Method for making composite structures

  • US 5,908,591 A
  • Filed: 08/04/1997
  • Issued: 06/01/1999
  • Est. Priority Date: 01/14/1994
  • Status: Expired due to Term
First Claim
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1. A method for making a composite structure, comprising the steps of:

  • arranging a single fabric layer in a configuration constrained against outward movement and defining a cavity between opposing surfaces of said fabric layer;

    dispensing a predetermined amount of a self-expanding, self-curable, uncured structural foam into said cavity, said foam expanding and curing in said cavity at a molding pressure determined by said predetermined amount of said foam and thereby attaching itself to said fabric layer to form said composite structure, said molding pressure causing said expanding foam to substantially fill only interstices of an inner portion of said fabric layer, without substantially penetrating an outer portion of said fabric layer; and

    ,freeing said cured composite structure from said constraint of said arranging step, said outer portion of said fabric layer of said composite structure being thereafter substantially completely saturable with a curable material for lamination to another structure in a subsequent processing step.

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