Abstract: A fiber-reinforced composite structure has two molded outer polymeric layers spaced apart from each other and defining a cavity therebetween. Each molded outer polymeric layer defines a sealing surface extending about a periphery of the respective layer, and the opposing sealing surfaces cooperate to define a hermetic seal extending about a periphery of the cavity. One or more multi-directional fiber reinforcement layers are adhesively attached in a discontinuous manner to each outer polymeric layer, and define a first region of the cavity extending between each respective outer polymeric layer and adjacent fiber reinforcement layer, and a second region of the cavity extending between the fiber reinforcement layers. A core is located between the two outer polymeric layers, and is made of a resinous core material capable of exhibiting a foamed character and a resinous character.

Abstract: A system and method for forming a composite structure involves providing at least two polymeric sheets as outer layers such that a cavity is formed therebetween, adhesively bonding fibrous layers to the polymeric layers to hold the fibrous layers in place during processing, and injecting into the cavity a polymeric core material capable of exhibiting a foamed character and a resinous character. The cavity is evacuated during filling with the core material, and a blowing agent of the core material is activated upon exposure to the evacuated cavity. The core material contacting the fibrous layers is reconverted to its resinous character and forms a relative dense, resinous interface between the core and fibrous layers. Upon filling the region of the cavity between the fibrous layers, a catalytic reaction is initiated in the core.

Abstract: A fiber-reinforced composite structure has two molded outer polymeric layers spaced apart from each other and defining a cavity therebetween. Each molded outer polymeric layer defines a sealing surface extending about a periphery of the respective layer, and the opposing sealing surfaces cooperate to define a hermetic seal extending about a periphery of the cavity. One or more multi-directional fiber reinforcement layers are adhesively attached in a discontinuous manner to each outer polymeric layer, and define a first region of the cavity extending between each respective outer polymeric layer and adjacent fiber reinforcement layer, and a second region of the cavity extending between the fiber reinforcement layers. A core is located between the two outer polymeric layers, and is made of a resinous core material capable of exhibiting a foamed character and a resinous character.

Abstract: A fiber-reinforced composite structure has two molded outer polymeric layers spaced apart from each other and defining a cavity therebetween. Each molded outer polymeric layer defines a sealing surface extending about a periphery of the respective layer, and the opposing sealing surfaces cooperate to define a hermetic seal extending about a periphery of the cavity. One or more multi-directional fiber reinforcement layers are adhesively attached in a discontinuous manner to each outer polymeric layer, and define a first region of the cavity extending between each respective outer polymeric layer and adjacent fiber reinforcement layer, and a second region of the cavity extending between the fiber reinforcement layers. A core is located between the two outer polymeric layers, and is made of a resinous core material capable of exhibiting a foamed character and a resinous character.

Abstract: A crash energy absorption system for a motor vehicle, formed of an assembly of panels of lightweight core material sandwiched within and bonded to reinforcing or stiffener skins. Preferably, the reinforcing or stiffener skins comprise fiberglass, graphite, Kevlar or Spectra reinforced polymers with any combination of fibers and/or fiber orientations, or metal sheets, or ceramic sheets, while the lightweight core material comprises a low-density, dimensionally stable material such as balsa wood, synthetic foam material such as polyurethane foam. The crash energy absorption system may take the form of removable parts that are replaceable after an accident, or may be formed as integral parts of a monocoque body, or as a part of a composite body load-bearing frame.