Systems and method for producing three-dimensional articles from flexible composite materials

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.

1 . (canceled) 
     
     
         2 . A manufacturing method comprising:
 inflating an elastomeric bladder into a forming tool;   assembling a layup on said forming tool to form a laid-up assembly by applying at least one unidirectional tape layer over said forming tool, said unidirectional tape layer comprising reinforcing fibers in parallel alignment, impregnated with an adhesive resin matrix; and   curing said laid-up assembly into a cured assembly comprising a cured composite on said forming tool.   
     
     
         3 . The method of  claim 2 , wherein said reinforcing fibers comprises ultra-high molecular weight polyethylene. 
     
     
         4 . The method of  claim 2 , wherein said assembling a layup on said forming tool further comprises the addition of fiber tows on said forming tool. 
     
     
         5 . The method of  claim 2 , wherein said laid-up assembly comprises at least two unidirectional tape layers disposed such that the fiber directions in any two adjacent unidirectional tape layers are not aligned. 
     
     
         6 . The method of  claim 2 , wherein said elastomeric bladder comprises a shape memory polymer having a polymer transition temperature, said polymer having rigidity at temperatures below said polymer transition temperature and elastomeric flexibility at temperatures above said polymer transition temperature. 
     
     
         7 . The method of  claim 6 , wherein said step of inflating comprises internally pressurizing said elastomeric bladder while said elastomeric bladder is inside a female mold maintained at a temperature above said polymer transition temperature, wherein said female mold comprises an internal cavity having a three-dimensional shape. 
     
     
         8 . The method of  claim 7 , further comprising cooling said female mold to a temperature below said polymer transition temperature, after said step of inflating, and removing said forming tool in a rigidized state from said female mold prior to said step of assembling, said forming tool comprising a three-dimensional shape complementary to said internal cavity. 
     
     
         9 . The method of  claim 8 , wherein said cured composite and said forming tool remain integrated following said step of curing. 
     
     
         10 . The method of  claim 8 , further comprising the step of removing said cured composite from said forming tool after said step of curing, wherein said step of removing comprises blowing hot air inside said elastomeric bladder. 
     
     
         11 . The method of  claim 6 , wherein said step of curing further comprises inflating said elastomeric bladder while said laid-up assembly is inside a female mold maintained at a temperature above said polymer transition temperature, wherein said female mold comprises an internal cavity having a three-dimensional shape, and wherein said cured assembly externally conforms to said three-dimensional shape of said internal cavity. 
     
     
         12 . The method of  claim 11 , further comprising both removing said cured assembly from said female mold and removing said cured composite from said forming tool at said temperature above said polymer transition temperature. 
     
     
         13 . The method of  claim 11 , further comprising the steps of cooling said female mold to a temperature below said polymer transition temperature and removing said cured assembly from said female mold. 
     
     
         14 . The method of  claim 13 , further comprising, after the step of removing said cured assembly from said female mold, removing said cured composite from said forming tool by blowing hot air inside said forming tool to soften it enough for removal from said cured composite.