Abstract: A method is provided for rapidly forming a cementitious panel. A cementitious mixture is introduced into a mold configured to provide the desired surface appearance and profile of the cementitious panel. The cementitious mixture is then subject to an accelerated curing process by applying microwave energy to the cementitious mixture for a predetermined time period. After a relatively short resting or cooling period, the resulting cementitious panel is ready to be removed from the mold.

Abstract: A semi-rigid integral skin foam having a low foamed integral skin layer and a highly foamed core is molded from a polyurethane formulation injected into a mold cavity having a reduced pressure of 400 Torr or below. The formulation comprises a polyol component, an isocyanate component, and at least one substance selected from among formic acid, an amine salt thereof and an amine salt of boric acid, while not containing any freon.

Abstract: Disclosed is a method of sizing nonderivatized extruded cellulosic tubes by the use of a mandrel structure that includes a hollow sizing portion having openings which gather gas bubbles that may evolve at the interface between the extruded tube and the sizing portion and allows the gas to pass into the hollow interior of the mandrel. The mandrel contains a sizing portion larger than the extruded tube, which allows for improved sizing of nonderivatized extruded tubes that are used as casings.

Abstract: A soy-based polyol is mixed with an isocyanate and aggregate to produce a soy-based polyurethane having superior mechanical properties. The aggregate composition may be varied to obtain different mechanical properties, as can the amount of resin. The resin may be crosslinked using a low molecular weight polyol, such as glycerine, to also improve structural performance. A catalyst may be added to accelerate curing time without reducing structural performance.

Abstract: A process for forming an end cap in an extruded ceramic tube. An end cap forming cavity of an end cap forming die is positioned so that, when the body of the end cap forming die is situated against an extrusion die, ceramic material is able to be forced into the end cap forming cavity, through a passageway communicating between the end cap forming cavity and a backfill reservoir, and into the backfill reservoir. A plunger projects into the backfill reservoir to force the ceramic material from the backfill reservoir back through the passageway and into the end cap forming cavity to compact the ceramic material so that the ceramic material within the end cap will be provided with a substantially uniform density.

Abstract: A method of constructing large, unitary, fiber-reinforced Polymer composite containers using a vacuum assisted resin transfer molding process. The method allows for the construction of container systems with only two separately molded parts—an open box consisting of a base (i.e., floor), 2 sidewalls and 2 endwalls, and a cover (i.e., roof). The method results in a structure which maintains the continuity of the reinforcement fibers across the junction between the floor, side, and end walls corners. This method can be applied to very large composite structures such as railcar bodies, intermodal containers, and shelters.

Abstract: A high throughput, automated process for coating ceramic monoliths used as catalytic converters that overcomes problems with coating monoliths individually in a mold. The monoliths are provided with end caps to cover the open functional ends, then loaded serially into an inlet channel leading to an extrusion chamber. As each monolith is pushed into the channel, one monolith enters the extrusion chamber, and the monolith just coated in the extrusion chamber is made to exit onto a finished part conveyor. Thereafter, the end caps are removed and cleaned for reuse on new monoliths yet to be coated.

Abstract: Solvent-free noncrystalline bioactive substances are prepared from the corresponding crystalline bioactive substances in an extruder by melting the substances in the extruder under reduced pressure and in the absence of auxiliaries, cooling and comminuting.

Abstract: The invention relates to a method for preparation of test bodies for analysis of porous, preferably thermally sprayed, surface layers, which are incorporated by casting in plastic. The method according to the invention is carried out by placing one or more test pieces of the surface layer in a mould introduced into a vacuum chamber, the pressure of which is lowered, pouring a ready-mixed, liquid casting resin into the mould containing the test pieces, again letting the air in into the chamber, lifting the test pieces out of the casting resin and allowing excess of casting resin to drip from the test pieces, and after that they are placed in a mould cavity of a hot moulding press, filling said mould cavity together with the test pieces with a pulverized resin, and applying pressure and heat to the mould cavity for a predetermined period of time, whereupon the test body is ready to be taken out and lapped.

