GB2367524A - A method of forming a rigid article from a non-rigid material - Google Patents

A method of forming a rigid article from a non-rigid material Download PDF

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Publication number
GB2367524A
GB2367524A GB0021875A GB0021875A GB2367524A GB 2367524 A GB2367524 A GB 2367524A GB 0021875 A GB0021875 A GB 0021875A GB 0021875 A GB0021875 A GB 0021875A GB 2367524 A GB2367524 A GB 2367524A
Authority
GB
United Kingdom
Prior art keywords
sheet
article
rigid
tensioned
setting agent
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB0021875A
Other versions
GB2367524A8 (en
GB0021875D0 (en
GB2367524B (en
Inventor
Tom Barker
Oliver Domeisen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BOX CONSULTANTS Ltd
DLM ARCHITECTURAL DESIGNERS LT
Original Assignee
BOX CONSULTANTS Ltd
DLM ARCHITECTURAL DESIGNERS LT
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by BOX CONSULTANTS Ltd, DLM ARCHITECTURAL DESIGNERS LT filed Critical BOX CONSULTANTS Ltd
Priority to GB0021875A priority Critical patent/GB2367524B/en
Publication of GB0021875D0 publication Critical patent/GB0021875D0/en
Priority to GB0121056A priority patent/GB2369599B/en
Publication of GB2367524A publication Critical patent/GB2367524A/en
Publication of GB2367524A8 publication Critical patent/GB2367524A8/en
Application granted granted Critical
Publication of GB2367524B publication Critical patent/GB2367524B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/56—Tensioning reinforcements before or during shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/026—Knitted fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/06—Open cell foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured

Abstract

A method is disclosed for forming a rigid article from a non-rigid sheet of material 1, the sheet of material 1 comprising stretchable fibres, the method comprising the steps of tensioning the sheet of material 1 into a desired configuration, applying a liquid setting agent to the sheet of material 1 in the desired configuration and setting the setting agent such that when the applied tension is removed, the article (5 of fig 3) is rigid and maintains the desired configuration. The setting agent may be a polymer resin and the sheet of material 1 may be held around the periphery of a frame 2 and tensioned by being either pulled or pushed out of the plane of the frame 2. Also disclosed is an article (5 of fig 3) comprising a sheet of pre-tensioned flexible material coated with a setting agent which maintains the rigidity of the article (5 of fig 3) in the pre-tensioned configuration.

