Fabric processing method and component
11390224 · 2022-07-19
Assignee
Inventors
Cpc classification
B29C70/34
PERFORMING OPERATIONS; TRANSPORTING
B32B3/263
PERFORMING OPERATIONS; TRANSPORTING
B32B1/00
PERFORMING OPERATIONS; TRANSPORTING
B29B11/16
PERFORMING OPERATIONS; TRANSPORTING
B29C65/72
PERFORMING OPERATIONS; TRANSPORTING
Y10T428/24628
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B60R13/02
PERFORMING OPERATIONS; TRANSPORTING
B32B2250/20
PERFORMING OPERATIONS; TRANSPORTING
B32B5/26
PERFORMING OPERATIONS; TRANSPORTING
B32B3/14
PERFORMING OPERATIONS; TRANSPORTING
B32B2262/106
PERFORMING OPERATIONS; TRANSPORTING
B32B3/08
PERFORMING OPERATIONS; TRANSPORTING
Y10T428/24033
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B32B3/18
PERFORMING OPERATIONS; TRANSPORTING
B32B5/06
PERFORMING OPERATIONS; TRANSPORTING
Y10T428/18
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
International classification
B60R13/02
PERFORMING OPERATIONS; TRANSPORTING
B29B11/16
PERFORMING OPERATIONS; TRANSPORTING
B32B1/00
PERFORMING OPERATIONS; TRANSPORTING
B29C70/34
PERFORMING OPERATIONS; TRANSPORTING
B32B3/08
PERFORMING OPERATIONS; TRANSPORTING
B32B3/14
PERFORMING OPERATIONS; TRANSPORTING
B32B3/18
PERFORMING OPERATIONS; TRANSPORTING
B32B5/26
PERFORMING OPERATIONS; TRANSPORTING
B32B5/06
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A fabric processing method and component (e.g., a vehicle component) includes providing and/or arranging a first fabric charge and a second fabric charge. A multi-piece fabric assembly is formed for single stage draping by stitching together the first and second fabric charges along a neutral stitching path. The multi-piece fabric assembly is formed into a three-dimensional shape and is then impregnated with a polymeric material to form the component.
Claims
1. A vehicle component, comprising: an impregnated multi-piece fabric assembly comprising at least a first fabric charge and a second fabric charge stitched together along a neutral stitching path, wherein the first and second fabric charges each have distal portions that are spaced apart from the neutral stitching path, and are three-dimensionally oriented relative to one another and relative to the neutral stitching path, wherein the first fabric charge is a V-shaped corner piece having an inner apex or apex side that forms a notch in the first fabric charge, an outer wide side, and a pair of flanking sides extending between the inner apex or apex side and the outer wide side.
2. The vehicle component of claim 1 wherein the distal portions of the first and second fabric charges are stitched together along one or more three-dimensional stitching paths.
3. The vehicle component of claim 2 wherein the one or more three dimensional stitching paths each intersect the neutral stitching path to form a stitching intersection and are each approximately perpendicular relative to the neutral stitching path at the stitching intersection.
4. The vehicle component of claim 1 wherein the multi-piece fabric assembly is formed from arranging each of the first and second fabric charges relative to one another on a single plane with at least one of the first and second fabric charges overlapping the other of the first and second fabric charges.
5. The vehicle component of claim 1 wherein the multi-piece fabric assembly further includes a third fabric charge that is stitched together with the first and second fabric charges along the neutral stitching path.
6. The vehicle component of claim 5 wherein the multi-piece fabric assembly is formed from arranging each of the first, second and third fabric charges relative to one another on a two-dimensional plane with the first, second and third fabric charges overlapping one another.
7. The vehicle component of claim 1 wherein the neutral stitching path extends along the first fabric charge between the pair of flanking sides and is spaced apart from each of the inner apex or apex side and the outer wide side.
8. The vehicle component of claim 1 wherein a local reinforcement charge is stitched onto the multi-piece fabric assembly, and the reinforcement charge is smaller in size than the each of the first and second fabric charges.
9. The vehicle component of claim 1, wherein a three-dimensional stitching path is disposed along a side in the pair of sides extending between the inner apex or apex side and the outer wide side of the first fabric charge, and disposed along a side of the second fabric charge overlapping the first fabric charge.
10. The vehicle component of claim 1, wherein the multi-piece fabric assembly is formed from draping the first fabric charge and the second fabric charge over a pre-form member such that central portions of the first fabric charge and the second fabric charge rest on an area of the pre-form member that defines a single plane, and the distal portions of the first fabric charge and the second fabric charge are arranged in orientations angled and varying relative to the single plane defined by the pre-form member.
