Systems and method for producing three-dimensional articles from flexible composite materials
AssigneeCubic Tech Corporation
InventorsRoland Joseph Downs, Christopher Michael Adams, Jon Michael Holweger
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Abstract
The present disclosure encompasses three-dimensional articles comprising flexible-composite materials and methods of manufacturing said three-dimensional articles. More particularly, the present system relates to methods for manufacturing seamless three-dimensional-shaped articles usable for such finished products as airbags/inflatable structures, bags, shoes, and similar three-dimensional products. A preferred manufacturing process combines composite molding methods with specific precursor materials to form fiber-reinforced continuous shaped articles that are flexible and collapsible.
Claims11
A method of producing a three-dimensional flexible composite part, the method comprising:
- providing a male mold and a female mold having compatible configurations;
- shaping a first composite layup of at least one fiber-reinforced scrim and optional first surface layer over the male mold, each scrim comprising two or more layers of unidirectional fibers placed at different configurations;
- transferring the first shaped layup from the male mold into conformity with the female mold;
- shaping a second composite layup of at least one fiber-reinforced scrim and optional second surface layer over the male mold, each scrim comprising two or more layers of unidirectional fibers placed at different configurations;
- transferring the second shaped layup from the male mold into the female mold over the first transferred layup;
- folding peripheral first layup material so as to overlap the periphery of the second transferred layup;
- and
- curing the first and second layups in the female mold to form a three-dimensional part having a seam formed only from the overlap thereby leaving a hollow space between remaining first and second cured layup material.
Dependencies are inferred from the claim text.