Abstract: A method for removing volatile components from wet, polymer powders using a vacuum vented extruder is described. Polymer powders containing substantial amounts of water, 1-20% by weight, are rapidly converted to polymer compositions containing less than about 0.5% by weight water at high throughput rates while avoiding complications resulting from excessive steam backflow through the extruder feed throat. The method provides a screw design comprising a powder seal section upstream of kneading and melting sections of the extruder. Steam generated as the polymer is heated flows downstream to one or more vacuum vents for removal. The partially devolatilized polymer melt is then subjected to additional melt kneading and vacuum venting. The method converts wet polycarbonate powder containing residual methylene chloride to essentially dry polycarbonate powder containing less than about 1 ppm methylene chloride.

Abstract: A process is disclosed for direct extrusion of an acrylic polymer highly filled with aluminum trihydroxide wherein a lubricant is introduced to permit the composition to be extruded at a temperature below about 200° C.

Abstract: A matrix is formed into a desired shape by pouring transparent liquid material into a mold. The material progressed from the liquid to the gelatinous state. Laser sculpting steps are performed when the material is still in a gelatinous condition to form small spots in the matrix. Because the material is non-solid gel when the laser beam applies its focused energy, there is no cracking or destruction. Intensity and duration of the laser pulse determine the size of the spots as does the timing in relation to the matrix material finally changing from gel to solid. Particular visual effects are produced at different degrees of solidity when sculpting. The liquid in the mold may be pressurized for removal of air bubbles after initial pouring of the matrix material and application of pressure after the laser sculpting controls the size of the spots in the finished product.

Abstract: A resin transfer molding (RTM) process is disclosed for rapidly filling a fibrous preform and/or a rigid, porous body with high viscosity resin or pitch. The process is suitable for impregnated multiple porous bodies stacked in a single mold. The process uses a fibrous preform or rigid porous body which is placed into a mold matching the desired part geometry. A resin is injected into the mold at temperature and pressure. After cooling, the infiltrated component is removed from the mold. The mold is constructed from two halves fitted to form at least one mold cavity. A gate fitted with a nozzle is set into one of the mold halves, and a valve admits resin or pitch into the gate area. Venting or vacuum can be applied to the mold. The mold is held in a hydraulic press and an extruder, optionally fitted with an accumulator, supplies molten resin or pitch to the mold.

Abstract: A method of manufacturing a resin impregnated article includes the steps of providing a mold onto which a reinforcing material is placed, sealing the reinforcing material with an impervious sheet and regulating the pressure on the material and temperature of the material and resin by placing a fluid in contact with the impervious sheet and regulating the pressure and temperature of the fluid.

Abstract: A molten material supply unit includes a heating cylinder. The heating cylinder may receive and heat the material in a substantially vacuum condition. A molding apparatus may include a pressurizing and charging unit in addition to the molten material supply unit. The pressurizing and charging unit is adapted to receive the melted material from the molten material supply unit and to charge the melted material into a die under pressure.

Abstract: The method of molding a fishing lure having multiple circumferentially extending skirts comprised of whiskers, in a single action, and a novel mold for casting such a lure in which platens which are mirror images of one another are formed with pockets for receiving die blocks, each having formed thereon passages in the shape of half of the lure to be cast, the passages adapted to receive plasticized material, which when cooled defines the lure.

Abstract: The invention relates to a gear extruder for plasticizing and homogenizing rubber mixtures, having at least two gears disposed in chambers in the extruder housing, with the teeth of the gears meshing with one another, and having a port for feeding the rubber mixture to the front of the gears in the extruder housing. The invention is characterized in that gas vent ports are provided in the extruder housing, at the ends of the teeth of the gears, in an area in which the teeth disengage, and/or that at the entrance side of the teeth filled with the rubber mixture. The gas vent ports are provided in the extruder housing in one embodiment so that they extend on the entrance side over no more than half of the circumference of the chambers. By such an arrangement of gas vent ports it has become possible to ventilate a rubber mixture such that volatile components and moisture contained therein can be outgassed, but the rubber mixture is unable to enter the gas vent ports and clog them.

Abstract: The present invention provides a method for extruding polymer blend resin which is capable of satisfying performances which are necessary as a resin-coated metal can even when the resin-coated metal can is produced through an extremely stringent working such as drawing, deep drawing, bend-elongation by drawing, stretching or ironing. After feeding thermoplastic resin A to a biaxial extruder through a first raw material feed port of the extruder, the thermoplastic resin A is plasticized in a molten state and is subjected to degassing under reduced pressure. Thereafter, thermoplastic resin B whose melting temperature or softening temperature is lower than a melting temperature or a softening temperature of the thermoplastic resin A is fed to the extruder through a second raw material feed port. Assuming Lb as a length of a blending zone and D as a screw diameter of the extruder, the thermoplastic resin B is blended with the thermoplastic resin A in the blending zone of Lb/D=0.5 to 5.

