APPARATUS FOR APPLYING REINFORCEMENT ELEMENTS TO A

SAIL

Technical Field

The present invention relates to an apparatus for applying reinforcement elements to a sail. Background Art

Sails are currently manufactured by means of a basic structure, typically made of polymeric material, with which reinforcement fibers are associated substantially at the tension or reinforcement lines. The sail, when used, is in fact subjected to traction stresses along specific tension lines (which therefore it is advisable to reinforce), which substantially connect the corners of the sail and have specific paths which are predominantly curved with the concavity directed toward the edges of the sail. Two different methods are generally used to associate the reinforcement fibers with the structure of the sail.

The first method consists in applying to the sail adhesive elements with which a plurality of sets of mutually spaced and parallel reinforcement fibers are associated. An operator then applies the adhesive strip, trying to follow the tension lines previously traced on the sail structure.

Generally, each adhesive strip is associated with some sets of fibers in order to allow to cover a discrete portion of the structure of the sail at each application.

However, it is evident that the method described above suffers a considerable drawback, caused by the fact that the sets of fibers arranged toward the inside of the curvature are not sufficiently tensioned and therefore, during use, do not discharge in an optimum manner the forces to which the sail is subjected in the portions that they occupy.

In order to try to limit this drawback, an attempt is made to reduce the curvature, thus approximating the shape of the tension and reinforcement

lines by means of broken lines. This allows to keep all the sets of fibers more tensioned, but as is evident it causes a reduced efficiency during use of the sail, since the sets of reinforcement fibers do not correspond exactly to the actual tension lines of the sail. As an alternative, a second method for the application of reinforcement elements entails arranging the sets of reinforcement fibers on a first panel made of polymeric material. A second panel, also made of polymeric material, is then arranged so as to face the first panel, so that the sets of fibers arranged at the tension lines are interposed between the two panels.

An adhesive, generally of the heat-activated type, is applied between the two panels and then the sail constituted by the two facing panels, with the sets of fibers interposed between them, are heated so as to activate the adhesive and obtain a finished sail. This method is extremely laborious from the practical standpoint: first of all, it is necessary to provide two panels and secondly, since the sail has a three-dimensional structure, enormous difficulties arise during the step for arranging the sets of fibers and during the heating step required to activate the adhesive. Disclosure of the Invention

The aim of the present invention is to provide an apparatus for applying reinforcement elements to a sail which is capable of eliminating, or at least reducing drastically, the drawbacks mentioned above.

Within this aim, an object of the invention is to provide an apparatus for applying reinforcement elements to a sail which can ensure correct positioning and tensioning of the reinforcement elements.

Another object of the invention is to provide an apparatus for applying reinforcement elements to a sail which allows to reduce application times in such a manner that its use is advantageous also from an economical standpoint.

This aim and these and other objects which will become better apparent hereinafter are achieved by an apparatus for applying reinforcement elements to a sail, characterized in that it comprises a supporting structure which can move with respect to a sail and is provided with means for depositing at least two bonding tapes which are associated with at least one respective elongated reinforcement element, said at least two bonding tapes being fed by mutually independent feeders, said feeders comprising a respective reel, said at least two bonding tapes unwinding from respective reels which are supported, so that they can rotate independently of each other, by said supporting structure. Brief description of the drawings

Further characteristics and advantages of the invention will become better apparent from the description of some preferred but not exclusive embodiments of an apparatus for applying reinforcement elements to a sail, illustrated by way of non-limiting example in the accompanying drawings, wherein:

Figure 1 is a side elevation view of an apparatus for applying reinforcement elements to a sail, according to the present invention;

Figure 2 is a front elevation view of the apparatus shown in Figure 1; Figure 3 is an enlarged-scale sectional view, taken along a longitudinal plane, of the supporting structure of the apparatus according to the present invention;

Figure 4 is a top view of the apparatus during the application of the reinforcement elements to a sail; Figure 5 is an enlarged-scale sectional view of a portion of the apparatus at the means for coupling the reinforcement elements to the corresponding bonding tape;

Figure 6 is a view of a variation of the tensioning means of the reinforcement elements. In the exemplary embodiments that follow, individual characteristics,

given in relation to specific examples, may actually be interchanged with other different characteristics that exist in other exemplary embodiments.

Moreover, it is noted that anything found to be already known during the patenting process is understood not to be claimed and to be the subject of a disclaimer.

Ways to carrying out the Invention

With reference to the figures, the present invention relates to an apparatus, generally designated by the reference numeral 1, for applying reinforcement elements to a sail 100. In particular, the apparatus 1 comprises a supporting structure 2, which can move with respect to the sail 100 and is provided with means 3 for depositing at least two bonding tapes 4 which are associated with at least one respective elongated reinforcement element 5.

