Method of producing a composite high strength to weight structur

Plastic and nonmetallic article shaping or treating: processes – Pore forming in situ – Composite article making

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156245, 264 466, 264 469, 264257, 264259, 264271, 264DIG5, 264DIG13, 264DIG17, B29D 2700

Patent

active

041246705

ABSTRACT:
A novel structural member, such as a tennis racket frame, having an unusually high strength to weight ratio is provided comprising an expanded foamed plastic core integrally bonded to a shell comprising at least one layer of resin-coated unidirectionally oriented graphite fibers, the shell completely encasing the core at any transverse cross section of the structural member, said core comprising from about 25 to about 75 volume percent of a low density cellular filler material, such as chopped cork, and from zero to about 60 weight percent of a high density weight control material, such as barium sulfate.
The structural member is prepared by preparing a foamable resin composition comprising a resin component, a blowing agent, from about 7 to about 50 weight percent of a low density cellular filler material and from zero to about 60 weight percent of a high density weight control material, forming said composition into an elongated core strip, wrapping said core strip with at least one sheet of resin-coated unidirectionally oriented graphite fibers, arranging said wrapped core within a mold cavity, sealing the mold cavity and activating the foamable resin composition to cause expansion and generate pressure within the mold cavity and thereby provide intimate bonding of the core to the shell.

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