Manufacture of foam-containing structures

Details Manufacture of foam-containing structures Manufacture of foam-containing structures

1998-07-16

1999-09-21

Kuhns, Allan R.

Plastic and nonmetallic article shaping or treating: processes

Pore forming in situ

Composite article making

264 464, 264 466, 264 52, 264255, 264257, B29C 4404, B29C 4406

Patent

active

059550139

ABSTRACT:
A method for producing a foam-containing structure. In a first embodiment, a defoamer is applied to the inner surface of an impermeable carrier. A foamed resin is introduced inside the carrier and contacts the defoamer to form a liquid resin layer on the inner surface. The foamed resin and liquid resin layer are cured to produce a foamed resin inner core and a solid resin outer layer. In a second embodiment, a permeable carrier is covered with an impermeable release material. A defoamer is applied to the carrier. A foamed resin is introduced inside the carrier and contacts the defoamer to form a liquid resin layer impregnating the carrier. The foamed resin and liquid resin layer are cured to produce a foamed resin inner core, the carrier as a facer material, and a solid resin layer impregnating the carrier. In a third embodiment, a defoamer and a catalyst are applied to a permeable carrier. A foamed resin is introduced inside the carrier and contacts the defoamer to form a liquid resin layer impregnating the carrier. At least a portion of the liquid resin layer contacts the catalyst and cures into a solid resin layer. The foamed resin and any uncured portion of the liquid resin layer are cured to produce a foamed resin inner core, the carrier as a facer material, and a solid resin layer impregnating the carrier.

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