Polymer Composite Beam with In-Molded Flange Inserts

1 . A solid molded polymer composite beam comprising:

a. a first flange;

b. a second flange;

c. at least one web extending between the two flanges

d. wherein the first and second flanges are configured normal to the at least one web;

e. the first flange and the second flange each contains an in-molded rigid insert in the plane of the flanges normal to the at least one web.

2 . The solid molded polymer composite beam of claim 1 wherein the in-molded rigid insert in the flanges comprises a composite structure of two thin rigid inserts in the plane of the flange separated from each other by a filler material.

3 . The solid molded polymer composite beam of claim 1 wherein only one web extends between the two flanges.

4 . The solid molded polymer composite beam of claim 2 wherein only one web extends between the two flanges.

5 . The solid molded polymer composite beam of claim 4 wherein the only one web is a truss structure.

6 . A method of forming a solid molded polymer composite beam with inserts comprising:

a. providing a mold apparatus comprising;

i. a upper mold portion having an exterior pressable surface and an interior surface;

ii. a lower mold portion having an exterior pressable surface and an interior surface;

iii. a press having a press surface, a portion of said upper mold portion extending beyond said press surface and having an outside the press upper mold portion exterior surface and an outside the press upper mold portion interior surface, a portion of said lower mold portion extending beyond said press surface and having an outside the press lower mold portion exterior surface and an outside the press lower mold portion interior surface;

iv. said press being positioned to reversibly position said interior surface of said upper mold portion and said interior surface of said lower mold portion towards each other;

v. said outside the press upper mold portion interior surface and said outside the press lower mold portion interior surface together defining an outside the press internal mold space, when said upper mold portion and said lower mold portion are pressed together;

vi. a plate having a first surface and a second surface, said second surface of said plate being opposed to said outside the press upper mold portion exterior surface, said plate being separate from said press;

vii. at least one expandable member interposed between said second surface of said plate and said outside the press upper mold portion exterior surface;

viii. a plurality of vertical arms attached to opposite sides of said plate and forming a plurality of oppositely paired vertical arms, each vertical arm extending towards said lower mold portion, each vertical arm having a terminal portion having a guide, each pair of oppositely paired vertical arms together forming an aligned pair of guides, each aligned pair of guides being dimensioned to receive reversibly a lateral arm there-through;

b. attaching preconfigured inserts into said lower mold portion into the flange portions of said lower mold portion;

c. introducing a molten composite polymeric material onto said interior surface of said lower mold portion;

d. pressing said upper mold portion and said lower mold portion together by means of said press, and compressing said molten composite polymeric material between said interior surface of said upper mold portion and said interior surface of said lower mold portion, said guide of each vertical arm concurrently being positioned beyond said outside the press lower mold portion exterior surface;

e. inserting said lateral arm through each aligned pair of guides;

f. expanding each expandable member resulting in said plate moving away from said outside the press upper mold portion exterior surface and each lateral arm being brought into compressive contact with said outside the press lower mold portion exterior surface, and correspondingly compressing further said molten composite polymeric material residing within said outside the press internal mold space, thereby forming said molded article.

7 . The method of claim 7 wherein each expandable member is an expandable pillow interposed between said second surface of said plate and said outside the press upper mold portion exterior surface.

8 . The method of claim 7 wherein each expandable member is an expandable tube interposed between said second surface of said plate and said outside the press upper mold portion exterior surface.