Advantageously, each bonding tape 4 is associated with a single elongated reinforcement element 5.

The at least two bonding tapes 4 are fed by mutually independent feeders.

Advantageously, such feeders comprise a respective reel 4a: in practice, the two or more bonding tapes 4 unwind from respective reels 4a which are supported, so that they can rotate independently of each other, by the supporting structure 2.

In particular, as shown in the accompanying figures, the supporting structure 2 can be constituted by two lateral shoulders 2a, which are interconnected by means of an interconnection cross-member 2b. The two reels 4a can be supported rotatably by a supporting cylinder 6, which rests, at its ends 6a, on a respective containment recess 7 which is defined on the lateral shoulders 2a.

To allow quick and effective positioning of the various reels 4a, it is possible to interpose spacers between them. According to a first and preferred embodiment, the apparatus 1 is

provided, between the reels 4a and the deposition means 3, with means 8 for coupling the elongated reinforcement elements 5 to a face 4b of the corresponding bonding tape 4 designed to be coupled to the sail 100.

In this particular case, the elongated reinforcement elements 5 can be fed by respective feeder assemblies, which, as shown, can be constituted by respective spools 5a.

As an alternative, there is nothing to prevent the reels 4a from supporting a respective bonding tape which is already coupled to at least one elongated reinforcement element 5. It has been found that it is preferable to use reels 4a of bonding tapes

4 in which a portion of separator tape (made for example of polymeric, vinyl material and in general adhesive-resistant material) is interposed between each turn, and is designed to facilitate the unwinding of the bonding tape 4 from the respective reel 4a. In this regard, if, as mentioned, reels 4a provided with separator tapes are used, it is convenient but not necessary to provide means for unloading and/or collecting said separator tape.

In greater detail, the deposition means 3 can also comprise at least one first presser roller 9 which can be engaged, along at least one portion 9a of its outer side wall 9b, by the two or more bonding tapes 4 (which are associated with the respective elongated reinforcement element or elements 5) and can be moved on the sail 100.

The first presser roller 9 can be provided by providing at least two roller portions which have the same diameter and are mutually adjacent along their own axis of rotation. The two or more roller portions are supported, so that they can rotate independently of each other, by the supporting structure 2 (typically about a rotating supporting shaft) so as to limit friction between the sail 100 and the first presser roller 9, which would cause imperfect application of the bonding tapes 4 with the elongated reinforcement elements 5 associated therewith.

Conveniently, the elongated reinforcement elements 5 can be constituted by respective sets of reinforcement fibers.

The coupling means 8 can be provided by making the supporting structure 2 support, optionally so that it can rotate, a coupling roller 10. The bonding tapes 4 and the elongated reinforcement elements 5 gather at a portion 10a of the outer side wall of the coupling roller 10. In particular, the bonding tapes 4 are arranged adjacent to the portion 10a at the face that lies opposite the face 4b, which is optionally provided with adhesive and at which the elongated reinforcement elements 5 are designed to engage. Advantageously, the apparatus 1 is provided with means 11 for tensioning the elongated reinforcement elements 5, which are conveniently arranged directly upstream of the coupling means 8.

In particular, the tensioning means 11 comprise (as shown in the embodiment shown in Figure 3), at least one forced passage hole 11a for the elongated reinforcement element 5: to ensure correct tension, it is advantageous for the forced passage hole 11a to be axially offset with respect to the direction that connects the spool 5a and the coupling means 8.

In order to make the tension of the elongated reinforcement elements

5 even more effective, it is possible to provide on a plate 12, which is supported above the coupling means 8 by the supporting structure 2, first and second forced passage holes 11a and l ib, which can be crossed on opposite sides, as shown clearly in the enlarged-scale sectional view of Figure 5, by the elongated reinforcement element 5.

In another constructive variation, shown in the sectional view of Figure 6, the tensioning means 11 can be constituted by a through opening l ie, which in this case can also be arranged so that its own axis lies along the line that connects the spool 5a and the coupling means 8, provided by a fixed plate Hd and a movable plate l ie. Elastic means Hf act between an adjustment wheel 1 Ig and the movable plate 1 Ie, so as to adjust the width of the section of the through opening l ie and therefore of the elongated

reinforcement element 5 that is designed to pass through it.

Advantageously, the apparatus 1 can be provided with at least two stabilizing maneuvering wheels 15, which are arranged laterally with respect to the deposition means 3 and are raised, during use, with respect to the sail 100.