Abstract: A method and an apparatus for manufacturing a polyurethane foam injected with strand mats. After a polyurethane foam solution is sprayed on the strand mats, the strand mats are moved upward and downward by prominences and depressions and then intermittently pressed by a pressing device, thereby the air in the strand mats being exhausted to the outside. Therefore, the polyurethane foam solution uniformly permeates into the strand mats. As a result, the insulating effect and mechanical strength of the polyurethane foam are increased, uniform surface with no air spaces is obtained, the mechanical properties are made uniform, and shrinkage, cracking, distortion and the like are prevented under a super-low temperature such as less than −165° C.

Abstract: A method and apparatus for compacting particles or granules in discrete cavities spaced along an article or articles such as a cigarette filter rod moved underneath the compacting system. The compacting system can be provided with spaced lugs or other protrusions that selectively compact particles within cavities, or a smooth outer periphery that results in progressive compaction of the entire article being moved underneath the compaction system. The article having cavities with particles that need to be compacted can be supported on a support rail with side support rails that maintain the shape of the article during the compaction process.

Abstract: A silicone gel sheet is heat-molded from a silicone gel composition comprising metal oxide magnetic particles and a thermoconductive filler. The sheet has a high electromagnetic wave absorbing property at a frequency ranging from 500 to 800 MHz. The hardness of the composition after hardening treatment is set in the range of 10-95 when measured with an ASKER F-type hardness meter. The metal oxide magnetic particles used here can be either Mn—Zn ferrite or Ni—Zn ferrite whose average particle diameter is 1-50 &mgr;m. For the thermoconductive filler, a metal oxide, aluminum nitride, boron nitride, silicon nitride, or silicon carbide can be used. In the silicone gel molded sheet, an electroconductive mesh is embedded in one surface layer of the silicone gel layers while the other surface is provided with adhesiveness.

Abstract: An automobile interior trim component includes a molded substrate laminated onto a cover sheet including a foam backing and a skin film having a surface texture. The cover sheet is preheated so the skin film is in a melted viscous liquid state above its melting temperature, and the foam backing remains in a solid elastic foam state below its melting temperature. The preheated cover sheet is mechanically pre-molded by a back mold into a front mold. Pressurized air is applied through the back mold, to blow-mold the cover sheet against the front mold, so the melted skin film reproduces a surface texture of the front mold surface while the solid foam backing acts as a buffer and air barrier layer. Vacuum is applied through the front mold surface. The mold is opened, a substrate is introduced, and the back mold then molds and thermally laminates the substrate against the foam backing of the cover sheet.

Abstract: An apparatus for fabricating fiber reinforced plastic structures is disclosed. In detail, the apparatus includes a mold surface upon which can be supported a lay-up of one or more layers of a fibrous material, and over which can be placed a fluid impervious outer sheet with an inlet port and having its edges marginally sealed upon the mold surface to form a chamber. A vacuum outlet is connected to the chamber for drawing a vacuum therefrom. A resin distribution system is positioned between the lay-up and the fluid impervious sheet. The resin distribution system includes a distribution sheet for receiving resin from the inlet port and at least one flat resin distribution line connected to the inlet port.

Abstract: The present invention is a continuous in-line compounding and extrusion system that does not require pre-dried wood flour or pelletized feed stock of cellulosic/polymer composite materials in order to produce net shapes from cellulosic/polymer composite materials. An exemplary embodiment of the present invention utilizes automated loss-in-weight feeders to dispense wood flour and all of the other cellulosic/polymer composite materials into a compounder. The compounder blends the cellulosic/polymer composite materials into a composite melt. The composite melt is continuously devolitalized as it travels through the compounder, a transition chute, and a finish extruder. The composite melt is then forced through a profile die which is fitted to the finish extruder in order to achieve a net shape.

