Stock material or miscellaneous articles – Web or sheet containing structurally defined element or... – Composite having voids in a component
Reexamination Certificate
2002-09-04
2010-06-08
Vo, Hai (Department: 1787)
Stock material or miscellaneous articles
Web or sheet containing structurally defined element or...
Composite having voids in a component
C428S071000, C428S076000, C428S306600, C428S316600, C442S224000
Reexamination Certificate
active
07732044
ABSTRACT:
A surface-reinforced article includes a core assembly (12) comprising a foam core (20) with a surface region (22) that includes fine inner fibrous material intimately surround by foam that is integral with foam of the core, and an outer reinforcing covering (14) which includes an outer layer (32) of fibrous material and a resin (30) surrounding the outer layer of fibrous material and covering the primarily foam core assembly. The fine inner fibrous material (91-94) includes coupling fibers (100) with inner ends (102) embedded in the foam and outer ends (106) embedded in the resin, to better hold the resin to the foam. The primarily foam core assembly is molded within a first mold cavity (64) formed between spacers (60, 62) that lie within a second mold cavity (50). After the core assembly is molded, the spacers are removed, the core assembly is wrapped in the outer fibrous material, and the wrapped core assembly (120) is placed in the second mold cavity that is formed by the original mold but without the spacers. When resin is injected into the second mold cavity it forms an outer reinforcing covering of largely uniform thickness. The fine fiber reinforcement of the core assembly prevents it from being deformed at the pressure of the injected resin.
REFERENCES:
patent: 3873654 (1975-03-01), Smith
patent: 4510105 (1985-04-01), Sherwood
patent: 4664974 (1987-05-01), Sherwood
patent: 5112663 (1992-05-01), Morenz et al.
patent: 6355339 (2002-03-01), Sherwood
Foam Matrix, Inc.
Rosen Leon D.
Vo Hai
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