The supporting structure is further associated with a supporting frame 16 for the spools 5a. Such supporting frame 16 can be constituted by two lateral uprights 16a, which are fixed at their end portions 16c to the lateral shoulders 2a of the supporting structure. The two lateral uprights 16a are further interconnected by means of rotary supporting cross-members 16b for the spools 5a. To facilitate the insertion of the spools 5 a, the rotary supporting cross-members 16b can be insertable within inclined containment slots 16e which are provided in said lateral uprights 16a. Moreover, the lateral uprights 16a have, at their free ends, maneuvering handles 17, which allow to turn the supporting structure 2 so that it is supported by the stabilizing and maneuvering wheels during the steps for positioning and moving the apparatus 1.

To be able to ensure correct application of the bonding tapes 4 to the sail 100, the apparatus 1 is provided with means 18 for retention in position, which are adapted to keep the two or more bonding tapes 4 along a direction which is substantially parallel to the movement path 101 of the supporting structure 2.

In particular, the means 18 for retention in position comprise a plurality of spacer laminas 19, which during use are arranged at right angles to the plane of arrangement of the sail 100 and parallel to the movement path 101 of the supporting structure 2. To facilitate the operations required to move the supporting structure 2 (and therefore the bonding tapes 4), along the movement path 101, which is constituted typically by a curved line, as shown in the top view of Figure 4, the apparatus 1 is associated with

a maneuvering device 20.

As shown in the side elevation view of Figure 1, the maneuvering device comprises a control handlebar 21, which is articulated at the supporting structure 2. A traction element 22 can be articulated to the connecting cross- member 2b and can support a heating device 23 which is arranged to the rear with respect to the advancement direction.

Such heating device 23 can be constituted by a device for generating a stream of hot air or by a heating element such as an electric coil. Of course, there is nothing to prevent a similar heating device from being arranged directly on the supporting structure 2 so as to allow heating of the bonding tapes 4, optionally associated with the respective elongated reinforcement elements 5, before they can be arranged at the deposition means 3. For this purpose, merely by way of example, the heating device can substantially face the region in which the spacer laminas 19 are arranged. This solution is believed to be satisfactory especially if a heat-activated adhesive is used on the bonding tapes 4.

Conveniently, the traction element 22 is rotatably coupled to the interconnection cross-member 2b about an articulation axis 102 which is substantially perpendicular to the supporting surface of the sail 100.

Moreover, advantageously, the traction element 22 comprises a second presser roller 24, which is arranged to the rear of the heating device 23 with respect to the advancement direction. Such second presser roller 24, as already explained in relation to the first presser roller 9, also can be provided by providing at least two portions of the roller which have the same diameter and are mutually adjacent along their own axis of rotation. The two or more roller portions are supported, so that they can rotate independently of each other, by the traction element 22 so as to limit in this case also friction between the sail 100 and the second

presser roller 24, which would cause a less than perfect application of the bonding tapes 4.

The second presser roller 24 can be advantageously harder on its surface than the first presser roller 9. The apparatus 1 can be moved with the aid of motor movement means

(for example an electric motor), which are conveniently connected to a traction roller which is arranged to the rear of the supporting structure 2 or, if present, the traction element 22.

The motorized traction roller can also be arranged in front or to the side of the supporting structure 2.

Of course, there is nothing to prevent the motor means from being able to act directly on the first presser roller 9 or on the second presser roller 24.

However, in this case, if the moved presser rollers are provided by means of a plurality of portions of mutually adjacent rollers which can rotate independently of each other, it is necessary to provide a device of the differential type which is capable of adjusting the speed of each portion of the roller as a function of the curve radius.

The apparatus 1 can also be moved directly by a person assigned to the operations for applying the elongated reinforcement elements 5, without the aid of motor means but for example simply by pushing the apparatus 1.

As shown in Figures 1 and 4, the apparatus 1 can be provided with a kinematic interconnection device 25 for connection between the supporting structure 2 and the traction element 22. Such kinematic interconnection device 25 is adapted to maintain the rotation axis of the second presser roller 24 substantially at right angles to the movement path 101, or rather to the bonding tapes 4 (associated with respective elongated reinforcement elements 5) applied to the sail 100.

In particular, the kinematic interconnection device 25 comprises a lever system which is constituted, in the illustrated embodiment, by a first

main lever 26, which is associated with the supporting structure 2 and is connected kinematically, by means of a guiding lever 28 supported rotatably by the traction element 22, to a second actuation lever 27, which acts on a supporting body 29 of the second presser roller 24. The supporting body 29 (and accordingly the rotation axis of the second presser roller 24) is articulated rotatably to the traction element 22 about a steering axis 103, which is substantially perpendicular to the supporting and arrangement surface of the sail 100.

There is nothing to prevent the maneuvering device from being provided directly by such lever system: in this case, it is possible to provide manual or also remote actuation means which are adapted to move part of such lever system with respect to the supporting structure 2 or the traction element 22: it is evident that this movement changes the movement path 101 of the apparatus 1 on the sail 100. It is possible, for example by using the lever system as explained, to provide the maneuvering device, to preset in a fully automatic manner the movement paths 101 of the apparatus 1.

