Method of making composite structures
AssigneeCompsys, Inc.
InventorsScott M. Lewit, Neil Rohan
Life of this patent
Estimating the term…
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.
Claims18
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:
- attaching a reinforcing fabric layer to a non-woven fabric layer on one side thereof;
- arranging said attached fabric layers in a configuration constrained against outward movement and with the non-woven fabric layer facing inwardly and defining a cavity between opposing surfaces thereof;
- 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 non-woven fabric layer to form said composite structure, said molding pressure causing said expanding foam to substantially fill only interstices of said non-woven fabric layer, without substantially penetrating the reinforcing fabric layer;
- and,
- freeing said cured composite structure from said constraint of said arranging step, said reinforcing fabric layer of said composite structure being thereafter substantially completely saturatable with a curable material for lamination to another structure in a subsequent processing step.
A method of making a composite structure, comprising the steps of:
- attaching a reinforcing fabric layer to a non-woven fabric layer on one side thereof;
- providing a mold for said composite structure having at least one port;
- laying said attached fabric layers into said mold with the non-woven fabric layer facing the interior of the mold;
- providing an opening in said attached fabric layers where the layers cover said port;
- 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 to thereby result in said composite structure, and allowing excess foam to escape through said port.
A method of making a composite structure specially configured for subsequent use as a structural element to be laminated into a larger structure comprised of composite materials, and having an exposed reinforcing fabric layer free of structural foam and curable resin, said method comprising the steps of:
- 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 at least a portion of said reinforcing fabric layer being formed as a flap section to facilitate bonding of the composite structure into a larger structure;
- predetermining an amount of foam for the mold to fill interstices of the non-woven fabric layer without penetrating through the reinforcing fabric layer;
- pre-setting a dispensing device for a self-expanding self-curable, uncured structural foam to dispense said amount of said foam;
- filling said mold with said amount of said 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 and said composite structure has been removed from said mold.
Dependencies are inferred from the claim text.