Abstract: An apparatus for fabricating fiber reinforced plastic structures is disclosed. In detail, the apparatus includes a mold surface upon which can be supported a lay-up of one or more layers of a fibrous material, and over which can be placed a fluid impervious outer sheet with an inlet port and having its edges marginally sealed upon the mold surface to form a chamber. A vacuum outlet is connected to the chamber for drawing a vacuum there from. A resin distribution is positioned between the lay-up and the fluid impervious sheet. The resin distribution system includes a resin distribution medium for receiving resin from the inlet port and a resin containment layer between the resin distribution medium and lay-up for preventing resin flowing from the resin distribution medium into the lay-up until the resin distribution medium is substantially filled with resin.

Abstract: An automated method and apparatus is provided to mold, cure and package soft contact lenses. A conveyor system transports an array of molds through a plurality of automated work stations. The front curve mold halves are partially filled with a polymerizable monomer or monomer mixture and assembled and clamped to displace any excess hydrogel from the mold cavity. The assembly is precured and then transported through a cure station using UV radiation to complete polymerization, The assemblies are then pried apart in an automated station, with any excess monomer adhering to the removed mold half. The newly molded lens is then hydrated and separated from the front curve mold half in a hydration station. Following hydration the array of lens is automatically deposited into a plurality of packages with a robotic transfer device having a plurality of figures which transfer the lenses.

Abstract: A process for producing a carbon foam heat sink is disclosed which obviates the need for conventional oxidative stabilization. The process employs mesophase or isotropic pitch and a simplified process using a single mold. The foam has a relatively uniform distribution of pore sizes and a highly aligned graphic structure in the struts. The foam material can be made into a composite which is useful in high temperature sandwich panels for both thermal and structural applications. The foam is encased and filled with a phase change material to provide a very efficient heat sink device.

Abstract: An apparatus for manufacturing an elongate composite element in undefined lengths, the composite element containing reinforcement fibers embedded in a matrix based on a composition containing a curable resin, including a vacuum chamber, rigid-walled inlet tubing, an impregnation chamber, rigid-walled transfer tubing between the vacuum chamber and the impregnation chamber, a sizing die and, downstream of the sizing die, irradiation tubes providing radiation in the ultraviolet-visible spectrum to prepolymerize the resin.

Abstract: Methods and devices for manufacturing a conduit for placing a target vessel in fluid communication with a source of blood, such as a heart chamber containing blood. The conduit includes first and second portion adapted to be placed in fluid communication with a heart chamber and a target vessel. The conduit lies on the exterior of the myocardium between the blood source and the target vessel and delivers blood in multiple directions within the lumen of the target vessel. The conduit, which may be formed of any suitable synthetic vascular graft material, is generally T-shaped with the leg having two free ends disposed in the target vessel, preferably being secured thereto via a suture-free attachment. The conduit comprises vascular graft material and may be manufactured various ways, such as molding a conduit from any suitable biocompatible material or fabricating a conduit from one or more pieces of vascular graft material.

Abstract: A method for producing fibre-reinforced plastic components made of dry fibre composite preforms by means of an injection method for injecting matrix material. Arrangement of the fibre composite preform (1) on one surface (11) of the preform (1) resulting in a flow promoting device (15), on a tool (3), creates a first space (10) by means of a gas-permeable and matrix-material-impermeable membrane (7) surrounding the preforms (1). Formation of a second space (27) situated between the first space and the surroundings by means of a foil (19) which is impermeable to gaseous material and matrix material, is provided, with removal by suction, of air from the second space (27) resulting in matrix material being sucked from a reservoir into the evacuated first space (10) and with the flow promoting device (15) causing distribution of the matrix material above the surface (11) of the preform (1) facing said flow promoting device (15), thus causing the matrix material to penetrate the preform (1) vertically.

Abstract: A method of manufacturing a resin impregnated article comprises the steps of providing a mold onto which a reinforcing material is placed, sealing the reinforcing material with an impervious sheet and regulating the temperature of the reinforcing material and resin by placing a fluid in contact with the impervious sheet and regulating the temperature of the fluid.

Abstract: A method for quartz crucible formation wherein an at least substantially enclosed chamber surrounds a crucible mold. The atmosphere in the chamber is controlled to include a desired gas or combination of gases at a positive pressure. The positive pressure is achieved because the total outflow of gas is less than the total inflow of gas. A heat source is initiated to melt a quartz material lining the mold once the desired atmosphere is achieved, and the quartz material is fused.

