WO2002087878A1 - Procede et appareil de creation d'une structure - Google Patents

Procede et appareil de creation d'une structure Download PDF

Info

Publication number
WO2002087878A1
WO2002087878A1 PCT/US2002/012896 US0212896W WO02087878A1 WO 2002087878 A1 WO2002087878 A1 WO 2002087878A1 US 0212896 W US0212896 W US 0212896W WO 02087878 A1 WO02087878 A1 WO 02087878A1
Authority
WO
WIPO (PCT)
Prior art keywords
blanket
continuous
forming
mixture
forming apparatus
Prior art date
Application number
PCT/US2002/012896
Other languages
English (en)
Inventor
Leroy Payne
Original Assignee
Leroy Payne
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
Priority claimed from PCT/US2001/025740 external-priority patent/WO2004007198A1/fr
Application filed by Leroy Payne filed Critical Leroy Payne
Priority to US10/475,863 priority Critical patent/US20040129376A1/en
Priority to CA002442746A priority patent/CA2442746A1/fr
Publication of WO2002087878A1 publication Critical patent/WO2002087878A1/fr

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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
    • 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
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/021—Combinations of fibrous reinforcement and non-fibrous material
    • B29C70/025—Combinations of fibrous reinforcement and non-fibrous material with particular filler
    • 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
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/32—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core on a rotating mould, former or core
    • 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
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/38—Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
    • 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
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C19/00—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving
    • E01C19/46—Machines, tools or auxiliary devices for preparing or distributing paving materials, for working the placed materials, or for forming, consolidating, or finishing the paving for preparing and placing the materials, e.g. slurry seals
    • E—FIXED CONSTRUCTIONS
    • E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
    • E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
    • E01C23/00—Auxiliary devices or arrangements for constructing, repairing, reconditioning, or taking-up road or like surfaces
    • E01C23/03—Arrangements for curing paving; Devices for applying curing means; Devices for laying prefabricated underlay, e.g. sheets, membranes; Protecting paving under construction or while curing, e.g. use of tents
    • 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
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/70—Automated, e.g. using a computer or microcomputer
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
    • B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only

