Patent ID: 6159414
Filing Date: 2000-12-12
Classification: B29C,Y10T

Abstract:
A method of forming a composite structure comprising:providing a plurality of cores each having a peripheral surface, the cores including spaces therebetween and arranged in at least one row to form a layer having an upper surface and a lower surface;covering at least the upper surface of the layer with a fiber material;providing a resin distribution network of channels arranged to distribute uncured resin throughout the fiber material and the spaces between the cores;providing a feeder channel in fluid communication with the resin distribution network, the feeder channel having a larger cross-sectional area than individual ones of the channels of the resin distribution network;sealing the cores and the fiber material with the resin distribution network and the feeder channel in a forming structure, at least a first portion of the forming structure comprising a mold surface and at least a further portion of the forming structure comprising a flexible portion collapsible under vacuum against an adjacent portion of the cores and the fiber material;connecting a source of uncured resin through the flexible portion to the feeder channel;connecting the interior of the forming structure to a vacuum outlet;forcing the uncured resin under vacuum through the feeder channel and the resin distribution network to fill the forming structure to impregnate the fiber material and the spaces between the cores with the resin; andcuring the resin to form a composite structure.