US 2011/0214595 A1Published application

Sail and method of manufacture thereof

OwnerAaron Kissinventor

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Abstract

A sail includes at least two layers of durable sailcloth material (e.g., Mylar), a scrim of load bearing yarns arranged in predetermined load path orientations, and at least one heat-activated adhesive layer securing the layers of material to the scrim, such that the scrim is positioned between the layers of material. At least one of the layers of material includes visible content on an outside surface thereof. The visible content is preferably applied to the outside surface(s) of the layer(s) of material using dye sublimation to provide durable imaging. An opaque layer may be optionally included between the two outer layers of material to prevent the passage of light through the sail. Alternatively, the adhesive layer(s) may be dyed or otherwise colored to effectuate an opaque layer. The sail is preferably manufactured using a high temperature, vacuum lamination process to mitigate the quantity of voids between the layers of material.

Claims15

Dependent claims

A method for fabricating at least part of a sailboat sail, the method comprising:

providing a first layer of a durable sailcloth material having a first side and an opposing second side, the first layer of material including first dye sublimated, visible content on the first side thereof;
disposing a first heat-activatable adhesive layer onto the second side of the first layer of material;
positioning the first layer of material on a support structure with the first adhesive layer facing upwards;
positioning a plurality of load bearing yarns upon the first adhesive layer in predetermined load path orientations;
providing a second layer of the durable sailcloth material having a first side and an opposing second side;
providing a second heat-activatable adhesive layer;
positioning the second layer of material upon the first layer of material such the second adhesive layer is positioned between the first side of the second layer of material and the plurality of load bearing yarns, wherein at least the first layer of material, the first adhesive layer, the plurality of load bearing yarns, the second layer of material, and the second adhesive layer form a sail arrangement;
positioning the sail arrangement into a vacuum;
and
applying appropriate heat and pressure to the sail arrangement while the sail arrangement is in the vacuum to activate at least the first and second adhesive layers and to mitigate a quantity of voids between the first layer of material and the second layer of material.

7 more elements

Dependencies are inferred from the claim text.

Facts

Application: 12/718,669Filed 5 Mar 2010
Published: 8 Sep 2011
Term ends: Not estimatedThe source records don’t support an estimate.

Classification5 codes

B29C 65/02
Joining or sealing of preformed parts , e.g. welding of plastics materials; Apparatus therefor: by heating, with or without pressure
B29C 65/52
Using adhesives , i.e. using supplementary joining material; solvent bonding: characterised by the way of applying the adhesive
B63H 9/06
Using sails or like wind-catching surfaces: types of sail; Constructional features of sails; Arrangements thereof on vessels
B29C
Shaping or joining of plastics