Patent ID: 6117376
Filing Date: 2000-09-12
Classification: B29C,B64C,Y02T

Abstract:
A method of forming a volumetric part having a pair of fiber-reinforced resin skins about a solid foam interior body, using a pair of mold halves defining the outside configuration of the body, the method comprising the steps of:laying dry fiber skins in the mold halves to provide skins having substantially coextensive edges along at least two sides;wetting the skins with heat curable resin;joining the mold halves together along the coextensive edges to provide an interior volume sealed except for an access aperture;inserting catalyzed foamable exothermic material into the interior volume through the access aperture after wetting the skins with heat curable resin in an amount that is sufficient to overfill the entire interior volume when foamed;allowing the exotherm from the foaming to activate and cure the resin for a time sufficient to unite the foamed body to the resin of the skin while exerting expansive force thereon; andseparating the molds from the cured resin skins.