands in the fourth ply. The reinforced laminated canvas of claim 7, wherein the first acute angle is between about 10 ° and about 60 °. The reinforced laminated canvas of claim 7, wherein the first acute angle is between 20 ° and 40 °. The reinforced laminated canvas of claim 7, wherein one of the outer layers is formed by a layer of dimensionally stable resin.

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