Method of making composite cored structures

Claim 1

A METHOD OF PREPARING A STRUCTURAL PART HAVING A HONEYCOMB CORE ENCASED IN A STRUCTURALLY REINFORCED RESIN IN A PAIR OF HEATED MATCHED METAL DIES HELD IN A MOLDING PRESS, THE STEPS COMPRISING: A. COVERING A HONEYCOMB CORE WITH A REINFORCING MATERIAL PREIMPREGNATED WITH A RESIN ADVANCED TO THE "B" STAGE TO FROM A LAY-UP PART; B. INSERTING THE LAY-UP PART INTO A HEATED METAL DIE; C, ADVANCING A MATCHING METAL DIE UNTIL IT MAKES CONTACT WITH THE LAY-UP; D. HOLDING THE DIES AGAINST THE LAY-UP PART UNTIL THE RESIN STARTS TO SET-UP; E. BRINGING THE DIES TOGETHER TO FORM A COMPRESSION MOLD CONTAINING A FORMED PART; F. HOLDING THE DIES TOGETHER UNTIL THE RESIN IN THE PART IS CURED; AND G. COVERING THE LAY-UP PART WITH A LAYER OF A THERMOPLASTIC RESIN PRIOR TO PLACING THE PART IN THE DIE.

Claim 2

A METHOD OF PREPARING A STRUCTURAL PART HAVING A HONEYCOMB CORE ENCASED IN A STRUCTURALLY REINFORCED RESIN IN A PAIR OF HEATED MATCHED METAL DIES HELD IN A MOLDING PRESS, THE STEPS COMPRISING: A. COVERING A HONEYCOMB CORE WITH A REINFORCING MATERIAL PREIMPREGNATED WITH A RESIN ADVANCED TO THE "B" STAGE TO FROM A LAY-UP PART; B. INSERTING THE LAY-UP PART INTO A HEATED METAL DIE; C, ADVANCING A MATCHING METAL DIE UNTIL IT MAKES CONTACT WITH THE LAY-UP; D. HOLDING THE DIES AGAINST THE LAY-UP PART UNTIL THE RESIN STARTS TO SET-UP; E. BRINGING THE DIES TOGETHER TO FORM A COMPRESSION MOLD CONTAINING A FORMED PART; F. HOLDING THE DIES TOGETHER UNTIL THE RESIN IN THE PART IS CURED; AND G. COVERING THE LAY-UP PART WITH A LAYER OF A THERMOPLASTIC RESIN PRIOR TO PLACING THE PART IN THE DIE.

Claim 3

A method of preparing a structural part having a honeycomb core encased in a structurally reinforced resin in a pair of heated matched metal dies held in a molding press, the steps comprising: a. covering a honeycomb core with a reinforcing material preimpregnated with a resin advanced to the ''''B'''' stage to form a lay-up part; b. inserting the lay-up part into a heated metal die; c. advancing a matching metal die until it makes contact with the lay-up part; d. holding the dies against the lay-up part until the resin starts to set-up; e. bringing the dies together to form a compression mold containing a formed part; f. holding the dies together until the resin in the part is cured; and g. covering the lay-up part with a layer of a thermoplastic resin prior to placing the part in the die.

Claim 4

A method of preparing a structural part having a honeycomb core encased in a structurally reinforced resin in a pair of heated matched metal dies held in a molding press, the steps comprising: a. covering a honeycomb core with a reinforcing material preimpregnated with a resin advanced to the ''''B'''' stage to form a lay-up part; b. inserting the lay-up part into a heated metal die; c. advancing a matching metal die until it makes contact with the lay-up part; d. holding the dies against the lay-up part until the resin starts to set-up; e. bringing the dies together to form a compression mold containing a formed part; f. holding the dies together until the resin in the part is cured; and g. covering the lay-up part with a layer of a thermoplastic resin prior to placing the part in the die.

Claim 5

A method of preparing a structural part having a honeycomb core encased in a structurally reinforced resin in a pair of heated matched metal dies held in a molding press, the steps comprising: a. covering a honeycomb core with a reinforcing material preimpregnated with a resin advanced to the ''''B'''' stage; b. placing structural material impregnated with a thermosetting resin above and below and extending beyond the covered core to form a lay-up part; c. inserting the lay-up part into a heated metal die; d. advancing a matching mEtal die until it makes contact with the lay-up part; e. holding the dies against the lay-up part until the resin starts to set-up; f. bringing the dies together to form a compression mold containing a formed part; g. holding the dies together until the resin in the part is cured; and h. covering the lay-up part with a layer of thermoplastic resin prior to placing the part in the die.

