Patent Number: 6,168,735

Title: Method of making a foam core article

Abstract: A method of manufacturing a fiber-reinforced article by providing a foam core made from a polyol containing at least one unsaturated C.dbd.C group and a hydroxyl functional group. A fiber-reinforcing layer is placed adjacent the foam core. An uncured liquid resin wets the fiber reinforcing layer and the outer surface of the foam core. The resin reacts with the unsaturated C.dbd.C group of the polyol by a free radical reaction. The resin also cross-links and forms a solid polymer encasing the fiber-reinforcing layer. The resin bonds the fiber-reinforcing layer directly to the foam core. The fiber reinforcing layer, foam core and resin form a composite laminate structure that is stronger and more resistant to delamination because the resin is chemically bonded to the foam core.

Inventors: Wang; Jenny (Ann Arbor, MI), Hauser; Kevin Ray (Ann Arbor, MI)

Assignee: Ford Global Technologies, Inc.

International Classification: B29C 44/56 (20060101); B29C 44/34 (20060101); B29C 70/08 (20060101); B29C 067/20 ()

Expiration Date: 01/02/2018