For example, it is possible to provide the apparatus 1 with a receiver which is adapted to receive information related to the movement path from a transmitter which is connected to a personal computer. This information can also be determined by specific software used by sail manufacturers, which is capable of calculating, as a function of the different shapes of the sail, the correct distribution of the tension and reinforcement lines.

As an alternative, it is possible to trace on the sails the tension lines so that a reader, for example an optical reader, arranged on the apparatus 1, can locate their shape and therefore, by using a control and actuation unit, it is possible to act automatically on the maneuvering device so as to allow correct application of the reinforcement elements.

Moreover, it has been found that it is convenient for the apparatus 1 to have, in front of the first presser roller 9 with respect to the advancement

direction, means for spreading flap the sail portion arranged directly downstream of the deposition means 3 with respect to the advancement direction.

Such spreading means can be constituted by a spreading cross- member 30, constituted for example by a non-rotating roller or by a doctor blade which, by friction, flattens the portion of the sail 100 that is arranged directly downstream of the apparatus 1 with respect to the advancement direction.

Operation of an apparatus according to the present invention is evident from what has been expressed above.

In particular, after properly spreading on the supporting surface, for example a floor, the sail 100 onto which the elongated reinforcement elements 5 are to be applied, the apparatus 1 is positioned, conveniently at a corner. The bonding tapes 4, with which the elongated reinforcement elements 5 have been associated beforehand, are then moved into engagement with the first presser roller and then made to face, with their face 4b provided with adhesive, a respective region of the sail 100 on which the tension and reinforcement line is traced. The user or the automatic guiding means described earlier move the apparatus 1 along the movement path 101 so that the individual bonding tapes 4 (associated with the corresponding elongated reinforcement elements 5) match up with the tension lines.

The fact that each bonding tape 4 is fed by a respective feeder (in the illustrated examples, by respective reels which can rotate independently of each other) allows perfect application regardless of the turning radius of the tension and reinforcement lines and therefore of the movement path.

This aspect is further facilitated by the division of the first and, optionally, second pressure cylinder into a plurality of mutually rotationally independent portions.

All the characteristics of the invention indicated above as advantageous, convenient or the like may also be omitted or be replaced with equivalents.

The invention thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims.

Thus, for example, it is possible to use a device for moving the sail 100 constituted for example by a movement roller or by a conveyor belt which is designed to move on command the sail 100 along one of its directions of extension and in particular along its direction of maximum extension.

The apparatus 1 , in this case, can be supported by a fixed frame and at least the portion that supports the deposition means 3 can be movable with a back-and-forth motion along a direction which lies transversely to the advancement direction of the sail 100, so that in any case, by means of the combination of the movements of the sail 100 and of the apparatus 1, it is possible to reproduce the tension and reinforcement lines at which the bonding tapes 4 provided with the respective elongated reinforcement elements are to be applied. According to a further constructive variation, it is possible to minimize the transverse dimension of the bonding tapes 4 so that in practice they allow only temporary locking of the elongated reinforcement elements 5 to the sail 100. Once the step of application of all the bonding tapes 4 has ended, a second layer made of polymeric material is coupled to the sail to which the bonding tapes 4 are applied by interposing a layer of heat- activated adhesive.

Once coupling has been completed, the entire assembly is inserted within an electric blanket, which in turn is inserted in a container provided with an intake port with which a suction device is to be associated in order to generate vacuum inside the container and thus facilitate the heating of the

electric blanket and the activation of the adhesive.

It is possible to insert a spacing layer (typically of the open-cell type) between the electric blanket and the container, so as to allow, during the step for aspirating air from the container, first of all the collapse of the regions that are not occupied by the electric blanket, so as to avoid subsequent inflows of air with consequent reduction of the efficiency of the heating step.

Once the sail has been raised to the appropriate temperature inside the electric blanket and the adhesive has been activated, the entire system can be removed.

According to a further constructive variation, it is possible to provide a step for depositing a layer of adhesive (by means of a spray jet or by immersion within an adhesive containment tray) at the surface of the elongated reinforcement elements that is directed toward the sail. Finally, the bonding tapes wound onto the reels can be simple tapes made of non-adhesive polymeric material: in this case, it is possible to provide a step for spreading a layer of adhesive onto the bonding tape unwound from said reel at the surface of the tape that is designed to face the sail. In practice it has been found that the invention has achieved the intended aim and objects in all of the embodiments.

In practice, the materials used, as well as the dimensions, may be any according to requirements.

The disclosures in Italian Patent Application No. VR2006A000132 from which this application claims priority are incorporated herein by reference.

Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly such reference signs do not have any limiting effect on the interpretation of each

element identified by way of example by such reference signs.