Patent ID: 6206669
Filing Date: 2001-03-27
Classification: B29C,B29K,B32B,B60R,B63B,Y10T

Abstract:
An apparatus for manufacturing a composite structure having an exposed reinforcing fabric layer free of structural foam and curable resin, said apparatus comprising:a conveyor for conveying at least one fabric web along a conveying path, said at least one fabric web comprised of a layered fabric, said layered fabric having said reinforcing fabric layer and a non-woven fabric layer attached to one side thereof, having intestices into which structural foam is filled;an injection system for injecting a structural foam into a foam injection zone completely lined by said at least one fabric web, said non-woven fabric layer facing said interior of said foam injection zone;a die positioned along said conveying path, defining said injection zone and shaping said composite structure to a desired cross-sectional profile; andwherein said structural foam fills interstices of said non-woven fabric layer, thereby attaching said structural foam to said at least one fabnic web without allowing penetration of the structural foam into said reinforcing fabric layer, and wherein said reinforcing fabric layer remains free of structural foam and curable resin after said structural foam has cured.