This invention relates to extruded composite materials specifically focusing on the increasing load bearing capacity and the overall strength of composites. Injectable conformable structural core materials are used to replace foam cells inside extruded composite materials thereby increasing the overall load bearing stability and strength. The core materials are tailored to have a desired CTE with respect to the structural materials. The core materials may also incorporate fibers and solid structural fillers for increasing the strength of the composite member. The objective is to enable composite materials to have the highest structural load bearing capability possible so that these technologies can be used as the replacement of wood, in aerospace applications and for other purposes.

A carbon fiber casing of a goalkeeper PU foam hockey stick and a production process thereof are disclosed. The carbon fiber casing of the goalkeeper PU foam hockey stick comprises a reinforcing carbon fiber casing, a wood or fiber stick and PU foam. A reinforcing part is arranged on the PU foam. The reinforcing carbon fiber casing is forcibly disposed around the corresponding reinforcing part of the PU foam. The PU foam is laminated onto the wood or fiber stick together with the reinforcing carbon fiber casing. The reinforcing carbon fiber casing is formed by heating fibers and epoxy resin in a mold, so that the strength of the whole goalkeeper PU foam hockey stick is improved.

This invention relates to extruded composite materials specifically focusing on the increasing load bearing capacity and the overall strength of composites. Injectable conformable structural core materials are used to replace foam cells inside extruded composite materials thereby increasing the overall load bearing stability and strength. The core materials are tailored to have a desired CTE with respect to the structural materials. The core materials may also incorporate fibers and solid structural fillers for increasing the strength of the composite member. The objective is to enable composite materials to have the highest structural load bearing capability possible so that these technologies can be used as the replacement of wood, in aerospace applications and for other purposes.

A method of manufacturing building panels includes assembling a frame of a building panel. The frame defines at least one cavity and at least one injection aperture in fluid communication with the at least one cavity. The method also includes positioning the frame on one of a base and a shelf of a multi-panel consolidation device having a plurality of shelves, with the shelves being in an expanded configuration, and at least substantially enclosing the at least one cavity. The method also includes forcing the shelves of the multi-panel consolidation device into a collapsed configuration, and injecting an expandable polymer through the at least one injection aperture into the at least one cavity. The method further includes forcing the shelves into an expanded configuration after a predetermined period of time selected to permit the expandable polymer to form a foam bonded to the frame.

An exemplary reinforcing element (104) may be configured to be received within a longitudinally extending cavity (C) defined by a structure (102). The reinforcing element may include a base portion (106) having a bonding material (108, 160) applied thereon, and a member (110, 150) selectively secured to the base portion and configured to selectively extend away from the base portion when the reinforcing element is received within the cavity. Accordingly, the reinforcing element may define a first length (L1) when the member is in a first position with respect to the base portion, and a second length (L1+L2) when the member is in a second position extending away from the base portion, the second length being greater than the first length. The selectively extending arrangement of the reinforcing element may generally allow improved ease and accuracy of installing the reinforcing element within a generally closed structure.

The present invention relates to a molding made of reactive foam, wherein at least one fiber (F) is arranged partially inside the molding, i.e. is surrounded by the reactive foam. The two ends of the respective fiber (F) not surrounded by the reactive foam thus each project from one side of the corresponding molding. The reactive foam is produced by a double belt foaming process or a block foaming process. The present invention further provides a panel comprising at least one such molding and at least one further layer (S1). The present invention further provides processes for producing the moldings according to the invention from reactive foam/the panels according to the invention and also provides for the use thereof as a rotor blade in wind turbines for example.

A method of forming a support pole, comprising splitting one or more canes of bamboo, or similar tubular plant material, into a plurality of split lengths; inserting a bundle of the split lengths from one or more canes into an outer tube (4); tilting the outer tube (4) at an angle from horizontal and injecting a matrix material into the outer tube (4) so as to fill in between the split lengths and encapsulate the split lengths to form a substantially solid core. The method may comprise injecting the matrix material at multiple injection points (25a, 25b, 25c, 25d) along the length of the tube (4).

A process and assembly for producing a structural article, as well as an article produced according to any process and assembly. A mold has a base and a hinged lid, either or both of which include a cavity interior which defines a negative of the structural article to be produced. A structural insert placed within the mold, prior or subsequent to a plasticized and structural forming foam material also being placed within the mold. The foam cures and sets in encapsulating fashion around the insert so that, upon removal, the insert is coated within the formed material.

A foam molding article includes an outer-shell-configuring part, an insert that is at least partially embedded in the outer-shell-configuring part, and a fitting member. The outer-shell-configuring part includes a body side foam member. The body side foam member includes a foam and a missing part where a part of the foam is missing. The missing part is located in an intermediate part of the body side foam member, and the fitting member is mounted in the missing part.

The present invention relates to a method for reinforcing a vehicle subframe comprising one or more hollow sheet metal parts, comprising: determining at least one area on a hollow sheet metal part of a subframe with respect to specified conditions; preparing a reinforcement part which is insertable into the hollow sheet metal part at the determined area, wherein the reinforcement part comprises: a carrier having at least one hollow chamber; and a pre-foam of a foam material, which is able to expand after being heated, the pre-foam being isolated from the at least one hollow chamber and distributed at least partly on the periphery of the carrier; and installing the reinforcement part within the hollow sheet metal part at the determined area and heating the pre-foam such that it expands. The present invention also relates to a vehicle subframe reinforced by said method.