Abstract A resinous article and method for making the article wherein a body of fibrous reinforcing material and syntactic foam containing a low density filler are placed in a molding and curing chamber with the reinforcing material in contact with the surface of the chamber. A molding pressure is then exerted on the chamber to mold and cure the body of material into a finished article. The pressure exerted being sufficient to force a portion of the resinous material in the syntactic foam through the reinforcing material to form a resin rich surface on the article. However, the low density filler material is retained within the core area of the article by the reinforcing material and forms a lightweight syntactic foam core. The resulting article has an outer skin, a layer of fibrous reinforcing material beneath the skin and bonded to the skin, and a core of lower density syntactic foam.
A composite article comprising: a layer of low density syntactic foam comprising a resinous material and a low density filler; a reinforcing layer comprising fibrous reinforcing material superimposed on the layer of syntactic foam and penetrating thereinto; and, an outer skin of resinous material penetrating the reinforcing layer and the layer of syntactic foam, the resinous material of the layer of syntactic foam and the outer skin being a continuous phase in the composite article.
Claim 2
Dependent Claim
75 words
A composite article comprising: a layer of low density syntactic foam comprising a resinous material and a low density filler; a reinforcing layer comprising fibrous reinforcing material superimposed on the layer of syntactic foam and penetrating thereinto; and, an outer skin of resinous material penetrating the reinforcing layer and the layer of syntactic foam, the resinous material of the layer of syntactic foam and the outer skin being a continuous phase in the composite article.
Claim 3
Dependent Claim
14 words
The article of claim 1 wherein the layer of syntactic foam contains hollow microspheres.
Claim 4
Dependent Claim
15 words
The article of claim 1 wherein the layer of syntactic foam contains milled glass fibers.
Claim 5
Dependent Claim
23 words
The article of claim 2 wherein the resinous material of the layer of syntactic foam and the outer skin is a polyester resin.
Claim 6
Dependent Claim
23 words
The article of claim 1 wherein the resinous material of the layer of syntactic foam and the outer skin is an epoxy resin.
Claim 7
Dependent Claim
21 words
The article of claim 2 wherein there is at least 1% by weight of microspheres in the layer of syntactic foam.
Claim 8
Dependent Claim
22 words
The article of claim 2 wherein there is no greater than 15% by weight of microspheres in the layer of syntactic foam.
Claim 9
Dependent Claim
15 words
The article of claim 2 wherein the microspheres are at least 10 microns in diameter.
Claim 10
Dependent Claim
16 words
The article of claim 2 wherein the microspheres are no greater than 130 microns in diameter.