Claim 6

A method of preparing a structural part having a honeycomb core encased in a structurally reinforced resin in a pair of heated matched metal dies held in a molding press, the steps comprising: a. covering a honeycomb core with a reinforcing material preimpregnated with a resin advanced to the ''''B'''' stage; b. placing structural material impregnated with a thermosetting resin above and below and extending beyond the covered core to form a lay-up part; c. inserting the lay-up part into a heated metal die; d. advancing a matching mEtal die until it makes contact with the lay-up part; e. holding the dies against the lay-up part until the resin starts to set-up; f. bringing the dies together to form a compression mold containing a formed part; g. holding the dies together until the resin in the part is cured; and h. covering the lay-up part with a layer of thermoplastic resin prior to placing the part in the die.

Claim 7

A method of compression molding a structural part of core material covered with reinforced plastics in one mold step in a mold having matching metal dies the lower die having a recess with outwardly canted sides and the upper die extending downward to contact the canted sides when fully closed, the steps comprising: a. using a core slightly undersize in relation to the final shape of a structural part, selected from the group of materials consisting essentially of polymerized foamed resins, balsa wood, and honeycomb; b. placing a thermosetting resin impregnated structural reinforcing material above and below and extending beyond the core to form a lay-up part; c. inserting the lay-up part in a heated metal lower die; d. advancing an upper matching heated metal die to contact the lay-up part; e. holding the upper metal die in contact with the lay-up part so that heat from the heated matched metal die causes the thermosetting resin to flow; f. closing the dies, when the resin starts to setup, to pinch off the excess resin reinforced materials and apply pressure as the resin in the part cures; g. holding in the dies until the resin sets up; and h. placing a layer of a thermoplastic resin above and below the lay-up part prior to inserting said lay-up part in the heated metal lower die.

Claim 8

A method of compression molding a structural part of core material covered with reinforced plastics in one mold step in a mold having matching metal dies the lower die having a recess with outwardly canted sides and the upper die extending downward to contact the canted sides when fully closed, the steps comprising: a. using a core slightly undersize in relation to the final shape of a structural part, selected from the group of materials consisting essentially of polymerized foamed resins, balsa wood, and honeycomb; b. placing a thermosetting resin impregnated structural reinforcing material above and below and extending beyond the core to form a lay-up part; c. inserting the lay-up part in a heated metal lower die; d. advancing an upper matching heated metal die to contact the lay-up part; e. holding the upper metal die in contact with the lay-up part so that heat from the heated matched metal die causes the thermosetting resin to flow; f. closing the dies, when the resin starts to setup, to pinch off the excess resin reinforced materials and apply pressure as the resin in the part cures; g. holding in the dies until the resin sets up; and h. placing a layer of a thermoplastic resin above and below the lay-up part prior to inserting said lay-up part in the heated metal lower die.

Claim 17

A method of compression molding a structural part of core material covered with reinforced plastics in one mold step in a mold having matching metal dies, the steps comprising: a. using a core slightly undersize in relation to the final shape of a structural part, selected from the group of materials consisting essentially of polymerized foamed resins, and balsa wood; b. placing a thermosetting resin impregnated structural reinforcing material above and below and extending beyond the core to form a lay-up part; c. inserting the lay-up part in a heated metal lower die having a recess with outwardly and upwardly extending canted sides; d. lowering a matching heated upper die having essentially vertical sides, until the sides of the upper die contact the canted sides of the lower die; e. backing out the upper die to just retain contact with the lay-up part to allow the thermosetting resin to flow; f. holding the upper metal die in contact with the lay-up part so that heat from the heated matched metal die causes the thermosetting resin to flow; g. closing the dies, when the resin starts to set-up, to Pinch off the excess resin reinforced materials and apply pressure as the resin in the part cures; and h. holding in the dies until the resin sets up.

Claim 18

A method of compression molding a structural part of core material covered with reinforced plastics in one mold step in a mold having matching metal dies, the steps comprising: a. using a core slightly undersize in relation to the final shape of a structural part, selected from the group of materials consisting essentially of polymerized foamed resins, and balsa wood; b. placing a thermosetting resin impregnated structural reinforcing material above and below and extending beyond the core to form a lay-up part; c. inserting the lay-up part in a heated metal lower die having a recess with outwardly and upwardly extending canted sides; d. lowering a matching heated upper die having essentially vertical sides, until the sides of the upper die contact the canted sides of the lower die; e. backing out the upper die to just retain contact with the lay-up part to allow the thermosetting resin to flow; f. holding the upper metal die in contact with the lay-up part so that heat from the heated matched metal die causes the thermosetting resin to flow; g. closing the dies, when the resin starts to set-up, to Pinch off the excess resin reinforced materials and apply pressure as the resin in the part cures; and h. holding in the dies until the resin sets up.

