Patent ID: 7056567
Filing Date: 2006-06-06
Classification: B29C,B32B,C08G,Y10T

Abstract:
1. A composite structure, comprising: two molded outer polymeric layers spaced apart from each other and defining a cavity therebetween, wherein each molded outer polymeric layer defines a sealing surface extending about a periphery of the respective layer, and the opposing sealing surfaces cooperate to define a hermetic seal extending about a periphery of the cavity; at least two multi-directional fiber reinforcement layers, each multi-directional fiber reinforcement layer being mounted adjacent to a respective outer polymeric layer and defining a first region of the cavity extending between each respective outer polymeric layer and adjacent fiber reinforcement layer, and a second region of the cavity extending between the fiber reinforcement layers; and a core located between the two outer polymeric layers and made of a core material capable of exhibiting a foamed character and a resinous character; wherein the core material includes a resin and a blowing agent activatable upon exposure to a predetermined vacuum pressure within the cavity to convert the core material within the second region of the cavity from a resinous character to a foamed character; and wherein the second region of the cavity is substantially filled with the core material exhibiting the foamed character, each multi-directional fiber reinforcement layer is impregnated with the core material exhibiting a relatively dense, resinous character, and each first region of the cavity is substantially filled with the core material exhibiting a resinous character and fixedly securing the multi-directional fiber reinforcement layers to the outer polymeric layers.