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Abstract

A method of manufacturing solid composite panels utilizes an exothermic foam-forming resin to simultaneously consolidate and cure the heat activated resin of the composite panel without forming a foam-filled part. According to the method, composite fabric layers are laid up on the interior surface of a mold half that conforms to the surface configuration of the finished panel. Once the composite fabric layers are laid up, a flexible bladder is placed over the composite layup and the mold closed. The exothermic foam-forming resin is injected into the bladder within the mold cavity, which generates heat to cure the resin impregnated fabric layers above the cure temperature while simultaneously generating pressure within the cavity to consolidate the fabric layers into a substantially solid void-free composite panel.

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First Claim