Method for making a composite structure

• US 4,239,571 A
• Filed: 10/25/1978
• Issued: 12/16/1980
• Est. Priority Date: 10/25/1978
• Status: Expired due to Term

• Current Assignee: WR Grace & Company
• Original Assignee: Composite Technologies Corporation (CRH PLC)
• Inventors: Cobb, A. Lawrence
• Primary Examiner(s): Lesmes, George F.
• Assistant Examiner(s): Thomas, Alexander S.
• Application Number:
  US05/954,704
• Time in Patent Office: 783 Days
• Field of Search: 264/264, 264/265, 264/304, 264/338, 264/257, 264/321, 156/182, 156/196, 156/289, 156/295, 156/308-310, 156/313
• US Class Current: 156/196
• CPC Class Codes: B29C 33/56 Coatings , e.g. enameled or galvanised; Releasing, lubricating or separating agents in-mould coating B29C37/0028; using or applying separating agents B29C37/0067
• CPC Class Codes: B29C 44/10 Applying counter-pressure during expanding
• CPC Class Codes: B29C 44/5618 Impregnating foam articles
• CPC Class Codes: B29K 2105/045 with open cells
• CPC Class Codes: B29K 2105/24 crosslinked or vulcanised
• CPC Class Codes: B29L 2009/00 Layered products
• CPC Class Codes: B32B 2266/06 Open cell foam
• CPC Class Codes: B32B 2305/022 Foam
• CPC Class Codes: B32B 37/18 involving the assembly of discrete sheets or panels only
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: B32B 5/32 at least two layers being foamed and next to each other
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: Y10T 156/1002 with permanent bending or reshaping or surface deformation of self sustaining lamina
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 428/249999 Differentially filled foam, filled plural layers, or filled layer with coat of filling material

Abstract

A method of forming a layered composite material of the type formed under heat and low pressure and to one outer surface of which a protective thermosetting polymer is bonded.

Claims

1. The method of forming a composite structure comprising providing a first layer of open-cell, resilient foam material, impregnating said first foam layer with a first thermosetting resin system, providing a second layer of open-cell foam material, impregnating said second foam layer with a second thermosetting resin system, only said second resin system including a mold-release material incorporated therein, placing said first and second resin-impregnated foam layers in abutting relationship, overlaying each of the non-abutting surfaces of said respective foam layers with a layer of fibrous reinforcing material, providing a two-part mold, applying a mold-release material to the surface of one part of said two-part mold, applying a thermosetting gel coat over said mold-release material, placing the uncured and reinforced foam materials within the mold such that the second foam layer impregnated with the mold-release containing resin system is positioned adjacent the non-coated mold part and the first resin-impregnated foam layer is positioned adjacent the coated mold part, moving said mold parts toward each other so as to compress said foam layers whereby the open cells thereof are filled with their respective resin systems and curing said resin systems and gel coat while maintaining the foam layers in their compressed condition.

2. The method of forming a composite structure comprising providing a first layer of open-cell, resilient foam material, impregnating said first foam layer with a first thermosetting resin system, providing a second layer of open-cell foam material, impregnating said second foam layer with a second thermosetting resin system, only said second resin system including a mold-release material incorporated therein, placing said first and second resin-impregnated foam layers in abuttng relationship, overlaying each of the non-abutting surfaces of said respective foam layers with a layer of fibrous reinforcing material, providing a two-part mold, applying a mold-release material to the surface of one part of said two-part mold, applying a thermosetting gel coat over said mold-release material, placing the uncured and reinforced foam materials within the mold such that the second foam layer impregnated with the mold-release containing resin system is positioned adjacent the non-coated mold part and the first resin-impregnated foam layer is positioned adjacent the coated mold part, moving said mold parts toward each other so as to compress said foam layers with a pressure of between 20 and 50 psi whereby the open cells thereof are filled with their respective resin systems and curing said resin systems and gel coat while maintaining the foam layers in their compressed condition.

3. The method of forming a composite structure comprising providing a first layer of open-cell, resilient foam material, impregnating said first foam layer with a first thermosetting resin system, including an adhesive promoter in said first resin system, providing a second layer of open-cell foam material, impregnating said second foam layer with a second thermosetting resin system, incorporating a mold-release material in said second resin system, placing said first and second resin-impregnated foam layers in abutting relationship, overlaying each of the non-abutting surfaces of said respective foam layers with a layer of fibrous reinforcing material, providing a two-part mold, applying a mold-release material to the surface of one part of said two-part mold, applying a thermosetting gel coat over said mold-release material, placing the uncured and reinforced foam materials within the mold such that the second foam layer impregnated with the mold-release containing resin system is positioned adjacent the non-coated mold part and the first resin-impregnated foam layer is positioned adjacent the coated mold part, moving said mold parts toward each other so as to compress said foam layers whereby the open cells thereof are filled with their respective resin systems and curing said resin systems and gel coat while maintaining the foam layers in their compressed condition.

4. The method of forming a composite structure comprising providing a first layer of open-cell, resilient foam material, impregnating said first foam layer with a first thermosetting resin system, providing a second layer of open-cell foam material, impregnating said second foam layer with a second thermosetting resin system, incorporating a mold-release material in said second resin system, placing said first and second resin-impregnated foam layers in abutting relationship, overlaying each of the non-abutting surfaces of said respective foam layers with a layer of fibrous reinforcing material, providing a two-part mold, applying a mold-release material to the surface of one part of said two-part mold, applying a thermosetting gel coat over said mold-release material, placing the uncured and reinforced foam materials within the mold such that the second foam layer impregnated with the mold-release containing resin system is positioned adjacent the non-coated mold part and the first resin-impregnated foam layer is positioned adjacent the coated mold part, moving said mold parts toward each other so as to compress said foam layers with a pressure of between 20 and 50 psi whereby the open cells thereof are filled with their respective resin systems and curing said resin systems and gel coat while maintaining the foam layers in their compressed condition.

5. The method of forming a composite structure comprising providing a first layer of open-cell, resilient foam material, impregnating said first foam layer with a first thermosetting resin system, including an adhesive promoter in said first resin system, providing a second layer of open-cell foam material, impregnating said second foam layer with a second thermosetting resin system, incorporating a mold-release material in said second resin system, placing said first and second resin-impregnated foam layers in abutting relationship, overlaying each of the non-abutting surfaces of said respective foam layers with a layer of fibrous reinforcing material, providing a two-part mold, applying a mold-release material to the surface of one part of said two-part mold, applying a thermosetting gel coat over said mold-release material, placing the uncured and reinforced foam materials within the mold such that the second foam layer impregnated with the mold-release containing resin system is positioned adjacent the non-coated mold part and the first resin-impregnated foam layer is positioned adjacent the coated mold part, moving said mold parts toward each other so as to compress said foam layers with a pressure of between 20 and 50 psi whereby the open cells thereof are filled with their respective resin systems and curing said resin systems and gel coat while maintaining the foam layers in their compressed condition.