Claim 19

A method of compression molding a structural part of core material covered with reinforced plastics in one mold step in a mold having matching metal dies, the steps comprising: a. using a core slightly undersize in relation to the final shape of a structural part, selected from the group of materials consisting essentially of polymerized resins, and balsa wood; b. placing a thermosetting resin impregnated structural reinforcing material above and below and extending beyond the core to form a lay-up part; c. inserting the lay-up part in a heated metal lower die having a recess with outwardly and upwardly extending sides canted at about 2* to 7*; d. advancing an upper matching heated metal die, having essentially vertical sides, to contact the lay-up part; e. holding the upper metal die in contact with the lay-up part so that heat from the heated matched metal die causes the thermosetting resin to flow; f. closing the dies, when the resin starts to set-up, to pinch off the excess resin reinforced materials and apply pressure as the resin in the part cures; and g. holding in the dies until the resin sets up.

Claim 20

A method of compression molding a structural part of core material covered with reinforced plastics in one mold step in a mold having matching metal dies, the steps comprising: a. using a core slightly undersize in relation to the final shape of a structural part, selected from the group of materials consisting essentially of polymerized resins, and balsa wood; b. placing a thermosetting resin impregnated structural reinforcing material above and below and extending beyond the core to form a lay-up part; c. inserting the lay-up part in a heated metal lower die having a recess with outwardly and upwardly extending sides canted at about 2* to 7*; d. advancing an upper matching heated metal die, having essentially vertical sides, to contact the lay-up part; e. holding the upper metal die in contact with the lay-up part so that heat from the heated matched metal die causes the thermosetting resin to flow; f. closing the dies, when the resin starts to set-up, to pinch off the excess resin reinforced materials and apply pressure as the resin in the part cures; and g. holding in the dies until the resin sets up.

Claim 26

A method of preparing a structural part, with a core of honeycomb and a covering of a structurally reinforced resin, in a pair of matched heated metal dies held in a molding press, the steps comprising: a. cutting a honeycomb core to the width of a finished part; b. placing a first layer of structural material preimpregnated, with a resin in the ''''B'''' stage, above and below the honeycomb, the preimpregnated structural material having a width sufficient to cover the top and bottom of the honeycomb while conforming to the shape of the top and bottom surfaces of the honeycomb core; c. placing a second layer of a structural material impregnated with a resin above and below and extending beyond the honeycomb core with first layers of preimpregnated reinforcing material to form a lay-up part; d. inserting tHe lay-up part in a heated metal die having a recess with outwardly and upwardly canted sides; e. lowering an upper matching heated metal die, with sides extending downwardly at an angle of between two and ten degrees in relation to the canted sides of the lower metal die, to contact the lay-up part; f. holding the dies in contact against the lay-up part until the resin in the preimpregnated structural material starts to set-up; g. advancing the upper metal die until the edge of the extension of the upper die contacts the canted sides of the lower die, to form, contain, and pressurize a structural part and pinch off excess material; and h. leaving the formed part in the heated dies until the resin is cured.

Claim 27

A method of preparing a structural part, with a core of honeycomb and a covering of a structurally reinforced resin, in a pair of matched heated metal dies held in a molding press, the steps comprising: a. cutting a honeycomb core to the width of a finished part; b. placing a first layer of structural material preimpregnated, with a resin in the ''''B'''' stage, above and below the honeycomb, the preimpregnated structural material having a width sufficient to cover the top and bottom of the honeycomb while conforming to the shape of the top and bottom surfaces of the honeycomb core; c. placing a second layer of a structural material impregnated with a resin above and below and extending beyond the honeycomb core with first layers of preimpregnated reinforcing material to form a lay-up part; d. inserting tHe lay-up part in a heated metal die having a recess with outwardly and upwardly canted sides; e. lowering an upper matching heated metal die, with sides extending downwardly at an angle of between two and ten degrees in relation to the canted sides of the lower metal die, to contact the lay-up part; f. holding the dies in contact against the lay-up part until the resin in the preimpregnated structural material starts to set-up; g. advancing the upper metal die until the edge of the extension of the upper die contacts the canted sides of the lower die, to form, contain, and pressurize a structural part and pinch off excess material; and h. leaving the formed part in the heated dies until the resin is cured.

