RU2821466C1 - Method of connecting hard composite material with soft materials by means of sewing - Google Patents

Abstract

FIELD: various technological processes.

SUBSTANCE: invention relates to a method of making articles for various purposes, characterized by making at least one of the layers in the form of a solid composite material and bonded with soft materials, and can be used in making pillows, suitcases, upholstered furniture, vehicle upholstery, carpets. Method of connecting hard composite material with soft materials includes making a base by laying a layer of reinforcing material and an intermediate structural layer into the tooling and an upper flexible layer on top of them, wherein the upper flexible layer is made with a surface area greater than the surface area of the layers laid in the tooling, and forming a step; impregnating the base with a binder, followed by curing; making a workpiece from a soft sheet material in the shape of said base step; said workpiece is laid on the base in the area of said step and jointed thereto by sewing.

EFFECT: invention provides a simple and reliable method of fixing a hard composite material to a soft material of an article, as well as obtaining a flat surface of the material without protrusions.

6 cl, 2 dwg, 2 ex

Description

The invention relates to a method for manufacturing products for various purposes, characterized by the execution of at least one of the layers in the form of a solid composite material, in particular hardened carbon fiber, and connected to soft materials, and can be used in the manufacture of pillows, suitcases, upholstered furniture, and vehicle upholstery , carpets, etc.

There is a known method for manufacturing a fiber-reinforced composite structure (application US 20200307153, published 10/01/2020), including a plurality of carbon fiber-reinforced sheets that are laminated; and a seam extending through one or more carbon fiber reinforced sheets, the carbon fibers in the sheet being oriented in the same direction. A method for producing a composite structure includes: laminating a plurality of carbon fiber reinforced sheets; processing one or more laminated sheets reinforced with carbon fiber seam; and forming a composite structure by molding and curing laminated sheets.

There is a known method for manufacturing vehicle interior trim parts (patent FR 3121866, published 10.21.2022), containing an open upper composite layer and a lower supporting layer connected to each other. The method includes: creating a top composite layer comprising a flexible surface layer, in particular of the leather or textile type, an elastically compressible layer and, optionally, a functional or technical layer, and connecting the support layer to said top composite layer by crosslinking.

There is a known method for manufacturing a multiaxial textile-polymer material (US patent 11692306, published on July 4, 2023), which includes impregnation with a thermosetting resin of a multiaxial laminate of textile material containing sheets of fiber bundles laid in layers at different angles, and the sheets of fiber bundles contain unidirectional bundles fibers stitched with stitching threads consisting of a thermoplastic resin, the multiaxial laminate of textile material being pierced in the thickness direction with stitches in such a way that the threads reciprocate at predetermined intervals in the longitudinal direction; curing of thermosetting resin; and the process of formation of a two-phase continuous structure.

Known solutions consider the possibility of obtaining multilayer structures, incl. using composite materials. However, they do not provide the ability to sew hard composite materials into soft material. The disadvantage of the above technical solutions is the fragility of the structure, the lack of a strong connection between the layers, high wear resistance, increased moisture resistance, low thermal insulation and density of the products.

The technical objective of the claimed invention is to effectively and simply combine hard composite material with soft materials.

The technical result of the invention is a simple and reliable method of attaching a hard composite material to the soft material of a product, as well as ensuring a smooth surface of the material without protrusions.

The technical result is achieved in that the method of connecting a hard composite material with soft materials includes manufacturing a base by placing a layer of reinforcing material and an intermediate structural layer and an upper flexible layer on top of them, wherein the upper flexible layer is made with a surface area exceeding the surface area of the layers laid out in the equipment and forming a step; impregnation of the base with a binder followed by curing; manufacturing a blank from soft sheet material in the shape of said base step; laying the formed workpiece on the base in the area of the mentioned step and connecting it to it by sewing.

The invention is illustrated by the following figures:

In fig. 1 shows a general view of the base;

In fig. Figure 2 shows an example of the arrangement of the connected layers of the product.

A method of joining a hard composite material with soft materials, including manufacturing a base by placing a layer of carbon fabric or other reinforcing material (Kevlar, aramid, alutex), an intermediate structural layer of foamed polymer material, and/or a layer of reinforcing material, and/or a non-woven layer into the equipment. material and on top of the intermediate layer of the upper flexible layer, the upper flexible layer having a surface area greater than the area of the lower and intermediate layers and forming a step; impregnation of the base with a binder followed by curing; manufacturing a blank from soft sheet material in the shape of said base step; laying the formed workpiece on the base in the area of the mentioned step and connecting it to it by sewing.

