Method for making a dial table
A method of making a dial table is provided. A foam layout is interposed between a base assembly and a top assembly to form a composite layout. The base assembly includes a first segmented carbon fiber layout therein and the top assembly includes a second segmented carbon fiber layout therein. A caul plate is then placed adjacent to the composite layout. The caul plate includes a plurality of caul plate apertures. A vacuum is thereafter generated proximate the composite layout. A resin is drawn through the plurality of caul plate apertures using the generated vacuum until the composite layout is infused with the resin. The caul plate is removed from adjacent the composite layout and the resin-infused composite layout is baked. Thus, the dial table is made.
This patent application claims the benefit of U.S. Provisional Patent Application No. 60/564,715, filed Apr. 23, 2004, and U.S. Provisional Patent Application No. 60/659,262, filed Mar. 7, 2005.
FIELD OF THE INVENTIONThis invention generally relates to techniques for constructing a dial table and, in particular, a technique for constructing a carbon fiber dial table.
BACKGROUND OF THE INVENTIONDial tables are commonly used in assembly manufacturing. The dial table effectively holds pieces of everyday items (e.g., printed circuit boards, tooling bits, and the like) while machines above the dial table perform tasks on those items. To make the process more efficient, each time a particular task is performed by a certain machine, the dial table is rotated such that another machine can perform a different task on the item. This sequential process of working on an item and rotating the dial table can be continued a number of times, depending on how many workstations are provided to the dial table.
Conventional dial tables can be three, four, five, and up to twelve feet in diameter and range from several inches to more than a foot in thickness. Unfortunately, because dial tables that are used in the manufacturing industry are predominately formed from steel, aluminum, and other metals, the dial tables are extremely heavy and very expensive. Thus, a dial table that is lighter and less expensive than the conventional steel or aluminum dial table, yet comparably strong, would be desirable. The invention provides such a dial table. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.
BRIEF SUMMARY OF THE INVENTIONIn one aspect, the invention provides a dial table comprising a top assembly, a base assembly, a foam layout, and a resin. The top assembly includes a first segmented carbon fiber layout therein and the base assembly includes a second segmented carbon fiber layout therein. The foam layout is interposed between the base assembly and the top assembly. The resin is infused into the base assembly, the top assembly, and the foam layout.
In another aspect, the invention provides a method of making a dial table. A foam layout is interposed between a base assembly and a top assembly to form a composite layout. The base assembly includes a first segmented carbon fiber layout therein and the top assembly includes a second segmented carbon fiber layout therein. A caul plate is placed adjacent to the composite layout. The caul plate includes a plurality of caul plate apertures. A vacuum is generated proximate the composite layout. A resin is drawn through the plurality of caul plate apertures using the generated vacuum until the composite layout is infused with the resin. The caul plate is removed from adjacent the composite layout. The resin-infused composite layout is cured thereby forming the dial table.
In yet another aspect, a method of making a dial table is provided. Selected ones of a plurality of carbon fiber segments are arranged to form a first segmented carbon fiber layout. The first segmented carbon fiber layout is interposed between first and second glass cloth layouts to form a base assembly. Selected ones of a plurality of carbon fiber segments are arranged to form a second segmented carbon fiber layout. The second segmented carbon fiber layout is interposed between third and fourth glass cloth layouts to form a top assembly. The top assembly, the foam layout, and the base assembly are sequentially placed into a mold such that the foam layout is interposed between the top assembly and the bottom assembly to form a composite layout. A caul plate is placed adjacent to the composite layout. The caul plate includes a plurality of caul plate apertures. A vacuum is generated proximate the composite layout. A resin is drawn through the plurality of caul plate apertures using the generated vacuum until the composite layout is infused with the resin. The caul plate is removed from proximate the composite layout. The resin-infused composite layout is baked thereby curing the resin and forming the dial table.
Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGSThe accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.
DETAILED DESCRIPTION OF THE INVENTION Referring to
To begin the process of making the dial table 10, a generally triangular template 28 as shown in
The outer edge 32 can be straight or can be arcuate, beveled, and the like as shown in
After appropriately positioning the template 28 over the carbon fiber fabric 34, a number of carbon fiber segments 42 are cut or formed using the template. In a preferred embodiment, since the acute angle 30 is ten degrees, a total of thirty-six carbon fiber segments 42 are made for use within the top assembly 12 such that, by suitably arranging the segments, a complete three hundred sixty degree circle can be formed. In similar fashion, an additional thirty-six of the carbon fiber segments, having an acute angle 30 of ten degrees, are made for use within the base assembly 18. Again, if the additional thirty-six segments are suitably arranged, a further complete three hundred sixty degree circle can be formed from these segments. If desired, numerous further segments 42 can be formed using template 28. Additionally, other segments possessing some other angle can be cut or formed using another template. Notably, as illustrated in
Next, as shown in
Referring now to
Next, as shown in
Each of the carbon fiber segments 42, the plurality of discs 46, the plurality of discs 50, and the capping strip 16 all have small thicknesses compared to the foam layout 14. For example, in an exemplary embodiment, while the foam layout 14 has a thickness of approximately one inch (1.0″), each of the carbon fiber segments 42 has a thickness of approximately twenty-three thousandths of an inch (0.023″), each of the glass-cloth discs 46 has a dry thickness of approximately six thousandths of an inch (0.006″), each of the carbon fiber twill weave discs 50 has a dry thickness of about six thousandths of an inch (0.006″), and the carbon fiber capping strip 16 has an approximate dry thickness of twenty-two thousandths of an inch (0.022″). Despite the large dry thickness disparity between the carbon fiber segments 42, the layers 46, 50, and the capping strip 16 in relation to the dry thickness of the foam layout 14, to aid in the illustration and understanding of the invention, the dry thickness of the fiber layers has been exaggerated in the drawing figures.
