Method of manufacturing a composite structural member for an automobile

摘要

A method of making a lightweight reinforced composite framing member for an automotive vehicle comprises forming a foam core of resinous plastic material in the general shape and configuration of the composite framing number. A plurality of cover strips made of a sheet molding compound containing a thermosetting material is molded in an uncured or only partially cured, flexible, tacky condition and then pressed on the core in a manner covering substantially the entire outer surface of the core. The assembly consisting of the core with the cover strips adhered thereto is placed in a mold and by the application of heat and pressure the cover strips are caused to flow into a uniform and continuous sheath bonded on the core in the configuration of the reinforced composite framing member. While in the mold, the sheath is cured and set, completing the formation of the framing member.