11. A vehicle component, comprising: an impregnated multi-piece fabric assembly comprising at least a first fabric charge and a second fabric charge stitched together along a neutral stitching path, wherein the first and second fabric charges each have distal portions that are spaced apart from the neutral stitching path, and are three-dimensionally oriented relative to one another and relative to the neutral stitching path, wherein the first fabric charge is a V-shaped corner piece having an inner apex or apex side, an outer wide side, and a pair of flanking sides extending between the inner apex or apex side and the outer wide side, wherein the multi-piece fabric assembly further includes a third fabric charge that is stitched together with the first and second fabric charges along the neutral stitching path, wherein the second and third fabric charges are arranged, respectively, relative to the first fabric charge on a single two-dimensional plane such that the second and third fabric charges respectively overlap, or are overlapped by, the first fabric charge a greater amount adjacent the inner apex or apex side than adjacent the outer wide side, and wherein the second fabric charge is more proximal to a first flanking side in the pair of flanking sides as compared to a second flanking side in the pair of flanking sides, and the third fabric charge is more proximal to the second flanking side as compared to the first flanking side.
12. The vehicle component of claim 1, wherein the multi-piece fabric assembly is formed from arranging the first fabric charge and the second fabric charge relative to one another on a single plane provided by a staging platen, at least one of the first and second fabric charges overlapping the other of the first and second fabric charges along the staging platen.
13. A vehicle component, comprising: an impregnated multi-piece fabric assembly comprising at least a first fabric charge and a second fabric charge stitched together along a neutral stitching path, wherein the first and second fabric charges each have distal portions that are spaced apart from the neutral stitching path, and are three-dimensionally oriented relative to one another and relative to the neutral stitching path, wherein the distal portions of the first and second fabric charges are stitched together along one or more three-dimensional stitching paths, wherein one or more reinforcing stitching patterns extend parallel to the neutral stitching path and intersect the one or more three-dimensional stitching paths, wherein each of the first and second fabric charges are arranged relative to one another on a single plane and stitched along the neutral stitching path on the single plane, and the distal portions of the first and second fabric charges are arranged in orientations angled and varying relative to the single plane, wherein the first fabric charge is a V-shaped corner piece having an inner apex or apex side, an outer wide side, and a pair of flanking sides extending between the inner apex or apex side and the outer wide side, wherein the multi-piece fabric assembly further includes a third fabric charge that is stitched together with the first and second fabric charges along the neutral stitching path, and wherein the second fabric charge is more proximal to a first flanking side in the pair of flanking sides as compared to a second flanking side in the pair of flanking sides, and the third fabric charge is more proximal to the second flanking side as compared to the first flanking side, and wherein the second and third fabric charges respectively overlap, or are overlapped by, the first fabric charge a greater amount adjacent the inner apex or apex side than adjacent the outer wide side.
14. The vehicle component of claim 13 wherein the one or more three dimensional stitching paths each intersect the neutral stitching path to form a stitching intersection and are each approximately perpendicular relative to the neutral stitching path at the stitching intersection.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(16) Referring now to the drawings wherein the showings are only for purposes of illustrating one or more exemplary embodiments and not for purposes of limiting the same,
(17) Additionally, though not required, providing fabric charges in 12 can include providing any number of further fabric charges. For example, with further reference to
(18) Accordingly, at 18 in
(19) Once the fabric charges (e.g., fabric charges 14, 16, 18) are arranged relative to one another in a two-dimensional plane, such as on the staging platen 20 as shown in the illustrated embodiment, a multi-piece fabric assembly 30 can be formed for subsequent single stage draping as indicated at 32 in
(20) Though not shown in
(21) Specific to the illustrated embodiment, though not required, the first fabric charge 14 can be a V-shaped corner piece having, with specific reference back to
(22) As shown, the neutral stitching path 34 can extend along the first fabric charge 14 between the flanking sides 14c, 14d and can be spaced apart from each of the inner apex or apex side 14a and the outer wide side 14b. Similarly, the neutral stitching path 34 can be arranged along the second and third fabric charges such that the neutral stitching path 34 extends between respective pairs of flanking sides of the second and third fabric charges (i.e., flanking sides 16c and 16d of the second fabric charge 16 and flanking sides 22c, 22d of the third fabric charge 22). Also, the neutral stitching path can be spaced apart from inner sides 16a, 22a of, respectively, the second fabric charge 16 and the third fabric charge 22 and from outer sides 16Bb, 22bB of, respectively, the second fabric charge 16 and the third fabric charge 22. Of course, the exact neutral stitching path used can vary depending on the fabric charges and/or the final component to be formed.
