Patent ID: 7226559

Claim:
A method of manufacturing a molded composite structure, comprising: preparing a material stack, wherein the material stack comprises a core section having first and second opposing sides, and wherein preparing the material stack comprises: applying first and second substantially fibrous support layers on the first side and the second opposing side of the core section, wherein the substantially fibrous support layers provide a vacuum path for evacuation of the core section; applying an adhesive layer on the first and second support layers and on any other surface of the core not covered by the first and second support layers; and applying a thermoplastic barrier layer on the adhesive layers covering all surfaces of the core; preparing a resin; preparing a mold; placing the material stack in the mold; evacuating air from the core section of the material stack through the vacuum path provided by the substantially fibrous support layers; sealing the evacuated core section by curing the adhesive layer to adhere the support layers and thermoplastic barrier layer to the core section such that after sealing, the thermoplastic barrier layer prevents air from entering the core section, thereby forming an evacuated material stack; infusing the mold and the evacuated material stack with the resin to form the structure; curing the structure; and removing the structure from the mold.