# US 5,700,543 A · Elongate composite structural member and method of making

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- Number: US 5,700,543 A
- Document ID: US5700543A
- Status: Granted
- Kind: A
- Application number: 08/585,721
- Filed: 1996-01-16
- Granted: 1997-12-23
- Earliest claimed: 1994-07-13
- Inventors: Harry J. Bendick; Bret M. Kraner
- Web page: https://patentgrep.com/patent/US5700543A

## CPC

- B29C 44/386: {using a movable, elongate nozzle, e.g. to reach deep into the mould}
- B29C 44/1209: {by impregnating a preformed part, e.g. a porous lining}
- B29C 70/086: {and with one or more layers of pure plastics material, e.g. foam layers (applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86)}
- B29C 70/205: {the structure being shaped to form a three-dimensional configuration}
- B29K 2105/0854: {in the form of a non-woven mat}
- B29K 2105/101: {Oriented}
- B29K 2201/00: Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as reinforcement
- B29K 2311/10: Natural fibres, e.g. wool or cotton
- Y10T 428/233: Foamed or expanded material encased
- Y10T 428/24107: including mechanically interengaged strands, strand-portions or strand-like strips
- Y10T 428/24996: With internal element bridging layers, nonplanar interface between layers, or intermediate layer of commingled adjacent foam layers
- Y10T 428/249986: Void-containing component contains also a solid fiber or solid particle
- Y10T 428/249989: Integrally formed skin
- Y10T 442/15: Including a foam layer
- Y10T 442/195: Including a foam layer
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An elongate composite structural member and method of making the same which is particularly useful for forming the handle of hand-held striking and prying tools or implements. The elongate structure member comprises a foamed in place molded resin composition core and outer skin layer which is reinforced with intermediate layer of structurally strong, unidirectional oriented fibers. The expanded foam resin, intermediate fiber layer and the expanded foam resin outer skin are bound together by the cured foamed resin composition formed during the molding process to form a strong, integral composite structure.

## Claims

### Claim 1

An elongate structural element, comprising in combination:
a) an elongate compression molded core comprising an expanded resin foam material, said core having a generally cylindrical cross-sectional configuration;
b) a tubular layer surrounding said core including at least one sheet of longitudinally extending fibers disposed along the length of said core and having said expanded resin foam material forming said core extending into and through said tubular layer of longitudinally extending fibers, said longitudinally extending fibers being selected from the group consisting of fiber glass, graphite and boron;
c) said expanded resin foam material extending through said tubular layer of longitudinal extending fibers forming an outer skin layer overlying said tubular layer of longitudinally extending fibers to intimately bind said core, said longitudinally extending fiber layer, and said outer skin into an integral composite structure.

### Claim 2 (depends on 1)

The elongate structural element defined in claim 1, wherein said expanded foam resin material forming said core is formed from a resin having a free rise density of about 8 to 20 pounds per cubic foot.