CONTINUOUS MANUFACTURING OF A COMPOSITE STRUCTURE

1 . A composite structure, comprising:

an outer layer comprised of a first resin material and defining an outermost surface of the composite structure;

an inner layer comprised of the first resin material and defining an innermost surface of the composite structure;

a core material positioned intermediate the outer and inner layers; and

a second resin material in contact with the core material and at least one of the outer layer and the inner layer, wherein the second resin material is different from the first resin material.

2 . A method of manufacturing a composite structure, the method comprising:

providing a linear conveyor system having at least a first zone, a second zone, and a third zone, where the first, second, and third zones are linearly aligned with each other;

providing a first layer of precured resin material in the first zone;

providing a core material in the first zone, the core material being configured as foam preforms;

receiving the core material onto the precured resin material in the first zone in a direction transverse to the linear conveyor system;

providing a second layer of precured resin material in the first zone;

receiving the second layer of precured resin material on the foam material in the first zone;

integrally forming the composite structure from the first layer, the core material, and the second layer in the second zone;

cutting the formed composite structure to a predetermined size in the third zone; and

removing the cut composite structure from the linear conveyor in the third zone.

3 . The method of claim 2 , wherein the precured resin material is a thermoplastic material.

4 . The method of claim 2 , wherein integrally forming the composite structure includes applying at least one of heat or pressure to the first layer, the core material, and the second layer while the first layer, the core material, and the second layer move together through the second zone.

5 . The method of claim 2 , wherein the conveyor moves through the first, second, and third zones at a non-zero speed.

6 . The method of claim 2 , further comprising providing a non-cured resin material in the first zone and applying the non-cured resin material to at least the core material.

7 . A method of forming a composite structure, the method comprising:

providing a first layer of a thermoplastic resin material;

providing discontinuous core materials onto the first layer;

providing a second layer of the thermoplastic resin material onto the core materials;

providing a thermoset resin material to at least one of the first layer, the second layer, or the core materials, and wherein excess quantities of the thermoset resin material not provided to at least one of the first layer, the second layer, or the core materials are not recycled; and

curing the thermoset resin material separately from curing the thermoplastic resin material to integrally form the composite structure from the first layer, the core material, the second layer, and the thermoset resin material.

8 . The method of claim 7 , wherein the discontinuous core materials are a plurality of discrete core panels positioned transversely to a direction of the first layer.

9 . The method of claim 8 , further comprising:

providing a conveyor for directly receiving the first layer; and

moving the conveyor at a predetermined, non-zero speed along a linear movement axis;

wherein providing the discontinuous core materials includes positioning the discrete core panels transversely to the linear movement axis of the conveyor.

10 . The method of claim 8 , wherein providing the discontinuous core materials includes robotically providing the plurality of discrete core panels onto the first layer.

11 . The method of claim 7 , further comprising:

providing a thermoset resin supply;

wherein providing the thermoset resin material to at least one of the first layer, the second layer, or the core materials includes spraying the thermoset resin material from the thermoset resin supply onto at least one of the first layer, the second layer, or the core materials, and the excess quantities of the thermoset resin material are not recirculated to the thermoset resin supply.

12 . The method of claim 7 , further comprising:

cutting the formed composite structure to a predetermined size; and

sealing edges of the cut composite structure where exposed core materials are present.

13 . The method of claim 12 , further comprising:

providing a conveyor for directly receiving the first layer;

moving the conveyor at a predetermined, non-zero speed along a linear movement axis; and

inspecting the formed composite structure while the formed composite structure is moving on the conveyor at the predetermined, non-zero speed.

14 . A method of forming a composite structure, the method comprising:

providing a manufacturing surface having a first direction;

providing a first layer of resin material on the manufacturing surface;

providing discontinuous core materials onto the first layer;

providing a second layer of resin material onto the core materials, wherein excess quantities of the resin material not provided to at least one of the first layer, the second layer, or the core materials are not recycled;

curing the first layer of resin material and the second layer of resin material to form a composite material;

removing the composite material from the manufacturing surface; and

maintaining the first layer of resin, the core materials, and the second layer of resin material in the first direction when forming the composite material, wherein the composite material is removed from the manufacturing surface while extending in the first direction.