US5470632A
Expired / Lapsed
US
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Composite material for fabrication of sails and other articles
Assignee: Cubic Tech Corp
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Filing: 1994-07-18
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Granted: 1995-11-28
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Expires: 2014-07-18
Abstract
Abstract An improved reinforced laminate for use in sails or other flexible sheet or membrane applications utilizes a pull-truded thin lightweight reinforcing sheet of unidirectional extruded monofilaments in which the reinforcing sheet or sheets form one or more uni-tapes laminated to a polymer film such as Mylar, or other extended sheet of material. The monofilaments are uniformly embedded in the uni-tape via an elastomeric polymer matrix, with the reinforcing sheet, when incorporated into sails via lamination resulting in sails with reinforcing monofilaments having diameters 5 times less than conventional strands or threads. The use of small diameter monofilaments greatly increases the monofilament-over-monofilament crossover density, resulting in a dramatic increase in shear strength, and Youngs' Modulus, with an accompanying dramatic decrease in weight. In one embodiment the improvement in specific modulus over conventional sail laminates is about six-fold. For example, at only one-third the weight, stretch resistance is two times better. In a preferred embodiment, autoclaving is used in the lamination process to rid the laminate of voids which dramatically reduce shear strength by as much as 30 percent. Alternative void-free laminating processes include a silicone interliner/heated platen technique.
Inventors
- 👤 Heiner Meldner
- 👤 Roland J. Downs
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 19:53
CPC Classifications
B; B32; B32B; B32B27/00; B32B27/12; B29; B29C; B29C70/00; B29C70/04; B29C70/28; B29C70/40; B29C70/42; B29C70/44; B32B27/36; B32B5/00; B32B5/02; B32B5/12; B32B5/22; B32B5/24; B32B5/26; B63; B63H; B63H9/00; B63H9/04; B63H9/06; B63H9/067; B63H9/0678; B32B2262/00; B32B2262/10; B32B2262/105; B32B2262/106; B32B2605/00; B32B2605/12; Y; Y10; Y10S; Y10S428/00; Y10S428/902; Y10T; Y10T428/00; Y10T428/24; Y10T428/24058; Y10T428/24074; Y10T428/24091; Y10T428/24099; Y10T428/249921; Y10T428/249924; Y10T428/24994; Y10T428/249942; Y10T428/249945; Y10T428/31504; Y10T428/31652; Y10T428/31663
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
78 words
A material for use as a flexible foldable sheet having improved shear strength comprising: a laminate including reinforcing elements therein, said reinforcing elements including at least two unidirectional tapes, each having extruded monofilaments therein, all of such monofilaments lying in a predetermined direction within the tape, said tapes being placed one atop the other within the laminate in a crossed fashion, with the monofilaments of one tape being at an angle to the monofilaments of an adjacent tape.
Claim 2
Dependent Claim
78 words
A material for use as a flexible foldable sheet having improved shear strength comprising: a laminate including reinforcing elements therein, said reinforcing elements including at least two unidirectional tapes, each having extruded monofilaments therein, all of such monofilaments lying in a predetermined direction within the tape, said tapes being placed one atop the other within the laminate in a crossed fashion, with the monofilaments of one tape being at an angle to the monofilaments of an adjacent tape.
Claim 3
Dependent Claim
20 words
The material of claim 1, wherein said unidirectional tapes are formed in a pull-trusion process to provide a pull-truded tape.
Claim 4
Dependent Claim
33 words
The material of claim 1, wherein said tape includes a monofilament and resin matrix and wherein said resin is flexible when cured, such that the resulting reinforced laminate is both flexible and foldable.
Claim 5
Dependent Claim
27 words
The material of claim 1, wherein said laminate includes a top and bottom film, with said reinforcing elements sandwiched therebetween, said laminate being free of voids therein.
Claim 6
Dependent Claim
21 words
The material of claim 1, wherein said monofilaments have diameters less than 20 microns for permitting an increase in crossover density.
Claim 7
Dependent Claim
54 words
A reinforcing element for use within a laminate comprising a unidirectional tape having monofilaments running in one direction therethrough, said tape having been made by passing side-by-side bands having extruded monofilaments therein through a resin bath and passing the resin-coated bands through fixed gap pinch rollers which marry the individual bands into a tape.
Claim 8
Dependent Claim
54 words
A reinforcing element for use within a laminate comprising a unidirectional tape having monofilaments running in one direction therethrough, said tape having been made by passing side-by-side bands having extruded monofilaments therein through a resin bath and passing the resin-coated bands through fixed gap pinch rollers which marry the individual bands into a tape.
Claim 9
Dependent Claim
13 words
The reinforcing element of claim 6, wherein said resin is flexible when cured.
Claim 10
Dependent Claim
20 words
The reinforcing element of claim 6, wherein the unified tape from the rotary die is first heated and then cooled.
Claim 11
Dependent Claim
37 words
A flexible foldable composite sheet comprising top and bottom films, and unidirectional tape reinforcing elements laminated between band films, each tape reinforcing element having monofilaments therein, with the directions of the monofilaments in adjacent tapes being different.
Claim 12
Dependent Claim
37 words
A flexible foldable composite sheet comprising top and bottom films, and unidirectional tape reinforcing elements laminated between band films, each tape reinforcing element having monofilaments therein, with the directions of the monofilaments in adjacent tapes being different.
Claim 13
Dependent Claim
13 words
The composite sheet of claim 9, wherein the laminate is formed via autoclaving.
Claim 14
Dependent Claim
15 words
The composite sheet of claim 9, wherein the laminate is formed by heat and pressure.
Claim 15
Dependent Claim
14 words
The composite sheet of claim 11, wherein the laminate is cured by UV light.
Claim 16
Dependent Claim
57 words
The composite sheet of claim 9, wherein the laminate is formed by confining said laminate top and bottom with over and underlying sheets respectively and providing a silicone interliner adjacent the laminate, said interliner expanding with heat to provide uniform pressure to effectuate lamination without the formation of voids by forcing evolved gas back into the laminate.
Claim 17
Dependent Claim
13 words
The composite of claim 9, wherein each tape includes monofilaments of different material.
Claim 18
Dependent Claim
13 words
The composite of claim 14, wherein said different material are carbon and polymers.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1998-11-27 | 1999-05-29 | 1999-11-28 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2002-11-27 | 2003-05-29 | 2003-11-28 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2006-11-27 | 2007-05-29 | 2007-11-28 | $7700.00 | Window Closed / Lapsed |