(23) Returning reference to
(24) In particular, the final three-dimensional shape 40 is shown in
(25) As shown in the illustrated embodiment (and particularly shown in
(26) Accordingly, forming the fabric charges 14, 16, 22 into the three-dimensional shape 40 of
(27) Returning reference to
(28) As shown, the one or more three-dimensional stitching paths, including stitching paths 50 and 52, can each intersect the neutral stitching path 34 and thus the stitching 36 to form respective stitching intersections 54, 56 with each of the three-dimensional stitching paths being approximately perpendicular (i.e., perpendicular or nearly perpendicular, such as 90 degrees+/−five degrees) relative to the neutral stitching path 34 and thus stitching 36 at the respective stitching intersections 54, 56. In the illustrated embodiment, the first stitching path 50 is formed or disposed along the side 16d of the second fabric charge and the side 14c of the first fabric charge 14. As already discussed herein, the side 16d can slightly overlap (e.g., 15 mm overlap) the side 14c of the first fabric charge 14. Similarly, the second stitching path 52 can be disposed on or adjacent the side 22c of the third fabric charge 22 and the side 14d of the first fabric charge 14 with a slight overlap (e.g., 15 mm overlap). Although not shown, it is to be appreciated that other variations of overlap could be used. For example, the overlap could be approximately 30 mm or some other dimension.
(29) In addition to the three-dimensional stitching paths 50, 52, additional stitching can be applied to functionally critical geometries of the fabric charges, including the first, second, and third fabric charges 14, 16, and 22. This additional stitching allows for more efficient connectivity between the fabric layers rather than depending on the shear stress transfer through a much lower stiffness resin matrix. By way of example, in
(30) Alternatively, the fabric charges 14, 16, and 22 could be sized and arranged such that when stitched together along the neutral stitching path 34 there is no measurable overlap between the fabric charges 14, 16, 22 when the multi-piece fabric assembly 30 is formed into the three-dimensional shape 40 without any trimming occurring after the fabric charges 14, 16, 22 are stitched together along the neutral stitching path 34. Thus, there would be no overlap between the fabric charges. In this case, there would be no three-dimensional stitching and step 48 could be removed from the method 10 of
(31) With or without the further stitching, returning reference to
(32) With reference now to
(33) Now with reference to
(34) The resultant product is a three-dimensional component that can be applied on a vehicle, such as forming the vehicle's frame (or a portion of the frame) or some other vehicle component. Such a vehicle component formed according to the method or methods described hereinabove can comprise an impregnated multi-piece fabric assembly, such as multi-piece fabric assembly 30, that itself comprises at least a first fabric charge and a second fabric charge (e.g., first, second, and third fabric charges 14, 16, and 22) stitched together along the neutral stitching path 34. As already described herein, the fabric charges can have distal portions spaced apart from the neutral stitching path 34 that are three-dimensionally oriented relative to one another and relative to the neutral stitching path 34. Optionally, the distal portions 14e, 14f, 16e, 16f, 22e, 22f of the fabric charges 14, 16, 22 can be stitched together along one or more three-dimensionally stitching paths, such as the stitching paths 50 and 52.
(35) It is contemplated that different stitch patterns can be used, particularly along the neutral stitching path 34. Such different stitching patterns can be used to balance differential forming loads between sides of the fabric charges, particularly during draping over the pre-form member. To minimize excessive local fabric distortion and stitching or even within a given fabric charge, different stitching patterns can be employed to help create compliance between different fabric charges and/or to help stabilize a fabric local area against highly localized distortion due to challenging forming geometry.
(36) Still further, it is contemplated that multiple layers of fabric charges could be added and built up on top of one another to create the thickened fabric charge. Such material could then be stitched along a neutral stitching path as described herein in order to allow a single draping operation to apply shape to the material. Still further, optional frictional inserts (not shown) could be interposed between layers of fabric charges to help ease forming. In particular, this could avoid unwanted distortion in the material. The material for the friction reducing member could be in the form of a powder, as part of a thermal plastic material binder used in pre-forming fabrics, or could be a separate sheet material that is installed during a stacking process for the fabric charges and then removed after draping has been completed (and before resin injection)
(37) It will be appreciated that the above-disclosed features and functions, or alternatives or varieties thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the present disclosure.