Definitions

  • This invention relates to a novel continuous structure forming method and apparatus.
  • the present invention provides a novel method and apparatus which overcome the shortcomings of previous expedients.
  • the method and apparatus provide features and advantages not found in earlier technology.
  • the method and apparatus of the invention can be modified to form a variety of structures of high quality.
  • a novel method of the present invention for forming a substantially continuous composite structure includes the steps of preselecting a solid particulate reactive resin forming material, a liquid reactive resin forming material and a porous blanket.
  • the solid particulate reactive resin forming material is mixed with the liquid reactive resin forming material to form a stable liquid mixture.
  • the liquid mixture is applied to the blanket and the solid particulate resin forming material therein is liquified.
  • the liquified resin forming material is reacted with the liquid resin forming material in an exothermic reaction.
  • the mixture-treated blanket is deposited along a preselected final surface. Part of the resin forming mixture is migrated through the blanket substantially uniformly to form a continuous resin matrix within the blanket. A tight permanent bond is formed between the matrix/blanket and the preselected final surface.
  • the solid particulate resin forming material may be liqui ied before or after the treated blanket is applied to the final surface.
  • the liquifying of the solid particulate resin forming material is accomplished by heating it.
  • a preselected tension preferably is created in the blanket as it is advanced into contact with the final surface.
  • pressure is applied to the treated blanket to form the permanent bond.
  • the mixture-treated blanket preferably is cut into predetermined lengths and a plurality of the treated blanket lengths arranged successively in a preselected overlapping relationship to form a continuous structural assembly of considerable length.
  • Figure 1 is a view in perspective of one form of continuous structure forming apparatus of the present invention
  • Figure 2 is an enlarged fragmentary side view of the structure forming apparatus of the invention shown in Figure 1;
  • Figure 3 is a schematic illustration of the structure forming apparatus of the invention shown in Figure 1 in use;
  • Figure 4 is a schematic illustration of an alternate form of the structure forming apparatus of the invention shown in Figure 3 at a later stage of use;
  • Figure 5 is an enlarged schematic illustration of the grasping portion of the structure forming apparatus of the invention.
  • FIG. 6 is a fragmentary schematic illustration of an alternate form of the structure forming apparatus of the invention.
  • a novel continuous structure forming apparatus 11 of the present invention includes a supporting portion 12, a material supplying portion 13, a matrix forming portion 15, a positioning portion 16 and a control portion 17.
  • the supporting portion 12 of the structure forming apparatus of the invention includes a plurality of spaced upstanding frame members 20,21,22,23.
  • a plurality of frame members 25,26,27,28 join the frame members 20-23 to provide a frame assembly 29.
  • the supporting portion 12 advantageously includes connector means 31 as well as accessories such as electrical generators, air compressors, hydraulic pumps, etc. (not shown). Such accessories can be mounted on and/or suspended from the frame members.
  • the material supplying portion 13 of the apparatus 11 includes a reservoir 32 operatively connected with the supporting portion 12.
  • the reservoir is connected with the matrix forming portion 15, preferably through conduit means 37.
  • the matrix forming portion 15 of the apparatus 11 includes mixture distributing means 45 adjacent a delivery conduit 37 of the reservoir and adjustable downwardly therefrom.
  • the mixture distributing means 45 as shown in the drawings includes a pair of spaced elongated transversely disposed arcuate members 47,48 with generally horizontal lower edges adjustably oriented closer together than upper edges thereof .
  • the matrix forming portion 15 also may include second mixture distributing means (not shown) adjacent the first mixture distributing means 45.
  • the second mixture distributing means may include a plurality of spaced nozzles or other distributing means.
  • the positioning portion 16 of the structure forming apparatus of the invention includes resin liquifying means 49.
  • the liquifying means may include heating means employing conductive rods, wires, etc. utilizing conventional or microwave energy. Liquifying of the resin may be done prior to application to the final surface (Fig. 3) or after as shown in Figure 6.
  • the positioning portion 16 includes elongated structure grasping means 55 mounted on a vehicle 35.
  • the structure grasping means preferably is mounted along the side of the vehicle adjacent to the apparatus 11.
  • the grasping means 55 most preferably includes cooperating hinge sections 56 extending from pivotable link members 58. The operation of the grasping means is coordinated with the operation of the apparatus 11.
  • Pressure applying means shown as pivotable pressure roller 53 is extendable beyond an edge 54 of the apparatus.
  • a cutter blade 60 advantageously is disposed on a pivoting arm member 61.
  • the blade preferably is engageable with a roller such as pressure roller 53 disposed on an adjacent pivoting arm member 62.
  • the apparatus 11 may include removable outer panels 63 selectively hung from the apparatus to enclose the apparatus during storage. Also, the panels help to control wind, temperature, other weather conditions, etc. during operation.
  • the structure forming apparatus is suspended from a cantilever extendable arm assembly 65 extending from a 360 degree rotatable turntable on a vehicle 35 such as an excavator, tractor, truck, trailer or the like.
