Multistage method and apparatus for continuously forming a...

B - Operations – Transporting – 32 – B

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B32B 5/18 (2006.01) B29C 39/00 (2006.01) B29C 44/24 (2006.01) B29C 47/06 (2006.01)

Patent

CA 2538917

There is disclosed a multistage molding apparatus and method for continuously forming a composite article. The apparatus comprises a first stage for forming a skin, a second stage for applying a structural foam to the skin as the skin is being cured to form the composite article and a third stage for curing the composite article. The method comprises the steps of impregnating a skin forming material with a first resin at a first stage, curing the skin forming material to form a skin, while applying a foam to the impregnated skin forming material before the impregnated skin forming material is fully cured in a second stage, and curing the foamed skin to form the composite article at a third stage. There is also disclosed a composite article comprising a skin layer bonded to a foam layer.

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