Claim 32

A method of preparing a structural part having a honeycomb core encased in a structurally reinforced resin in a pair of heated matched metal dies held in a molding press, the steps comprising: a. heating aluminum honeycomb core at about 250* F for about an hour; b. cooling the core; c. machining the core material; d. covering the core material with a layer of reinforcing material preimpregnated with a resin advanced to the ''''B'''' stage; e. curing the resin while contained, to form a shaped covered core; f. placing a structural material impregnated with a resin above and below and extending beyond the shaped covered core to form a lay-up part; g. inserting the lay-up part in a heated metal lower die having upwardly and outwardly extending canted sides at between two and ten degrees from vertical; h. advancing a matching upper heated metal die, having essentially vertically downward extending sides, until the upper die contacts the lay-up part; i. holding the upper metal die against the lay-up part until the resin starts to set-up, j. extending the upper die into the lower die to bring the edges of the downwardly extending upper die in contact with the canted sides of the lower die, to contain and pressurize the part being formed and to pinch off excess material; and k. holding the dies together until the resin is fully cured.

Claim 33

A method of preparing a structural part having a honeycomb core encased in a structurally reinforced resin in a pair of heated matched metal dies held in a molding press, the steps comprising: a. heating aluminum honeycomb core at about 250* F for about an hour; b. cooling the core; c. machining the core material; d. covering the core material with a layer of reinforcing material preimpregnated with a resin advanced to the ''''B'''' stage; e. curing the resin while contained, to form a shaped covered core; f. placing a structural material impregnated with a resin above and below and extending beyond the shaped covered core to form a lay-up part; g. inserting the lay-up part in a heated metal lower die having upwardly and outwardly extending canted sides at between two and ten degrees from vertical; h. advancing a matching upper heated metal die, having essentially vertically downward extending sides, until the upper die contacts the lay-up part; i. holding the upper metal die against the lay-up part until the resin starts to set-up, j. extending the upper die into the lower die to bring the edges of the downwardly extending upper die in contact with the canted sides of the lower die, to contain and pressurize the part being formed and to pinch off excess material; and k. holding the dies together until the resin is fully cured.

Claim 36

A method of preparing a structural part having a honeycomb core encased in a structurally reinforced resin in a pair of heated matched metal dies held in a molding press, the steps comprising: a. curing a layer of reinforcing material preimpregnated with a resin advanced to the ''''B'''' stage on one surface of a honeycomb core material; b. machining the core material; c. covering the remainder of the core material with a layer of reinforcing material preimpregnated with a resin advanced to the ''''B'''' stage; d. curing the resin while contained to form a shaped covered core; e. placing a structural materiAl impregnated with a resin above and below and extending beyond the shaped covered core to form a lay-up part; f. inserting the lay-up part in a heated metal lower die having upwardly and outwardly extending canted sides at between two and ten degrees from vertical; g. advancing a matching upper heated metal die, having essentially vertically downward extending sides, until the upper die contacts the lay-up part; h. holding the upper metal die against the lay-up part until the resin starts to set-up, i. extending the upper die into the lower die to bring the edges of the downwardly extending upper die in contact with the canted sides of the lower die, to contain and pressurize the part being formed and to pinch off excess material; and j. holding the dies together until the resin is cured.

Claim 37

A method of preparing a structural part having a honeycomb core encased in a structurally reinforced resin in a pair of heated matched metal dies held in a molding press, the steps comprising: a. curing a layer of reinforcing material preimpregnated with a resin advanced to the ''''B'''' stage on one surface of a honeycomb core material; b. machining the core material; c. covering the remainder of the core material with a layer of reinforcing material preimpregnated with a resin advanced to the ''''B'''' stage; d. curing the resin while contained to form a shaped covered core; e. placing a structural materiAl impregnated with a resin above and below and extending beyond the shaped covered core to form a lay-up part; f. inserting the lay-up part in a heated metal lower die having upwardly and outwardly extending canted sides at between two and ten degrees from vertical; g. advancing a matching upper heated metal die, having essentially vertically downward extending sides, until the upper die contacts the lay-up part; h. holding the upper metal die against the lay-up part until the resin starts to set-up, i. extending the upper die into the lower die to bring the edges of the downwardly extending upper die in contact with the canted sides of the lower die, to contain and pressurize the part being formed and to pinch off excess material; and j. holding the dies together until the resin is cured.