Coretex is formed from using braided carbon or other fibre over a flexible foam core to form a 'rope'. This rope is then placed in a mould either by hand or by machine. The ropes can go round nodes to form frame structures. When the mould is filled with Coretex it is closed and epoxy resin drawn in under vacuum. The part is then cured at 60 degrees in a low temperature oven. Inserts can be added during the laying up process to take loads from attachments, which in the case of automobiles, are doors, suspension and engine mounting.
A simple T-piece beam is shown in the diagram and the internal structure of the beam made from 9 'ropes' is shown. In term of design data, Coretex provides a stiffness ( In plane elastic modulus E) of between 50 and 65 Gpa which is equivalent to woven carbon fibre prepreg laminates. This therefore translates to an equivalent weight saving to high cost prepreg structures. Typically 20% compared to aluminium and 60% compared to steel.
The Coretex manufacturing method and Coretex structural material is subject to patents and patent applications in UK, Europe, USA, Japan and India. Coretex know-how can be licensed worldwide.
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