To construct the base assembly 18 of
In one embodiment, as shown in
Since each of the carbon fiber segments 42 is, in an earlier mentioned preferred embodiment approximately ten degrees, it is correspondingly preferable that the stacked carbon fiber segment layers 60, 60′ are offset about five degrees or about two and a half degrees. The exact amount of offset can be adjusted to a variety of differing degrees. As will be recognized by those skilled in the art, such offset can depend on the number of carbon fiber segment layers 60, 60′ that are arranged in this fashion, the acute angle 30 of each of the carbon fiber segments 42, the diameter of the dial table 10, and the like.
Referring back to
After the base assembly 18 is constructed, the same or similar procedure is employed to form the top assembly 12 as shown in
After the top surface assembly is constructed, a plurality of serrating cuts 68 are formed in the top assembly 12. These serrating cuts 68 are generally oriented radially inwardly toward the center of the top assembly 12. In a preferred embodiment, seventeen of these serrating cuts are formed around a top assembly periphery 70, are angled slightly so as not to be oriented directly radially inwardly, and are about one inch (1.0″) deep.
Referring to
The foam layout 14 can, if desired, be formed from a single large piece of foam. However, since the composite dial table can be several feet in diameter, the foam layout 14 must often be manufactured and/or assembled from several smaller pieces or portions of foam that are either stacked upon each other and/or placed side-by-side to attain a desired thickness, height, and/or width for the foam layout 14. In one embodiment, two or more portions of foam, having a glass scrim covering one surface, are employed to create the foam layout 14. In such an embodiment, foam portions are positioned such that the glass scrim portions are in an abutting relationship. As will be recognized by those skilled in the art, the foam layout 14 can be constructed in a variety of ways and can include materials therein.
The foam layout 14 can vary in thickness as the diameter of the dial table 10 increases. For example, when a dial table 10 that has a diameter of six inches is made, the foam layout 14 has a thickness of about one-quarter inch (0.25″) while when constructing a dial table that has a diameter of ten feet or more the foam layout has a thickness of about two and a half inches (2.5″).
Referring now to
Referring now to
As shown in
As shown in
In a preferred embodiment, a top assembly periphery portion 116 is folded over a base assembly periphery portion 118. The task of folding is made considerably easier as a result of the serrating cuts 68 (
After assembling the composite layer 114 with the washers 20, 22 and the sleeve 24 thereon, the caul plate 88 (or 88′) as shown in
After the caul plate 88 and the circular tube 120 have been positioned relative to the composite layout 114, a vacuum producing device 122 is placed in and/or adjacent to central aperture 26 (
As and after the vacuum is created, the circular tube is permitted to release the resin such that the resin is introduced into the composite layout 114 and the mold 96 in general via the caul plate apertures 92. In other words, the base assembly 18, the foam layout 14, and the top assembly 12 are infused with the resin. The resin also preferably coats all or a portion of one or more of the washers 20, 22 and the sleeve 24. Because of the low pressure created by the vacuum producing device 122, the resin generally migrates from the circular tube 120 towards the infusion ports 112. In an exemplary embodiment, one or more of the serrating cuts 68 in the top assembly 12, the infusion slots 80 and the infusion holes 82 in the foam layout 14, and the infusion grooves 110 in the sleeve 24 promote distribution of the resin within the composite layout 114 and about the washers 20, 22 and the sleeve 24.
After a predetermined amount of time and/or after a predetermined amount of the resin has penetrated and/or been infused into the composite layer 114, as well as around the washers 20, 22 and the sleeve 24, each of the caul plate 88, the circular tube 120, and the vacuum producing device 122 is removed. Thereafter, the entire resin-infused assembly (e.g., the composite layout 114, the washers 20, 22, and the sleeve 24) is cured, either in or out of the mold 96, to harden the resin. In a preferred embodiment, the resin is cured by baking. In an exemplary embodiment, the entire assembly is baked for four hours at approximately one hundred fifty degrees Fahrenheit.
