Composite sheet having a core having end walls and a mat with fibers

Abstract

This invention relates to a composite sheet and a method of making a composite sheet. A core having end walls is provided. Continuous fibers or a continuous fiber mat is secured to the core such that the continuous fibers align with the end walls of the core. Various manufacturing methods are disclosed.

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         15 . A method of making a composite having end walls, the method comprising: inserting a flowable material into a first mold half having a predetermined shape and structures to create a core having end walls; placing continuous fibers into the first mold half such that the fibers are oriented proximate the structures that create the end walls such that the continuous fibers will orient along the ends of the composite; allowing the flowable material to solidify so that the composite can be removed from the first mold half. 
     
     
         16 . The method of  claim 15  wherein a second mold half compresses the flowable material and the fibers into the predetermined shape. 
     
     
         17 . The method of  claim 15  wherein the flowable material is put under negative pressure to assist the flowable material to conform to the predetermined shape. 
     
     
         18 . The method of  claim 15  wherein the fibers are impregnated within a resin to form a skin having a bi-axial fiber pattern. 
     
     
         19 . The method of  claim 18  wherein the skin has a predetermined shape to correspond to the predetermined shape of first mold half. 
     
     
         20 . A method of making a composite having end walls, the method comprising: providing a first mold half having structures to create a core having end walls; providing a second mold half having structures to create a core having end walls; placing continuous fibers in the first mold half such that the fibers are oriented with the end wall structure such that the continuous fibers will orient along the ends of the composite; compressing the second mold half and the first mold half; injecting a flowable material between the two mold halves; allowing the flowable material to solidify; and removing the composite from the first mold half. 
     
     
         21 . The method of  claim 20  wherein the fibers are preformed and hence being held taut prior to being placed into the first mold half. 
     
     
         22 . The method of  claim 20  wherein the continuous fibers are placed in both mold halves. 
     
     
         23 . A method of making a composite having end walls, the method comprising: creating a screen of continuous fibers; placing a flowable material onto the screen of continuous fibers; placing the screen and flowable material into a first mold half having a predetermined shape and structures to create a core having end walls such that the fibers are oriented proximate the structures that create the end walls such that the continuous fibers will orient along the ends of the composite; allowing the flowable material to solidify so that the composite can be removed from the first mold half. 
     
     
         24 . The method of  claim 23  further comprising creating a second screen of continuous fibers and placing the second screen on top of the flowable material before placing the screen and flowable material into the first mold half. 
     
     
         25 . The method of  claim 23  further comprising placing a film on the screen of the continuous fibers and placing the flowable material onto the screen.