RU2751310C1 - Method for manufacture of products from fibrous materials - Google Patents

Abstract

FIELD: fibres.SUBSTANCE: method for manufacture of products from fibrous materials consists: in creating a 3D image of a tooling for manufacturing products from fibrous materials, including removable pins for holding loops of threads of fibrous materials, in creating a tooling using a CNC machine by a 3D image of a tooling, in protecting the tooling with films, film-forming release agents preventing adhesion of the fibrous materials to the tooling, in supplying one or several threads of the fibres into a container with a liquid hardening composition, in laying the impregnated one or several threads of the fibres along a curvilinear path on a pre-prepared tooling to create a main body, in hardening (polymerising) the threads of the fibres laid on the tooling at room temperature using convection drying or using IR or UV emission, in removing the removable pins and obtaining the finished product.EFFECT: simplified manufacture and improved accuracy of products with complex shape.7 cl, 3 dwg

Description

The claimed invention relates to methods for the production of products of complex shapes from fiber materials moistened with a special non-cured polymer composition to impart rigidity and a certain color. The combination of a polymer material and a thread wetted by it with a special composition, when cured, gives the latter rigidity and can be formed using special equipment.

A known method of manufacturing a product from a binder with a fibrous facing coating, see RF patent No. 2493011, from 20.03.2011. The method includes applying a binder solution to the first fibrous mat containing polymer or mineral fibers and a water-repellent coating, which is placed in contact with the binder solution on at least one of the surfaces of the mat, curing the binder solution and fixing it on the water-repellent mat coating by embedding the mat into a solution to obtain a product from a binder with a fibrous facing, while less than 50% of the thickness of the mat is monolized into the solution. The disadvantage of this method is the impossibility of obtaining products of complex shapes.

The object of the claimed invention is a method of forming a fiber thread into two-dimensional and three-dimensional openwork products for multipurpose purposes.

The technical result is to simplify the manufacture and increase the accuracy of products of complex shape.

The technical result is achieved by the fact that the method for manufacturing products from fiber materials consists of:

- in creating a 3D image of a tooling for the manufacture of products from fiber materials, including removable pins for holding loops of filaments of fiber materials,

- in the manufacture of tooling using a CNC machine according to the 3D image of the tooling,

- in the protection of the tooling with films, film-forming release agents or other means that prevent the adhesion of fiber materials to the tooling,

- in the supply of one or more filaments of fibers into a container with a liquid composition that hardens under certain conditions, made transparent or colored,

- in the impregnation of one or more filaments of fibers specified above, a composition that hardens under certain conditions,

- in laying the impregnated one or several filaments of fibers along a curved trajectory on a previously prepared rig to create the main body,

- in the curing (polymerization) of filaments laid on the equipment at room temperature, using convection drying or using IR or UV radiation,

- in removing, if necessary, removable pins and receiving the finished product.

In this case, the tooling is made of foamed materials, which, if necessary, can be dissolved inside the finished product without violating the integrity of the final product itself, using solvents on an organic or inorganic basis, or using any other means that dissolve the foam base and do not harm the product.

As a fiber thread, one or more threads selected from threads of inorganic origin selected from the following families are used: crystal fibers, silica fibers, basalt fibers, carbon fibers; or selected from vegetable yarns, selected from the following families: flax fibers, hemp fibers, cotton fibers, seaweed fibers, coconut fibers, palm fibers, rattan fibers, banana fibers; or selected from threads of animal origin, selected from the following families: wool fibers, silk fibers.

The composition hardening under certain conditions is made on the basis of materials: having an epoxy or polyester base, a curable polymer or phenolic binder, or thermoplastics - polyethylene, or polyethylene terephthalate.

The proposed solution describes a method of manufacturing products with a changing three-dimensional structure of one undivided part by using materials of sufficient rigidity in the tooling to form a curved surface capable of holding its shape when the fiber thread is pulled, for example, foamed materials, pre-processed by hand or machine, aligned with the base with bypass pins fixed in it, removable or not removable at the final stage of the cycle, depending on the complexity of the product and equipment.

Foamed materials to increase the rigidity and strength of the tooling can be treated with a reinforcing compound from the family of sprayed or hand-applied polyurethanes, polyureas, hybrid and other reinforcing systems, as well as using prepregs (semi-finished composite material consisting of a fibrous reinforcing filler and applied with one or two sides of the binder).

