Method for making composite structures

Abstract

A method for making a composite structure, comprising the steps of: arranging a fabric layer in a configuration constrained against outward movement and defining a cavity between opposing surfaces of the fabric layer; dispensing a predetermined amount of a self-expanding, self-curable, uncured structural foam into the cavity, the foam expanding and curing in the cavity at a molding pressure determined by the predetermined amount of the foam and thereby attaching itself to the fabric layer to form the composite structure, the molding pressure causing the expanding foam to substantially fill only interstices of an inner portion of the fabric layer, without substantially penetrating an outer portion of the fabric layer; and, freeing the cured composite structure from the constraint of the arranging step, the outer portion of the fabric layer of the composite structure being thereafter substantially completely saturable with a curable material for lamination to another structure in a subsequent processing step. The method can further comprise the step of laminating the cured composite structure to another composite structure by saturating the outer portion of the fabric layer of the cured composite structure with a curable resin.

Dependencies are inferred from the claim text.