After the resin has been cured and has sufficiently hardened, the assembly can, if not already, be removed from the mold 96. Thus, the composite dial table 10 of
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
Claims
1. A dial table comprising:
- a top assembly including a first segmented carbon fiber layout therein;
- a base assembly including a second segmented carbon fiber layout therein;
- a foam layout interposed between the base assembly and the top assembly; and
- a resin infused into the base assembly, the top assembly, and the foam layout.
2. The dial table of claim 1, wherein the first and second segmented carbon fiber layouts are formed from a unidirectional carbon fiber and the base assembly and the top assembly each further include a glass cloth layout formed from a bi-directional carbon fiber.
3. The dial table of claim 1, wherein the first and second segmented carbon fiber layouts are formed from a plurality of segmented carbon fiber layers.
4. The dial table of claim 3, wherein each of the plurality of segmented carbon fiber layers is offset from an adjacent layer.
5. The dial table of claim 1, wherein the base assembly and the top assembly each further include a carbon fiber twill layout.
6. The dial table of claim 1, wherein the foam layout includes a plurality of grooves and a plurality of holes to promote infusion of the resin.
7. A method of making a dial table, the method comprising the steps of:
- interposing a foam layout between a base assembly and a top assembly to form a composite layout, the base assembly including a first segmented carbon fiber layout therein and the top assembly including a second segmented carbon fiber layout therein;
- placing a caul plate adjacent to the composite layout, the caul plate including a plurality of caul plate apertures;
- generating a vacuum proximate the composite layout;
- drawing a resin through the plurality of caul plate apertures using the generated vacuum until the composite layout is infused with the resin;
- removing the caul plate from adjacent the composite layout; and
- curing the resin-infused composite layout and thereby forming the dial table.
8. The method of claim 7, wherein the method further comprises the step of forming at least one of the first and second segmented carbon fiber layouts from one or more layers of radial unidirectional carbon fiber segments.
9. The method of claim 8, wherein the method further comprises the step of arranging each of the layers of radial unidirectional carbon fiber segments such that adjacent layers are offset from each other.
10. The method of claim 7, wherein at least one of the top assembly and the base assembly further include one of a glass cloth layout and a carbon fiber twill layout, the glass cloth layout formed from a bi-directional carbon fiber fabric and the carbon fiber twill layout formed from a carbon fiber twill fabric.
11. The method of claim 7, wherein the curing step is performed by baking the resin-infused composite layout.
12. The method of claim 7, wherein the method further comprises the step of forming a plurality of radially inward serrating cuts in at least one of the base assembly, the top assembly, and the foam layout to promote infusing of the resin.
13. The method of claim 7, wherein the method further comprises the step of bonding a first washer to the top assembly and a second washer to the base assembly with the resin.
14. The method of claim 7, wherein the method further comprises the step of sequentially placing the top assembly, the foam layout, and the base assembly in a mold.
15. The method of claim 7, wherein the method further comprises the step of placing a sleeve adjacent to an inner periphery of the composite layout, the sleeve including a plurality of grooves and an infusion port therein to promote distribution of the resin through the composite layer.
16. A method of making a dial table, the method comprising the steps of:
- arranging selected ones of a plurality of carbon fiber segments to form a first segmented carbon fiber layout;
- interposing the first segmented carbon fiber layout between first and second glass cloth layouts to form a base assembly;
- arranging selected ones of a plurality of carbon fiber segments to form a second segmented carbon fiber layout;
- interposing the second segmented carbon fiber layout between third and fourth glass cloth layouts to form a top assembly;
- sequentially placing the top assembly, the foam layout, and the base assembly into a mold such that the foam layout is interposed between the top assembly and the bottom assembly to form a composite layout;
- placing a caul plate adjacent to the composite layout, the caul plate including a plurality of caul plate apertures;
- generating a vacuum proximate the composite layout;
- drawing a resin through the plurality of caul plate apertures using the generated vacuum until the composite layout is infused with the resin;
- removing the caul plate from proximate the composite layout; and
- baking the resin-infused composite layout thereby curing the resin and forming the dial table.
17. The method of claim 16, the method further comprising the step of folding an outer base assembly periphery portion over an outer top periphery portion.
18. The method of claim 16, wherein the method further comprises securing a first washer and a second washer to the composite layout using the resin.
19. The method of claim 16, wherein the method further comprises the step of forming a plurality of radially inward serrating cuts in the top assembly to promote infusing of the resin and adhering a carbon fiber capping strip to an outer foam periphery of the foam layout.
20. The method of claim 16, wherein the plurality of carbon fiber segments are formed from a unidirectional carbon fiber fabric and at least one of the first, second, third, and fourth glass cloth layouts are formed from a bi-directional carbon fiber fabric and the method further comprises the step of dispensing an adhesive upon the plurality of carbon fiber segments prior to at least one of the arranging selected ones steps.
Type: Application
Filed: Apr 22, 2005
Publication Date: Oct 27, 2005
Applicant: Scientific Composites (Rockford, IL)
Inventors: Anthony Blakeley (Rockford, IL), Dan Kelly (Rockford, IL)
Application Number: 11/112,028