Method of making and using flexible mandrel

Abstract

The invention provides a method of making an elastomeric mandrel for use in formation of parts from composite materials. The method of making includes providing a separable mold with an interior chamber shaped to provide a desired exterior mandrel size and shape; applying uncured elastomeric material to surfaces of the interior chamber of separated parts of the mold; joining the elastomeric material by assembling the mold parts prior to cure such that the material joins at seams and allowing the elastomeric material to cure into a shape of the desired flexible mandrel. The mandrel is provided with a fill opening such that it is fillable with a particulate solid media and evacuable to compact the media. The invention also provides a method of using a flexible mandrel including the steps of providing a hollow elastomeric mandrel with a predetermined exterior size and shape, a fill opening, and an evacuation port and providing a separable mold having an interior cavity surface sized and shaped to correspond to a desired exterior size and shape of the mandrel in use. The mandrel is placed into the mold and an external vacuum is provided within the mold to draw the mandrel snugly against the mold's interior cavity surface. The mandrel is then filled with a particulate solid media through the fill opening and an internal vacuum is provided within the mandrel through the evacuation port to compact said media into a substantially rigid form. The external vacuum is then released while maintaining the internal vacuum and the mandrel is removed from the mold for use.

Dependencies are inferred from the claim text.