Method of making a structural element and the element so made

摘要

The invention relates to a method of making a sandwich-type structural element with a mould consisting of at least two parts, which includes the steps of: a) applying a layer of gelcoat coating comprising unsaturated polyester, which contains the first free radical catalyst acting at a temperature in the range of from circa 0 to 35 DEG C, to the inner surface of the mould, b) keeping the inner surface of the said mould so that the temperature of the gelcoat coating is in the range of from 0 and 35 DEG C, in order to activate the first free radical catalyst and partially set the gelcoat coating, c) applying a layer of a fibrous reinforcing material comprising an unsaturated polyester and containing a second free radical catalyst, to the partially hardened layer of gelcoat coating, d) placing the solid core of the structural element on the layer of a reinforcing material, e) closing the mould around the solid core by joining together the two parts of the mould, f) keeping the mould so that the reinforcing material has the temperature required for activating the second free radical catalyst, in order to activate the second free radical catalyst and to set the reinforcing material, and g) opening the mould and removing the blank and finishing it if necessary. The invention includes the steps of I) step c) comprises applying a layer of a reinforcing material, which comprises a free radical catalyst acting at a temperature within the range of from 35 to 175 DEG C, to a partially hardened layer of gelcoat coating, and ii) step f) comprises warming the mould so that the temperature of the reinforcing material is higher than the temperature of step b), which is in the range of from 35 and 175 DEG C, in order to activate the said second free radical catalyst and to partially set the reinforcing material.