  • the machinery is transferred to a job site and positioned adjacent to a previously selected starting position.
  • Operation of the structure forming apparatus 11 is begun by preselecting a solid particulate reactive resin forming material, a liquid reactive resin forming material and a porous blanket.
  • the solid particulate and liquid reactive resin forming materials preferably are mixed in advance at their fabricating site since the resulting mixture is stable. This procedure simplifies the design and operation of the structure forming apparatus 11.
  • the mixture delivered from outlet 40 of the reservior 32 passes downwardly between elongated arcuate members 47,48 into contact with a porous blanket or blankets 44 moving therethrough.
  • the mixture is delivered at a rate sufficient to form a residual pool 46 between the arcuate members.
  • the leading edge 68 of blanket 44 exits the liquid pool with the arcuate members closely adjacent to the preselected final location, the leading edge is grasped by cooperating hinge sections 56 as shown in Figure 3 and advanced substantially immediately into permanent contact with a preselected edge 66 of ditch 67 and adhered thereto.
  • the apparatus 11 including the arcuate surfaces which is suspended from the cantilever arm assembly 65 of vehicle 35 is withdrawn and the blanket being delivered therefrom is deposited along a preselected path across the ditch surface while migrating part of the resin forming materials through the blanket substantially uniformly to form a continuous resin matrix within the blanket.
  • Uniform tension is maintained by adjusting the relative speed of the apparatus across the ditch surface.
  • roller 53 applies pressure to tightly bond the structure to the ditch surface 69.
  • Blade 60 then is pivoted against roller 53 to cut the blanket into a preselected length ( Figure 4). Thereafter, the apparatus 11 may be moved to a position adjacent to and slightly overlapping the blanket deposited previously.
  • the steps of the method are repeated to deposit additional lengths of the structure individually in an overlapping relationship with the previous structure length and thereby form a continuous structural assembly of considerable length. Since each length is maintained under tension until installed into the ditch, the structural liner produced is uniform and smooth without folds or other imperfections.
  • control portion 17 of the structure forming apparatus 11 of the invention includes programmable memory means 72 and actuating means 73 responsive thereto in combination with coordinating means 74 to control the operation of the various components of apparatus 11.
  • the coordinating means includes a process controller 75 that initiates changes in the flows of materials and speeds of drives to bring variations therein back to the rates specified in the programs present in the memory 72.
  • the control portion may control the lateral position of the blanket 44 with respect to a preselected path.
  • This coordination commonly is achieved through the transmission of information such as digital pulses from monitors and/or sensors at the control components to the process controller 75.
  • the operating information is compared with the preselected programming parameters stored in the memory 72. If differences are detected, instructions from the controller 75 change the operation of the components to restore the various operations to the preselected processing specifications.
  • the reactive resin forming materials employed to produce composite structures of the invention are selected to provide a particulate resin forming material that is a solid at ambient temperatures and a liquid resin formiing material t,hat is compatible with the liquified solid particles and capable of reaction therewith to form the particular resin matrix or coating desired in the final structure.
  • the materials form a thermosetting resin such as a polyurethane or polyester.
  • the solid particles preferably mixed with the liquid resin forming material at the fabrication site so that a single supply of the resin forming material may be utilized. Additional components can be premixed with the resin formers, e.g. fillers, reinforcements, colors and the like.
  • the resin forming mixture may contain different partially formed materials which upon mixing interact to form the desired polyurethane.
  • partially formed materials include so-called "A stage” resins and "B stage” resins.
  • An inert particulate solid additive material may be mixed with the reactive resin forming materials, preferably, in a proportion significantly greater than that of the resin forming materials.
  • the inert additive particles may be any of a wide variety of inexpensive materials readily available at a particular job site. Natural mineral particulate materials such as sand and gravel normally are available or can be produced simply by crushing rock at the site. Also, materials such as waste or recycled materials which can be shredded or ground into particles of suitable size can be utilized. Especially useful are particles formed by shredding or grinding discarded tires. Since the particles are encapsulated with resin forming material and not saturated therewith, many different waste materials may be employed.
  • Suitable porous blankets include woven, knit, non-woven structures, etc.
  • the blankets e.g. fabrics, mats, etc. may be formed of continuous or discontinuous fibers, yarns, slit ribbons and similar natural and synthetic fibrous materials.
  • Reinforcing members such as ropes, cables, etc. extending longitudinally and/or transversely of the blanket centerline may be included if desired.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Robotics (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)