Foamed materials to form a permanent one-piece final product can be dissolved inside the body of the product without disturbing the integrity of the final product itself using organic and inorganic solvents, as well as any other means known to those skilled in the art that dissolve the foam base and do not harm the product.

Thus, the geometry of the tooling can allow the production of smooth, coherent and stable shapes known to the skilled artisan from impact-resistant materials with various properties.

The method makes it possible to manufacture products both with a pre-prepared frame (for example, from metal, wood, composite, plastic and other materials), and without it, in this case, a rigid edging of composite parts or a curved frame of an integral product acts as rigid supports.

Manufacturing technology of products according to the described tooling consists of several stages. The fiber is directed, along one or more strands, to a container with a pre-mixed, but not yet hardened, hardening composition, transparent or colored. Next, the process of wetting and laying the thread is carried out. Laying is done with special dies or manually. Next, the thread is laid along a curved path on a previously prepared rig, in such a way as to create the main body, as well as an inseparable frame edging. It is allowed to manufacture individual elements of a separate part, crosshairs and overlapping threads of both the same and different colors are allowed.

After the end of weaving, the resin is cured (polymerized) at room temperature using convection drying or using IR or UV radiation.

Fiber yarn includes fibers:

1.inorganic, selected from the following families: crystalline fibers, silica fibers, basalt fibers, carbon fibers;

2. of vegetable origin, selected from the following families: flax fibers, hemp fibers, cotton fibers, seaweed fibers, coconut fibers, palm fibers, rattan fibers, banana fibers;

3. of animal origin, selected from the following families: wool fibers, silk fibers.

The curing substance or binder for this thread includes materials that have an epoxy, polyester base, a curable polymer (or another thermosetting plastic, for example, a phenolic binder), as well as based on thermoplastics - polyethylene or polyethylene terephthalate (PET).

The binder may also contain additives such as cobalt or peroxides to improve the cure of the resin. The use of additives known to those skilled in the art is allowed, for example, fire retardants that improve the quality and other characteristics of the binder and the final product.

Figures 1-3 show various tooling for the manufacture of articles.

Figure 1 shows a tooling for the manufacture of a hemisphere - foam material,

FIG. 2 - shows a tooling for the manufacture of a hemisphere - made by a combined method,

The figures indicate the following elements:

1 - base, in this case, formed by a foam material (for example, foam), pre-processed on a CNC machine (numerical control);

2 - limiter of the frame edging, for dense packing of the wetted fiber and the formation of a polymer frame;

3 - pins to create loops and retaining frame for the fiber thread;

4 - metal edging to extend the service life of the tooling;

5 - edges of reference points of a curved surface.

It should be noted that constituent element 4 allows to extend the service life of the tooling by increasing the surface rigidity of the edge of the tool base (pins are inserted there), forming a guide hole - it keeps the pin from deviations relative to the largest plane in terms of area, as well as deviations from imaginary lines drawn from points, such as the center of a circle, to the perimeter. Steel edging, allows you to protect the body of the rig, softer in structure, from human errors (not getting the pin into the hole), among other things, this allows the use of automated devices for installing pins. Fixation of the pin from axial displacement is performed due to the known effect of friction of dissimilar materials (base, pin).

Rigging can be made in a variety of ways.

1) A method of manufacturing tooling for embossed products, made only on a CNC machine, in the form of a hemispherical part, which subsequently forms a sphere or other product that is suitable in design. The rig is shown in Fig. 1.

Description of the process of creating a snap-in:

- creation of a 3d model of the product;

- optimization for production facilities with a preliminary design calculation of reliability and rigidity, as well as for more natural connections of structural elements - a reference point to natural or natural forms, or to the idea of a designer (developer);

- preparation of tooling components - engineering work, processing of forms on CNC machines, manual finishing and assembly;

- protection of the tooling with films, film-forming release agents or other means that prevent adhesion of the fiber to the tooling;

- installation of removable pins 3.

And then the following is carried out: the production of weaving - the application of the thread on the tooling in the way described above;

- drying (polymerization);

- dismantling the product from the tooling. To simplify the process of removing nails / pins, special pneumatic equipment is used;

- cleaning the product from sharp edges for comfortable operation, as well as other methods of processing the product (for example, painting, varnishing, metallization). However, any other processing method known to those skilled in the art can be considered.

