Apparatus And Method Of Producing Reinforced Laminated Panels As A Continuous Batch

Abstract

An apparatus and method for producing multiple panels of a reinforced laminated membrane are provided. The apparatus and method utilize an accommodator between a yarn-laying station and a plotting and cutting station to allow these stations to operate simultaneously and without interruption on more than one part of a sheet of material. Reinforcing yarns are deposited on the sheet of material at the yarn-laying station in one or more patterns. Panels are cut at the cutting station after lamination. The accommodator accommodates material between these stations.

1 . A method of continuously producing multiple sail panels for sails having one or more patterns of reinforcing yarns, comprising the steps of:
 providing a sheet of sail panel material;   adding first reinforcing yarns to a first portion of the sheet in a first pattern;   laminating the first reinforcing yarns to the first portion of the sheet to form a first reinforced laminated sailcloth;   advancing the first reinforced laminated sailcloth through an accommodating station to a cutting station;   fixing the first reinforced laminated sailcloth in place at the cutting station;   cutting the first reinforced laminated sailcloth into a first sail panel;   while cutting the first sail panel, adding second reinforcing yarns to a second portion of the sheet in a second pattern;   laminating the second reinforcing yarns to the second portion of the sheet to form a second reinforced laminated sail cloth;   accommodating the second reinforced laminated sailcloth in the accommodating station until cutting of the first sail panel from the first reinforced laminated sailcloth complete.   
     
     
         2 . The method of  claim 1 , wherein the first pattern and the second pattern are the same. 
     
     
         3 . The method of  claim 1 , wherein the first pattern and the second pattern are different. 
     
     
         4 . The method of  claim 3 , further comprising the steps of:
 advancing the second reinforced laminated sailcloth to the cutting station;   fixing the second reinforced laminated sailcloth in place at the cutting station; and   cutting the second reinforced laminated sailcloth into a second sail panel, where the second sail panel and the first sail panel are intended to form parts of a sail.   
     
     
         5 . The method of  claim 4 , wherein the second panel is cut to a different shape than the first panel. 
     
     
         6 . The method of  claim 1 , wherein the steps of laminating comprise laminating the first and second reinforcing yarns and the first and second portions of the sheet of sail panel material to a previously laminated material. 
     
     
         7 . The method of  claim 6 , wherein the previously laminated material comprises reinforced sailcloth. 
     
     
         8 . The method of  claim 1 , wherein the step of accommodating comprises translating at least one roller to vary the distance to be travelled by the second reinforced laminated sailcloth to arrive at the cutting station. 
     
     
         9 . The method of  claim 1 , wherein the steps of laminating comprise advancing the first and second reinforcing yarns and the first and second portions of the sheet of sail panel material between a heated metal roll and a flexible counter roll. 
     
     
         10 . The method of  claim 1 , wherein the step of adding first reinforcing yarns to a sheet of sail panel material comprises adding first reinforcing yarns along expected load-paths in a sail panel. 
     
     
         11 . An apparatus for continuously producing multiple panels of a laminated membrane having one or more patterns of reinforcing yarn, comprising:
 a yarn-laying head for adding first reinforcing yarn to a first portion of a sheet of material in a first pattern and second reinforcing yarn to a second portion of the sheet of material in a second pattern;   a laminator for laminating the first reinforcing yarn to the first portion of the sheet to form a first portion of reinforced laminated membrane and the second reinforcing yarn to the second portion of the sheet to form a second portion of reinforced laminated membrane;   a cutting device for cutting panels from the first and second portions of reinforced laminated membrane; and   an accommodator disposed between the yarn-laying head and the cutting device for accommodating the second portion of the sheet of material until the cutting of a first panel from the first portion of reinforced laminated membrane is completed by the cutting device.   
     
     
         12 . The apparatus of  claim 11 , further comprising a cutting table on which the first portion of reinforced laminated membrane is fixed while panels are cut by the cutting device. 
     
     
         13 . The apparatus of  claim 12 , wherein the cutting table includes a vacuum surface. 
     
     
         14 . The apparatus of  claim 11 , wherein the first pattern and the second pattern are different. 
     
     
         15 . The apparatus of  claim 11 , wherein the first pattern and the second pattern are the same. 
     
     
         16 . The apparatus of  claim 11 , wherein the accommodator comprises a plurality of translatable rollers for varying the distance travelled by the second reinforced laminated membrane between the laminator and the cutting device. 
     
     
         17 . The apparatus of  claim 11 , wherein the laminator comprises a heated metal roll and a flexible counter roll. 
     
     
         18 . The apparatus of  claim 11 , wherein the laminator laminates the first and second reinforcing yarns and the first and second portions of the sheet of material to a previously laminated membrane. 
     
     
         19 . The apparatus of  claim 11 , further comprising a yarn-laying table on which the sheet of material is secured while the yarn-laying head adds the first reinforcing yarn to the sheet. 
     
     
         20 . The apparatus of  claim 11 , wherein the yarn-laying head adds the first reinforcing yarns to the sheet of material along expected load-paths in the panel. 
     
     
         21 . The apparatus of  claim 11 , wherein the laminator is disposed between the yarn-laying head and the cutting device and the accommodator is disposed between the yarn-laying head and the laminator. 
     
     
         22 . The apparatus of  claim 11 , wherein the laminator is disposed between the yarn-laying head and the cutting device and the accommodator is disposed between the cutting device and the laminator.