Expanded compression molding of composite plastics

A method of forming a molded article 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. introducing a polymeric material onto said interior surface of said lower mold portion;
• c. pressing said upper mold portion and said lower mold portion together by means of said press, and compressing said plastic 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;
• d. inserting said lateral arm through each aligned pair of guides;
• e. 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 plastic material residing within said outside the press internal mold space, thereby forming said molded article.