- launching the equipment in a repeated cycle.

2) A method for the production of tooling for embossed products, made by a combined method, in the form of a hemispherical part, which subsequently forms a product, with a curvilinear geometry. The rig is shown in Fig. 2.

Description of the process of creating a rig in a combined way:

- creation of a 3d model of the product;

- optimization for production facilities with a preliminary design calculation of reliability and rigidity, as well as for more natural connections of structural elements - a reference point to natural or natural forms, or to the idea of a designer (developer);

- preparation of tooling components - engineering work, mold processing on CNC machines, manual finishing and assembly of base 1, applying sheet material on the base 1 in the form of ribs 5 to obtain a frame of complex shape, partially or completely repeating the geometry of the tooling being manufactured, then foaming adhesive is used composition (for example, polyurethane foam) or a specially prepared polymer mixture in order to fill the thickness of the frame to the forming surface, then, if necessary, it is brought manually or mechanically to the required detail;

- protection of the tooling with films, film-forming release agents or other means that prevent adhesion of the fiber to the tooling;

After the preparation of the rig, it is used in the same way as in the previous described method 1).

3) A method of manufacturing tooling for parts with flat surfaces, see figure 3, forming a prefabricated product or independent interior parts.

For ease of understanding, the tooling of the cube section is shown (consists of six parts), see Fig. 3

The manufacture of such a tooling is carried out in the same way as the manufacture of tooling for embossed products 1).

The usefulness of the proposed method is due to the fact that the products obtained using this method:

- turn out to be more realistic, close to what is found in nature or as close as possible to the idea of the designer (developer);

- can be used both with frames and without special frames and consist only of polymerized fiber yarn of different designs;

- consist of the optimal number of component parts, taking into account the customer's requirements;

- by their geometry, in fact, limited by the human imagination;

- can be performed both manually and by machine;

- adaptable for convenient storage and transportation;

- performed with a high percentage of repeatability;

- can be interchangeable, as a result, they can reduce the cost of the final product for the buyer.

With the resulting tooling, it is possible to use any fiber known to specialists, the tooling is lightweight, the materials are used quite inexpensively, the possibility of scaling the finished product at the stage of preparing the information model of the tooling is provided, the minimum cost is ensured with high quality.

Claims (15)

1. A method of manufacturing products from fiber materials, which consists of: - in the creation of a 3D image of a tooling for the manufacture of products from fiber materials, including removable pins for holding loops of filaments of fiber materials, - in the manufacture of tooling using a CNC machine according to the 3D image of the tooling, - in the protection of equipment with films or film-forming release agents, - in the supply of one or more filaments of fibers into a container with a liquid hardening composition, made transparent or colored, - in the impregnation of one or more filaments of fibers with the above-mentioned hardening composition, - in laying the impregnated one or more filaments of fibers along a curved trajectory on a previously prepared rig to create the main body, - in the curing, polymerization of the filaments laid on the equipment at room temperature using convection drying or using IR or UV radiation, - in removing, if necessary, removable pins and receiving the finished product. 2. The method according to claim 1, characterized in that the tooling is made of foamed materials. 3. A method according to claim 2, characterized in that the foamed materials are dissolved inside the finished product without disturbing the integrity of the final product itself using organic or inorganic solvents. 4. A method according to claim 1, characterized in that one or more threads selected from threads of inorganic origin selected from the following families are used as the fiber thread: crystal fibers, silica fibers, basalt fibers, carbon fibers. 5. The method according to claim 1, characterized in that one or more threads selected from threads of plant origin selected from the following families are used as a thread of fibers: flax fibers, hemp fibers, cotton fibers, seaweed fibers, coconut fiber, palm fiber, rattan fiber, banana fiber. 6. A method according to claim 1, characterized in that one or more threads selected from threads of animal origin selected from the following families are used as the thread of fibers: wool fibers, silk fibers. 7. The method according to claim 1, characterized in that the hardening composition is made on the basis of materials having an epoxy or polyester base, a curable polymer or phenolic binder, or thermoplastics - polyethylene, or polyethylene terephthalate.

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