COMPOSITE MEMBER AND METHOD OF MAKING

摘要

A method of forming a composite member comprises placing a heat formable resin adjacent fibers to form a fiber member or members and forming the same into a plurality of for example tubular members. The fiber member is placed against a first mold part. An expandable material is distributed into a distributed configuration and expands under the application of heat. The distributed material is optionally stabilized in the distributed configuration to form an expandable member, which is placed said expandable member adjacent said fiber member. A second mold parts seals the mold forming a closed cavity containing the fiber member and the expandable member. The mold parts are heated, causing the expandable material to expand and form a pressure, which drives the fiber member against one of the mold parts, the mold parts also heating the resin adjacent the fibers. The resin then hardens to form the composite member.

主权项

1. A method of forming a composite member, comprising:
(a) placing a heat formable resin adjacent fibers to form a fiber member, (b) placing said fiber member, comprising a plurality of fibers against a first mold part; wherein the improvement comprises (c) distributing into a distributed configuration an expandable material which expands under the application of heat; (d) stabilizing said distributed material in said distributed configuration to form an expandable member; (e) placing said expandable member adjacent said fiber member; (f) placing a second mold part over said first mold part; (g) sealing a closed cavity e defined between said first and second mold parts, said closed cavity containing said fiber member and said expandable member; (h) heating said first and second mold parts, causing said expandable material to expand and form a pressure, said pressure driving said fiber member against one of said mold parts, said mold parts also heating the resin adjacent the fibers; and (i) hardening said resin to form said composite member.