Abstract: The invention relates to a method and device with which it is possible to arrange complicated shapes with considerable differences in height in wood fiber board, and in particular but not exclusively so called MDF (Medium Density Fiberboard). The deformation of the wood fiber board which can be achieved with the invention is known in the art as extusion, wherein a considerable plastic deformation takes place accompanied by flow and stretch of the material.

Abstract: A process for producing molded pitch based foam is shown which provides a more uniform density gradient throughout the ultimate product. The process utilizes a pressure drop during processing in order to induce foaming. By inducing foaming through process depressurization, additional viscosity manipulation can be achieved as well as improved density gradient characteristics in the ultimate product.

Abstract: A layered arrangement is fabricated by deposit on a mold surface to form a porous foam core of coated microballoons which is assembled within a sandwich between layers of fibrous skin. The sandwich supported on the mold surface is then is sealed within a film enclosure through which a one-shot infusion of liquid resin is performed. After curing and hardening of the infused resin, the film enclosure is removed from the sandwich to expose a multilayered structure.

Abstract: A resin infusion mold tool system for use in a vacuum assisted resin transfer molding process with a subsequent pressure bleed step. The mold tool system includes a mold assembly having an outer mold line tool connected to resin supply lines and supplying resin to the preform. A plurality of inner mold line tools form a hard interface with the inner mold line of the fiber preform and are held to within tight tolerances by an external locating fixture. Excess resin is drawn out of the fiber preform using a vacuum bag connected to vacuum lines and disposed over the inner mold line tools but not between the tools and the fiber preform. The mold assembly is placed in an autoclave, the resin supply lines are detached and the autoclave pressurized to bleed additional resin out of the preform to raise the fiber volume of the composite structure.

Abstract: A separator for fuel cells is efficiently mass-produced by heating and compression-molding a raw material mixture of a carbonaceous powder and a binder while reducing the residence time in a compression-molding machine without impairing the quality or functions of the separator to be obtained. In this process for producing a fuel cell separator, the raw material mixture of a carbonaceous powder and a binder is heated in a heating oven, subsequently introduced into a compression-molding machine, and then compression-molded therein.

Abstract: The invention relates to a method and device with which it is possible to arrange complicated shapes with considerable differences in height in wood fibre board, and in particular but not exclusively so-called MDF (Medium Density Fibreboard). The deformation of the wood fibre board which can be achieved with the invention is known in the art as extrusion, wherein a considerable plastic deformation takes place accompanied by flow and stretch of the material.

Abstract: A powder pressing apparatus comprises an upper punch and a lower punch for compression of a powder in a cavity formed in a through hole of a die. A gap between a side surface of the lower punch and a side surface of the through hole of the die is sealed by a sealing member. A lubricant is supplied with a gas from a nozzle in the side surface of the lower punch to the side surface of the through hole, and the lubricant applied to the side surface of the through hole is spread by an absorbing member. The cavity is filled with the powder while the cavity is under suction by a reduced pressure provided from the nozzle in the side surface of the lower punch. During the suction, a filtering member provides filtration for the lower punch not to draw the powder in.

Abstract: An apparatus and a method for filling high aspect ratio holes in electronic substrates that can be advantageously used for filling holes having aspect ratios larger than 5:1 are disclosed. In the apparatus, a filler plate and a vacuum plate are used in conjunction with a connection means such that a gap is formed between the two plates to accommodate an electronic substrate equipped with high aspect ratio via holes. The filler plate is equipped with an injection slot while the vacuum plate is equipped with a vacuum slot such that when a substrate is sandwiched therein, via holes can be evacuated of air and injected with a liquid simultaneously from a bottom side and a top side of the substrate. The present invention novel apparatus and method allows the filling of via holes that have small diameters, i.e., as small as 10 &mgr;m, and high aspect ratios, i.e.

Abstract: A method for fabricating fiber-reinforced composite structures, including centrifuge rotors, by resin transfer molding (RTM) is disclosed. The method involves loading reinforcing fibers into a mold and then injecting resin into the mold to coat the fibers to form the composite structure. Two types of reinforcing fibers are used—fabric preforms at the surfaces of the structure and chopped fibers at the interior of the structure. Also disclosed is a fiber-reinforced composite structure comprising a skin layer of reinforcing fabric, chopped fibers distributed throughout the interior of the structure, and epoxy resin that binds the fabric and chopped fibers together into a fiber-reinforced composite structure. The resin transfer molding method is especially useful for fabricating composite centrifuge rotors.