Description

2367524 A METHOD OF FORMING A RIGID ARTICLE FROM A NON-RIGID MATERIAL The
invention relates to a method of making a 5 rigid article/structure from a non-rigid sheet of material. The articles so formed may be of a complex or relatively simple configuration/shape.
In a first aspect, the invention provides a 10 method of forming a rigid article from a non-rigid sheet of material, the sheet of material comprising stretchable fibres, at least some of which are elongated when the material is stretched, the method comprising the steps of:
15 tensioning a sheet of material into a desired configuration; applying a liquid setting agent to the sheet of material in the desired configuration; and setting the setting agent such that,.when the 20 tension applied to the sheet of material is removed, the article is rigid and maintains the desired configuration.
The invention provides a low cost simple method 25 for forming rigid articles from non-rigid materials.
The method advantageously uses the ease of formability of non-rigid materials to create the desired shape of the article, and uses the setting agent to maintain the shape created. In addition, the invention avoids 30 the need for heat forming which is often necessary to make articles with complex configurations. The invention also avoids the need for complete surface moulds or three-dimensional patterns.
35 Materials with stretchable fibres give a designer greater freedom to manipulate the configuration of the sheet of material until the desired configuration is achieved. Such materials do not readily reach their elastic limit and thus are not prevented from being reformed into a number of different configurations 5 until the desired configuration is achieved.
The articles so produced are particularly suitable as decorative pieces, as furniture, or as architectural pieces. The method is suitable for 10 forming both large and small articles, and a number of articles formed by the method may be combined to form the desired finished article. The articles produced may be free standing or wall mountable.
15 Preferably, the non-rigid sheet of material is a woven fabric made from fibres which may be natural or synthetic. The sheet of material may be made from a mix of natural and synthetic fibres. Suitable woven materials include cotton, nylon, lycra(TM), Kevlar 20 (TM), Gortex (TM), and materials including glass/metal (particularly aluminium) fibres. The non-rigid sheet may also be made of an absorbent foam or a stretchable non-woven fabric, and may comprise a mix of felt or other non-woven fabric with stretchable fibres.
The setting agent is preferably a polymer resin, for example polyester, phenolic or epoxy. Generally, it is known to use fibres to reinforce a matrix. In this case, the matrix (resin) reinforces the material 30 fibres of the non-rigid sheet of material.
There are many different ways in which the sheet may be tensioned. For example, the material may be held at a number of discrete locations and tensioned.
35 The sheet may be tensioned in the plane of the sheet, or out of the plane of the sheet, or both. The tension in each plane may not be equal in magnitude and/or may be applied in a number of different directions.
Relatively complex articles may be formed by holding the sheet at a number of discrete locations, and using unequal tensioning in a number of different directions 5 and planes.
A convenient method is to hold the sheet of material in a frame and tension the sheet by pushing and/or pulling out of the plane of the frame using a 10 mould at one or more locations. The material may be held loosely or pre-tensioned in one or more directions by attaching the material to the frame.
The sheet may be tensioned by stretching it over 15 a mould such that the sheet conforms substantially to the underlying mould. The sheet of material need not necessarily fully conform to the shape of the underlying mould, as would be the case when using a mould having features with a high aspect ratio e.g. a spike.
In a second aspect, the invention provides an article comprising a sheet of pre-tensioned flexible material coated with a setting agent which maintains 25 the rigidity of the article in the pre-tensioned configuration.
Preferably, the flexible material is made from natural or synthetic fibres, or a mix of natural and 30 synthetic fibres. Suitable materials include cotton, nylon (TM), lycra (TM), Kevlar (TM), Gortex (TM), a mix of felt or other non-woven fabric and stretchable fibres, and woven materials comprising glass/metal fibres. Preferably the metal fibres are aluminium.
Examples in accordance with the invention will now be described with reference to the accompanying drawings in which:
Figure 1 illustrates the stages in the formation of a rigid article formed from a non-rigid sheet 5 of material according to a preferred embodiment of the invention; Figure 2 is a line frame illustration of the non rigid sheet of material tensioned into a desired 10 simple configuration in accordance with the invention; Figure 3 is a perspective view of a rigid article, formed into the rigid configuration of is Figure 2, and used to support a mannequin.
A hinged frame 2 (Figure 1) may be used in the method, this being particularly suitable for stretchable fabrics such as nylon (TM) or a lycra 20 (TM)/ cotton mix. The hinged frame 2 comprises two panels 10,20 hinged along one edge to overlie one another in a closed position (Figure 1a), and extend away from one another in an open position (Figure lb, 1c). The non-rigid material or fabric 1 is attached to 25 the periphery of panel 20 and also at a discrete location to panel 10, so that as the panels 10,20 are hinged open, the material is stretched into the desired configuration (Figure 1c). The fabric 1 may be pre- tensioned in one or more directions when attaching 30 it to the frame 2. Shaping members (not shown) may be applied to one or more surfaces to further deform the fabric 1. A setting agent is then applied to the stretched fabric and allowed to set. Once set, any shaping members are removed and the article 5 detached 35 from the frame 2 (Figures 2 and 3). The article 5 may be used to support a mannequin 30 (Figure 3).
The material 1 may be attached to both panels 10,20 at a number of different discrete locations. It will be appreciated that a frame is not necessary, and that any way of holding and forming the material in 5 the desired configuration is suitable. For example, the material may simply be grounded at one point and tensioned by applying a shaping member to one or more surfaces. The setting agent is then applied, preferably to both surfaces, prior to the removal of 10 the shaping member.
A colouring agent may be applied to the resin or the shape may be painted. Individual articles can be connected together to create a larger structure, and 15 the sheet of material may comprise a single sheet layer or be a multi- layer sheet. For example, the multi-layer sheet may comprise a number of adjacent layers joined to each other around their perimiters. Each layer in the multi-layer sheet may be tensioned 20 so as to pull it away from an adjacent layer to form a complex structure, optionally forming a hollow volume.

Claims (8)

