Abstract: The invention concerns a composite part, comprising an elongated foam core and a flow channel media attached to a first elongated side thereof. The flow channel media forms interstices for the passage of resin. At least one fabric layer is secured to the elongated foam core, and encloses a first elongated side of the foam core, including the flow channel media. In this way, a resin flow path is defined along the first elongated side. The fabric layer can further enclose at least a second and third elongated side of the foam core where, where each of the second and third elongated sides adjoin the first elongated side. Fabric tab portions can be provided extending from the second and third elongated sides for aiding in the installation of the composite part in a larger composite structure.

Abstract: The invention concerns a composite part, comprising an elongated foam core and a flow channel media attached to a first elongated side thereof. The flow channel media forms interstices for the passage of resin. At least one fabric layer is secured to the elongated foam core, and encloses a first elongated side of the foam core, including the flow channel media. In this way, a resin flow path is defined along the first elongated side. The fabric layer can further enclose at least a second and third elongated side of the foam core where, where each of the second and third elongated sides adjoin the first elongated side. Fabric tab portions can be provided extending from the second and third elongated sides for aiding in the installation of the composite part in a larger composite structure.

Abstract: Polymer blends of unsaturated polyetherester resins and dicyclopentadiene polyester resins give single-phase, cured thermosets having high tensile and flexural strength. The thermosets exhibit a single glass-transition temperature within the range of about 70.degree. C. to about 150.degree. C. The synergism resulting from polymer blending provides a cost-effective way to improve the strength properties of cured polyetherester thermosets, and coincidentally, gives a way to improve the flexibility and toughness of cured DCPD polyester thermosets. Glass-reinforced thermosets made from polyetherester resin blends show exceptional structural fatigue resistance.

Abstract: The technique uses an extruder for delivering a supply of softened thermoplastic resin material containing a foaming or expanding agent, the resin material being under pressure and therefore unexpanded in the extruder, but being delivered into an unconfined zone of lower pressure for partial expansion. The partially expanded resin material is drawn by a puller mechanism through a chilled shaping or sizing die of a cross sectional dimension smaller than that of the material in the unconfined zone. The material drawn into the sizing die continues its expansion in the interior of the profile with resultant development of porosity in the core of the profile while the surface layer is cooled and hardens as a substantially unexpanded structural shell.

Abstract: The technique uses an extruder for delivering a supply of softened thermoplastic resin material containing a foaming or expanding agent, the resin material being under pressure and therefore unexpanded in the extruder, but being delivered into an unconfined zone of lower pressure for partial expansion. The partially expanded resin material is drawn by a puller mechanism through a chilled shaping or sizing die of a cross sectional dimension smaller than that of the material in the unconfined zone. The material drawn into the sizing die continues its expansion in the interior of the profile with resultant development of porosity in the core of the profile while the surface layer is cooled and hardens as a substantially unexpanded structural shell.

Abstract: Thermoplastic polymers containing a blowing agent are extruded into an unconfined zone and allowed to partially expand. The polymers are then conveyed through a confined moving passage of predetermined configuration formed, for example, by intermeshing cooled rolls, to shape the extrudate to the predetermined configuration and solidify the surface layers. The extrudate is further cooled by subjecting alternate surfaces to cooled roll surfaces, whereby a continuous ribbon, or shaped extrudate, having a dense skin and a foamed core is formed. The method is particularly applicable to small cross-section profiles which can be cut into short lengths to be useful as ice-cream sticks or tongue depressors.