Structural composite preform wet-out and curing system and method

A method for applying resin to a composite structure, comprising the steps of:

• providing a composite structure, wherein said composite structure comprises a foam core at least partially covered with an unwetted fabric attached to said foam core, wherein it is desired to impregnate an area of said fabric with resin;
• said composite structure produced by injecting a self-expanding foam into a forming die while applying said fabric such that interstitial spaces in said fabric are filled with said self-expanding foam;
• providing a wetting station adapted to apply a resin to said area of said fabric, said wetting station comprising a resin pump for pumping resin into a wetting means;
• providing a resin collection sump system comprising a sump basin for collecting excess resin as it drains away from said wetting station, said sump basin in fluid communication with a sump pump, and said sump pump being in fluid communication with a reservoir, said reservoir being in fluid communication with said wetting means via said resin pump;
• continuously motivating said composite structure along a longitudinal axis of motivation through said wetting station;
• applying said resin to said area of said fabric by said wetting means while said composite structure is being motivated through said wetting station until said area of said fabric is impregnated with resin;
• collecting excess resin in said sump basin as it drains away from said wetting station;
• pumping said excess resin into said reservoir;
• and
• pumping said excess resin from said reservoir into said wetting means;
• wherein the steps of producing said composite structure, motivating said composite structure, and applying said resin all occur continually at a rate of speed;
• and
• wherein said composite structure is characterized by cross-sections of different shapes taken transverse to the longitudinal axis of motivation at different locations along a longitudinal axis of the composite structure.