The method according to the present invention includes:

- manufacturing a base 1 from a layer of carbon fiber or other reinforcing material with a sequentially applied intermediate structural layer and an upper flexible layer, wherein the base is made with a step 2 pre-formed by means of the upper flexible material along the entire perimeter, so that the central part of the base (reinforcing layer) and intermediate structural layer) are located above said step 2;

- impregnation of the base with 1 binder followed by curing;

- manufacturing a blank from soft sheet material in the shape of the step 2 of the base 1 by cutting;

- laying the formed blank on step 2 along the perimeter of base 1 and connecting it to base 1 by sewing to the soft layer of base 1.

The intermediate layer is designed to provide the necessary rigidity of the product and can be made of foamed polymer material and/or reinforcing material and/or non-woven material.

Polyvinyl chloride (PVC) with a closed or open cellular structure can be used as a foamed polymer material.

A layer of carbon fabric or fiberglass can be used as a reinforcing layer of the intermediate layer.

Coremat, structural foam, non-woven carbon fiber, non-woven basalt fiber, glass mat, and unidirectional fabrics can be used as a non-woven material for the intermediate layer.

Basalt fabric or other material can be used as a flexible base layer. Preferably the layer thickness is from 0.2 to 0.6 mm. The step formed by said layer of non-woven material is used for sewing with soft materials to obtain the effect of a flat plane between the hard composite material and the base material of the product.

To make the blank, various sheet materials can be used: fabric, artificial or genuine leather, etc.

Examples of implementation of the invention

Example 1

In the equipment - sheet plexiglass 2 mm thick - a cutout is made in the shape of the part to be sewn.

Plexiglas is laid on a flat, smooth surface (glass, plastic, metal). A 0.2 mm thick carbon fabric-based blank and a 1.8 mm thick layer of coremat (or other reinforcing material depending on the characteristics of the product) are placed in the plexiglass cutout. Next, a layer of basalt material 0.4 mm thick is laid on the plexiglass with carbon fiber and a layer of reinforcing material lined inside. Thus, a base 1 is formed with a step 2 along its perimeter.

After laying out the layers, a system for vacuum infusion is assembled and the assembled multilayer workpiece is impregnated with epoxy or polyester or vinyl ester resin and the base workpiece is cured. After polymerization of the resin, the workpiece is removed from the tooling. In this case, the step formed by the basalt material is impregnated with resin and then a layer of a pre-prepared piece of soft material (for example, leather) 2 mm thick, shaped like the said step, is sewn to it using a through seam. A hole is cut in the leather to the size of the visible part of the base 1, the step is hidden under the specified layer of soft material and as a result the product has a smooth surface. The formed part is additionally coated with varnish.

Example 2

In sheet plexiglass with a thickness of 3.6 mm, a cutout is made in the shape of the part to be sewn. The plexiglass cutout is laid out alternately: a layer of carbon fabric 3 with a thickness of 0.2 mm, a basalt sheet 4 with a thickness of 0.4 mm and a layer of structural polyethylene foam 5 with a thickness of 3 mm. Next, a layer of basalt material 6 with a thickness of 0.4 mm is laid on the plexiglass with carbon fiber lined inside and a layer of foam material. Thus, a base 1 is formed with a step 2 along its perimeter. Further stages of part formation are similar to example 1.

The advantage of the claimed invention is the ability to connect materials of different hardness to obtain a high-quality product with a long service life and having a smooth surface at the junction of materials. In addition, the method allows hard composite materials of various shapes and sizes to be sewn into soft material.

Claims (6)

1. A method of connecting a hard composite material with soft materials, including producing a base by placing a layer of reinforcing material and an intermediate structural layer in the tooling and an upper flexible layer on top of them, wherein the upper flexible layer is made with a surface area exceeding the surface area of the layers laid out in the tooling, and forming a step; impregnation of the base with a binder followed by curing; manufacturing a blank from soft sheet material in the shape of said base step; laying the formed workpiece on the base in the area of the mentioned step and connecting it to it by sewing. 2. The method according to claim 1, characterized in that carbon fabric is used as a reinforcing layer. 3. The method according to claim 1, characterized in that foamed polymer material and/or reinforcing material and/or non-woven material are used as an intermediate structural layer. 4. The method according to claim 1, characterized in that epoxy resin is used as a binder. 5. The method according to claim 1, characterized in that fabric, natural or artificial leather is used as a soft sheet material. 6. The method according to claim 1, characterized in that the soft sheet material is sewn to the upper flexible base layer using a through seam.