Abstract: The vacuum insulator in accordance with the present invention comprises glass white wool body which density is 0.1˜0.5 g/cm3 in density and is below 0.0023 kcal/mh° C. in thermal conductivity, and a non permeable container surrounding the body in which the pressure is between 10−6 ˜10−1 torr. The vacuum insulator is fabricated by piling up glass white wool, thermal-pressutizing the piled glass white wool to form a body of 0.1˜0.5 g/cm3 in density wherein the pressurizing is done at 0.007˜1.5 kg/cm2 and under 20° C. for more than 10 minutes, putting the body in the non-permeable container, and producing a vacuum in the container.

Abstract: A method and an apparatus for producing a shaped article or molding, which preponderantly includes plant material and a thermoplastic material, which are both introduced into an extruder. The plant material is compacted under pressure in a first extruder section and together with the thermoplastic material heated to an intended temperature at which the thermoplastic material melts. The pressure is then reduced to a value at which residual moisture of the heated material is transformed into water vapor or steam, which is removed from the extruder. The heated, dehumidified material is then compacted and extruded to the desired molding.

Abstract: The invention relates to a process for producing mouldings by injection moulding, the steps in the process being

Abstract: The present invention is a continuous in-line compounding and extrusion system that does not require pre-dried wood flour or pelletized feed stock of cellulosic/polymer composite materials in order to produce net shapes from cellulosic/polymer composite materials. A preferred embodiment of the present invention utilizes automated loss-in-weight feeders to dispense wood flour and all of the other cellulosic/polymer composite materials into a compounder. The compounder blends the cellulosic/polymer composite materials into a composite melt. The composite melt is continuously devolitalized as it travels through the compounder, a transition chute, and a finish extruder. The composite melt is then forced through a profile die which is fitted to the finish extruder in order to achieve a net shape.

Abstract: A mandrel-assisted resin transfer molding process and apparatus therefor provides a generally continuous, narrow annular channel between the perimeter of an inner male mold element and an outer female mold element. This channel allows air, heat and vapor to evenly escape and resin to outflow from the mold cavity everywhere around the edge of the part being molded. A very thin resin band forms in the channel is easily trimmed away, leaving the article completely finished on both sides and having a well defined edge that does not require shaping.

Abstract: A vacuum molding process includes selecting a flexible polymer cover for covering a selected cement container and at least partially filling the container with a cement mixture. The polymer cover is removably attached to the partially filled cement container and a vacuum is applied to the cement mixture in the container. The process may also include connecting a vibrator to the container for simultaneously vibrating the container and the placing of a hollow mold core member having a plurality of apertures therein in the middle of the container for the gas bubbles to escape as a result of the vibration of the cement mixture in a vacuum.

Abstract: A female mold for plastic sanitaryware manufacture has an open top to promote improved air escape from the mold as resinous backing resin fills the mold in order to reduce the number of gas inclusions within the backing material after it is cured. The female mold also provides thermal insulation for the curing backing material to permit better curing and to reduce the potential for delamination in the finished product. A production fixture is equipped with a gas impermeable lid for selective contact with the female mold, after the air has been expelled from the mold, in order to control undesirable styrene emissions.

Abstract: The present invention comprises a polycarbonate solid surface product through utilization of polycarbonate flakes. The polycarbonate flakes offer unique shapes and improved ultra-violet stability to the product. The polycarbonate flakes are also a source of consistent clear particulate and provide for increased mechanical properties in some areas over prior art 100% polyester products. Additional, fire retardant polycarbonate offers fire retardancy in a clear chip unlike opaque ATH filled polyester chips, or UV sensitive polyester that has been halogenated.

Abstract: A composite structure having first and second layers which are wrapped about one another to form a cylinder. The first layer is formed from an expandable film or foaming adhesive. The second layer is formed from a reinforcing member. The second layer is overlaid onto the first layer. The first and second layers are then rolled together in a jelly roll fashion. The roll is then cured to expand the film. The structure may thereafter be incorporated into a panel and drilled to receive a fastener. The composite structure is generally lightweight having a high compressive strength-to-density ratio. The physical properties of the composite structure may be tailored to a particular application. For example, the physical properties of the composite structure may be tailored to provide improved energy absorption or a reduced initial peak compressive strength. A method for forming a composite structure from an expandable film member and a reinforcing member is also provided.