Composite structures and method of making composite structures
DCFirst Claim
1. A composite structure having an exposed reinforcing fabric layer free of structural foam and curable resin, said structure comprising:
- a reinforcing fabric layer;
a non-woven fabric layer attached to said reinforcing fabric layer; and
a structural foam attached to said non-woven fabric layer on the side of said non-woven fabric layer opposite said reinforcing fabric layer by having filled interstices of said non-woven fabric layer without penetrating into the reinforcing fabric layer;
wherein said reinforcing fabric layer of said composite structure is capable of being saturated with curable resin after said structural foam has been attached to said non-woven fabric layer.
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Abstract
A composite structure and method of making the composite structure are disclosed. A reinforcing fabric such as fiberglass is mechanically attached, for example, by stitching to a non-woven polyester fabric. The attached fabrics are placed in a mold with the non-woven fabric facing the inside of the mold. A self-expanding, self-curing foam is filled into the mold in an amount sufficient so that upon expansion in the closed mold, the foam penetrates into the interstices of the non-woven fabric which upon curing forms a bond therewith. The resulting structure can be used in a number of applications wherein the reinforcing fabric is later impregnated, for example, with a resin, and allowed to cure. Typical use of such a structure is as a stringer in fiberglass boat construction.
102 Citations
32 Claims
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1. A composite structure having an exposed reinforcing fabric layer free of structural foam and curable resin, said structure comprising:
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a reinforcing fabric layer; a non-woven fabric layer attached to said reinforcing fabric layer; and a structural foam attached to said non-woven fabric layer on the side of said non-woven fabric layer opposite said reinforcing fabric layer by having filled interstices of said non-woven fabric layer without penetrating into the reinforcing fabric layer; wherein said reinforcing fabric layer of said composite structure is capable of being saturated with curable resin after said structural foam has been attached to said non-woven fabric layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method of making a composite structure having an exposed reinforcing fabric layer free of structural foam and curable resin, said method comprising the steps of:
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attaching a reinforcing fabric layer to a non-woven fabric layer on one side thereof; laying said attached fabric layers into a mold with the non-woven fabric layer facing the interior of the mold; filling said mold with a self-expanding, self-curable, uncured structural foam; and allowing said foam to expand and cure to attach itself to said non-woven fabric layer by filling interstices of said non-woven fabric layer in a manner such that said foam does not penetrate into the reinforcing fabric layer to thereby result in said composite structure, and wherein said reinforcing fabric layer of said composite structure is capable of being subsequently saturated with curable resin after said structural foam has been attached to said non-woven fabric layer. - View Dependent Claims (13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26)
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27. A method of manufacturing a boat, comprising the steps of:
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spraying a layer of gelcoat into a boat-hull mold and allowing said gelcoat layer to cure; laying a structural skin coat of fiberglass; laying stringers throughout said mold in a reinforcing arrangement on said structural skin coat of fiberglass, said stringers being made as a composite structure comprising, a reinforcing fabric layer, a non-woven fabric layer attached to said reinforcing fabric layer, a structural foam attached to said non-woven fabric layer on the side of said non-woven fabric layer opposite said reinforcing fabric layer by having filled interstices of said non-woven fabric layer, and said stringers having flaps of said attached reinforcing fabric layer and non-woven fabric layer extending therefrom and not attached to said foam, with said stringers being laid so that said flaps lay on said structural skin coat of fiberglass; impregnating said structural skin coat of fiberglass and said stringers with curable resin; and curing said resin to result in a boat hull having said stringers attached thereto. - View Dependent Claims (28, 29, 30, 32)
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31. A method as in clam 27 wherein said impregnation with resin is conducted prior to laying said stringers in said mold.
Specification