US 5,266,249 AGranted

Method of forming a fiber reinforced plastic structure

AssigneeFusion Composites, Inc.

InventorsPaul J. Grimes, III, Timothy M. Duffy

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Abstract

A method of forming a hollow structure in a female mold includes the step of assembling a vacuum bag and an uncured composite layer assembly comprising a fiber reinforced resin in a female mold, so that the composite layer assembly extends along the inner surfaces of the mold, and so that the vacuum bag is received inside the composite layer assembly in the mold. The method further includes the step of evacuating the area between the vacuum bag and the composite layer assembly, so that the vacuum bag applies outward pressure to the composite layer assembly in order to urge the composite layer assembly outwardly against the inner surface of the mold. The method still further includes the steps of curing the composite layer assembly while maintaining a vacuum on the area between the composite layer assembly and the vacuum bag, and thereafter releasing the vacuum and removing the cured composite layer assembly from the mold.

Claims21

Dependent claims

A method of forming a hollow structure having a predetermined outer configuration comprising:

a. assembling a vacuum bag, a composite layer assembly made at least partially from an uncured fiber reinforced plastic material, an interior support wall, and an uncured fiber reinforced plastic overlap layer in a female mold, said female mold having an exterior and having an inner mold surface which defines an inner configuration which is complimentary to said predetermined outer configuration, said mold including at least two mold sections which cooperate to define said inner mold surface, said composite layer assembly substantially covering said inner mold surface and having an inner composite layer assembly surface which defines a confined interior area, said support wall being assembled so that it extends between spaced portions of said composite layer assembly and so that said support wall meets said composite layer assembly at interior joint areas, said uncured fiber reinforced plastic overlap layer being assembled so that it extends between said support wall and said composite layer assembly at said interior joint areas, said vacuum bag being received in said confined interior area and cooperating with said composite layer assembly for defining an evacuation area therebetween, said vacuum bag having an exterior surface and having an interior which is at approximately the same pressure as the exterior of said mold, said vacuum bag being operable for applying outward pressure to said inner composite layer assembly surface by the application of a vacuum to the exterior surface of said vacuum bag;
b. evacuating said evacuation area so that said vacuum bag operates to apply outward pressure to said inner composite layer assembly surface;
c. curing said composite layer assembly to form a cured composite layer assembly;
d. releasing the vacuum in said evacuation area;
and
e. removing said cured composite layer assembly from said mold.

3 more elements

A method of forming an interior joint at an intersection between adjacent elements in an enclosed area during the construction of a hollow structure, said adjacent elements including an outer wall portion and an interior support wall, said method comprising:

a. assembling said elements with an uncured fiber reinforced plastic material and a vacuum bag, so that said outer wall portion and said interior support wall cooperate to define said joint and to least partially define said enclosed area with said uncured fiber reinforced plastic material extending between said outer wall portion and said interior support wall at said joint, so that said vacuum bag and said fiber reinforced plastic material are received in said enclosed area, and so that said vacuum bag extends along said uncured fiber reinforced plastic material so as to define an evacuation area between said uncured fiber reinforced plastic material and an adjacent portion of said vacuum bag, said evacuation area being evacuatable to draw said adjacent portion of said vacuum bag toward said fiber reinforced plastic material at said joint;
b. evacuating said evacuation area so that said adjacent portion of said vacuum bag operates to apply outward pressure to said fiber reinforced bag operates to apply outward pressure to said fiber reinforced plastic material at said joint;
and
c. curing said uncured fiber reinforced plastic material.

1 more element

A method of forming an interior joint at an intersection between adjacent elements in an at least partially enclosed area during the construction of a hollow structure, said adjacent elements including an outer wall portion and an interior support wall, said method comprising:

a. assembling said elements with an uncured fiber reinforced plastic material and a vacuum bag, so that said outer wall portion and said interior support wall cooperate to define said joint and to least partially define said at least partially enclosed area with said uncured fiber reinforced plastic material extending between said outer wall portion and said interior support wall at said joint, so that said vacuum bag and said fiber reinforced plastic material are received in said at least partially enclosed area, and so that said vacuum bag extends along said uncured fiber reinforced plastic material so as to define an evacuation area between said uncured fiber reinforced plastic material and an adjacent portion of said vacuum bag, said interior joint being inaccessible for assembling and positioning said vacuum bag in said at lest partially enclosed area once said elements have been assembled with said uncured fiber reinforced plastic material and said vacuum bag, said evacuation area being evacuatable to draw said adjacent portion of said vacuum bag toward said fiber reinforced plastic material at said joint;
b. evacuating said evacuation area so that said adjacent portion of said vacuum bag operates to apply outward pressure to said fiber reinforced plastic material at said joint;
and
c. curing said uncured fiber reinforced plastic material.

1 more element

Dependencies are inferred from the claim text.

Facts

Application: 07/815,504Filed 2 Jan 1992
Granted: 30 Nov 1993
Term ends: Not estimatedThe source records don’t support an estimate.

Classification9 codes

B29C 70/446
Using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding: moulding…
B29C 70/44
For producing articles of definite length, i.e. discrete articles: using isostatic pressure, e.g. pressure difference-moulding, vacuum…
B29L 2031/5272
Sports equipment ; Games; Articles for amusement; Toys: surf boards
B63B 32/57
Water sports boards; Accessories therefor: boards characterised by the material, e.g. laminated materials