| 摘要 |
The invention relates to a method and system for producing a composite structure, consisting of a foam core surrounded by an exterior shell. More specifically, the invention relates to a method of manufacturing a unitary composite article of a desired shape. The method broadly includes fabricating an exterior shell, which can be composed of either a single member or multiple portions, having the desired shape of the composite article. If there are multiple portions, those portions have peripheral edges which allow the portions to be assembled together to form the exterior shell. The exterior shell of the invention defines an internal cavity. A foam reaction mixture is injected into the cavity where it reacts exothermically and expands. During expansion, the foam adheres to the surface of the cavity. Prior to injection of the foam, the exterior shell is positioned within a structural frame which surrounds the shell. The frame resists movement of the exterior shell as the foam reaction mixture expands. Finally, after the foam core is set, the composite article is removed from the structural frame.
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