1. A method of forming a rigid article from a non rigid sheet of material, the sheet of material S comprising stretchable fibres, at least some of which are elongated when the material is stretched, the method comprising the steps of:
tensioning a sheet of material into a desired configuration; 10 applying a liquid setting agent to the sheet of material in the desired,configuration; and setting the setting agent such that, when the tension applied to the sheet of material is removed, the article is rigid and maintains the desired configuration.
2. The method of any of the preceding claims, wherein the setting agent is a polymer resin.
20
3. The method of any of the preceding claims, wherein the material is held at a number of discrete locations and tensioned.
4. The method of any of the preceding claims, 25 wherein the sheet of material is held around the periphery of a frame and tensioned by pushing and/or pulling out of the plane of the frame.
S. The method of any of the preceding claims, 30 wherein a mould is used to tension the material at one or more locations.
6. An article comprising a sheet of pre-tensioned flexible material coated with a setting agent which 35 maintains the rigidity of the article in the pretensioned configuration.
7. A method substantially as described, and with reference to the accompanying drawings.
8. An article substantially as described, and with reference to the accompanying drawings.
8. An article substantially as described, and with 5 reference to the accompanying drawings.
: 212498: MSAK: LSB: FURNDOCS q Amendments to the claims have been filed as follows 1. A method of forming a rigid article from a non rigid sheet of material, the sheet of material 5 comprising stretchable fibres, at least some of which are elongated when the material is stretched, the method comprising the steps of:
tensioning a sheet of material into a desired configuration without the use of heat; 10 applying a liquid setting agent to the sheet of material in the desired configuration; and setting the setting agent such that, when the tension applied to the sheet of material is removed, the article is rigid and maintains thedesired is configuration.
2. The method of any of the preceding claims, wherein the setting agent is a polymer resin.
20 3. The method of any of the preceding claims, wherein the material is held at a number of discrete locations and tensioned.
4. The method of any of the preceding claims, 25 wherein the sheet of material is held around the periphery of a frame and tensioned by pushing and/or pulling out of the plane of the frame.
5. The method of any of the preceding claims, 30 wherein a mould is used to tension the material at one or more locations.
6. An article comprising a sheet of pre-tensioned flexible material, which comprises stretchable fibres, 35 at least some of which have been elongated by the pre tensioning, wherein the sheet is coated with a setting agent which maintains the rigidity of the article in - Y - the pre-tensioned configuration.
7. A method substantially as described, and with reference to the accompanying drawings.
GB0021875A 2000-09-06 2000-09-06 A method of forming a rigid article from a non-rigid material Expired - Fee Related GB2367524B (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB0021875A GB2367524B (en) 2000-09-06 2000-09-06 A method of forming a rigid article from a non-rigid material
GB0121056A GB2369599B (en) 2000-09-06 2001-08-30 Laminated material

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0021875A GB2367524B (en) 2000-09-06 2000-09-06 A method of forming a rigid article from a non-rigid material

Publications (4)

Publication Number Publication Date
GB0021875D0 GB0021875D0 (en) 2000-10-18
GB2367524A true GB2367524A (en) 2002-04-10
GB2367524A8 GB2367524A8 (en) 2002-05-28
GB2367524B GB2367524B (en) 2004-09-15

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Family Applications (2)

Application Number Title Priority Date Filing Date
GB0021875A Expired - Fee Related GB2367524B (en) 2000-09-06 2000-09-06 A method of forming a rigid article from a non-rigid material
GB0121056A Expired - Fee Related GB2369599B (en) 2000-09-06 2001-08-30 Laminated material

Family Applications After (1)

Application Number Title Priority Date Filing Date
GB0121056A Expired - Fee Related GB2369599B (en) 2000-09-06 2001-08-30 Laminated material

Country Status (1)

Country Link
GB (2) GB2367524B (en)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4371575A (en) * 1979-11-05 1983-02-01 Rohm Gmbh Rigid, one-piece, biaxially stretched shaped body of synthetic resin and method for making the same
US4483814A (en) * 1982-06-04 1984-11-20 Rohm Gmbh Method and apparatus for forming stretched resin sheet

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3193437A (en) * 1961-07-19 1965-07-06 Freeman Chemical Corp Laminated articles containing sheets of flexible foamed plastics and method for makin the same
US4157416A (en) * 1978-05-04 1979-06-05 Composite Technology Corporation Composite foam structure
US5089328A (en) * 1988-02-26 1992-02-18 Van Dresser Corporation Panel and method of making the same

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4371575A (en) * 1979-11-05 1983-02-01 Rohm Gmbh Rigid, one-piece, biaxially stretched shaped body of synthetic resin and method for making the same
US4483814A (en) * 1982-06-04 1984-11-20 Rohm Gmbh Method and apparatus for forming stretched resin sheet

Also Published As

Publication number Publication date
GB2367524A8 (en) 2002-05-28
GB0021875D0 (en) 2000-10-18
GB0121056D0 (en) 2001-10-24
GB2369599B (en) 2002-10-30
GB2367524B (en) 2004-09-15
GB2369599A (en) 2002-06-05

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Legal Events

Date Code Title Description
732E Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977)
PCNP Patent ceased through non-payment of renewal fee

Effective date: 20041215