Method of making foam-filled composite products
First Claim
1. A method of forming a volumetric part having a pair of fiber-reinforced resin skins about a solid foam interior body, using a pair of mold halves defining the outside configuration of the body, the method comprising the steps of:
- laying dry fiber skins in the mold halves to provide skins having substantially coextensive edges along at least two sides;
wetting the skins with heat curable resin;
joining the mold halves together along the coextensive edges to provide an interior volume sealed except for an access aperture;
inserting catalyzed foamable exothermic material into the interior volume through the access aperture after wetting the skins with heat curable resin in an amount that is sufficient to overfill the entire interior volume when foamed;
allowing the exotherm from the foaming to activate and cure the resin for a time sufficient to unite the foamed body to the resin of the skin while exerting expansive force thereon; and
separating the molds from the cured resin skins.
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Accused Products
Abstract
A method for making foam-filled parts having fiber-reinforced skins or surfaces is disclosed. Mold halves of pressure-resisting thermally insulative material are covered with a release material, which is then covered with the fiber skins. The fiber skins are coated with heat-curable resin, and the mold halves are then clamped together to form a cavity. A catalyzed foam-forming mixture is poured into the cavity. The mixture foams and expands to the full volume of the cavity, and while it hardens generates heat sufficient to cure the resin.
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Citations
8 Claims
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1. A method of forming a volumetric part having a pair of fiber-reinforced resin skins about a solid foam interior body, using a pair of mold halves defining the outside configuration of the body, the method comprising the steps of:
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laying dry fiber skins in the mold halves to provide skins having substantially coextensive edges along at least two sides; wetting the skins with heat curable resin; joining the mold halves together along the coextensive edges to provide an interior volume sealed except for an access aperture; inserting catalyzed foamable exothermic material into the interior volume through the access aperture after wetting the skins with heat curable resin in an amount that is sufficient to overfill the entire interior volume when foamed; allowing the exotherm from the foaming to activate and cure the resin for a time sufficient to unite the foamed body to the resin of the skin while exerting expansive force thereon; and separating the molds from the cured resin skins. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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Specification