Abstract

L'invention concerne un procédé de création d'une structure composite continue, qui consiste à mélanger une matière formant une résine particulaire solide à une matière formant une résine liquide provenant de buses (39), et à appliquer ledit mélange sur un ou plusieurs blanchets poreux (44). La matière particulaire poreuse est liquéfiée à l'aide d'un moyen de liquéfaction de résine (49) et est mise en réaction avec la matière formant une résine liquide, dans une réaction exothermique. Le blanchet (44) est déposé le long d'une surface finale présélectionnée, à l'aide d'une presse (53), et une partie du mélange formant de la résine est traitée, de sorte qu'elle migre à travers le blanchet (44) de manière sensiblement homogène, et qu'un blanchet en résine continu soit formé.
PCT/US2002/012896 2001-04-26 2002-04-24 Procede et appareil de creation d'une structure WO2002087878A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US10/475,863 US20040129376A1 (en) 2001-08-13 2002-04-24 Structure forming method and apparatus
CA002442746A CA2442746A1 (fr) 2001-04-26 2002-04-24 Procede et appareil de creation d'une structure

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
USPCT/US01/25740 2001-04-26
PCT/US2001/025740 WO2004007198A1 (fr) 2000-07-13 2001-08-13 Procede et appareil de formation de structure

Publications (1)

Publication Number Publication Date
WO2002087878A1 true WO2002087878A1 (fr) 2002-11-07

Family

ID=21742781

Family Applications (2)

Application Number Title Priority Date Filing Date
PCT/US2002/002916 WO2002087879A1 (fr) 2001-04-26 2002-02-04 Appareil et procede de formage d'une structure
PCT/US2002/012896 WO2002087878A1 (fr) 2001-04-26 2002-04-24 Procede et appareil de creation d'une structure

Family Applications Before (1)

Application Number Title Priority Date Filing Date
PCT/US2002/002916 WO2002087879A1 (fr) 2001-04-26 2002-02-04 Appareil et procede de formage d'une structure

Country Status (3)

Country Link
AU (1) AU2001288282A1 (fr)
CA (3) CA2457749A1 (fr)
WO (2) WO2002087879A1 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102941676A (zh) * 2012-10-19 2013-02-27 湖北三江航天红阳机电有限公司 一种旋转体双层复合材料缠绕成型方法

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4483974A (en) * 1982-08-18 1984-11-20 Bayer Aktiengesellschaft Process for the production of stabilized polyisocyanates, the polyisocyanates so-stabilized and their use in the production of polyurethanes
US4990392A (en) * 1988-01-08 1991-02-05 Lainiere De Picardie, S.A. Thermo-adhesive textile product comprising a micro-encapsulated cross linking agent
US5330603A (en) * 1988-08-23 1994-07-19 Payne Leroy Continuous structure forming method
US5700345A (en) * 1988-08-23 1997-12-23 Payne; Leroy Continuous structure forming apparatus
US5725716A (en) * 1988-08-23 1998-03-10 Payne; Leroy Structure forming method and apparatus

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2338960A (en) * 1937-04-21 1944-01-11 Nottebohm Carl Ludwig Process and apparatus for the impregnation of fiber fleeces with binding agents
US2771387A (en) * 1951-11-21 1956-11-20 Owens Corning Fiberglass Corp Bituminous treated glass fiber structures and methods of producing them
US3888716A (en) * 1972-06-05 1975-06-10 Kemlite Corp Preparation of resin impregnated glass fiber sheets
US5496434A (en) * 1988-08-23 1996-03-05 Payne; Leroy Structure forming apparatus

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4483974A (en) * 1982-08-18 1984-11-20 Bayer Aktiengesellschaft Process for the production of stabilized polyisocyanates, the polyisocyanates so-stabilized and their use in the production of polyurethanes
US4990392A (en) * 1988-01-08 1991-02-05 Lainiere De Picardie, S.A. Thermo-adhesive textile product comprising a micro-encapsulated cross linking agent
US5330603A (en) * 1988-08-23 1994-07-19 Payne Leroy Continuous structure forming method
US5700345A (en) * 1988-08-23 1997-12-23 Payne; Leroy Continuous structure forming apparatus
US5725716A (en) * 1988-08-23 1998-03-10 Payne; Leroy Structure forming method and apparatus

Also Published As

Publication number Publication date
WO2002087879A1 (fr) 2002-11-07
AU2001288282A1 (en) 2004-02-02
CA2457749A1 (fr) 2004-01-22
CA2442746A1 (fr) 2002-11-07
CA2443063A1 (fr) 2002-11-07

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