Abstract: A compression molding apparatus including a top mold base, a top mold insert removably mounted in the top mold base, a bottom mold base, and a bottom mold insert removably mounted in the bottom mold base. The top and the bottom mold bases are pressed together to compress a molding material inserted between the top and the bottom mold inserts to compression mold a desired part. The top and bottom mold inserts are removed and replaced with different top and bottom mold inserts to compression mold a different part.

Abstract: A molding apparatus is provided which comprises a lower mold portion and an upper mold portion movable into engagement with the lower portion. A movable spray head is disposed on a traversing rack mounted within a retractable coating box. The coating box upper surface contains a first opening corresponding in size and shape to the outer periphery of the mold cavity of the upper mold and a second opening which corresponds in size and shape to the opening of an overspray recovery transition piece disposed at a position adjacent the fully disengaged upper mold portion. Prior to a molding operation, the coating box engages the upper mold permitting both the transition piece opening and cavity opening in the top surface of the box to align with the transition piece and cavity, respectively.

Abstract: The invention relates to a method and system for producing a composite structure, consisting of a foam core surrounded by an exterior shell. More specifically, the invention relates to a method of manufacturing a unitary composite article of a desired shape. The method broadly includes fabricating an exterior shell, which can be composed of either a single member or multiple portions, having the desired shape of the composite article. If there are multiple portions, those portions have peripheral edges which allow the portions to be assembled together to form the exterior shell. The exterior shell of the invention defines an internal cavity. A foam reaction mixture is injected into the cavity where it reacts exothermically and expands. During expansion, the foam adheres to the surface of the cavity. Prior to injection of the foam, the exterior shell is positioned within a structural frame which surrounds the shell. The frame resists movement of the exterior shell as the foam reaction mixture expands.

Abstract: The formation of a composite formed by spreading a liquid thermosetting resin over a continuously moving plastic film or sheet. Chopped fiber is added and a fabric or veil, such as dacron polyester cloth, is continuously laid over the top to form a reinforced composite. This continuously produced thermosetting resin composite is rolled into a coil. After a maturation period, the plastic film or sheet may be removed from the SMC composite and sections of appropriate size and weight are cut from the coil and placed over the die of a compression molding machine, veil side down, up or both. The material is then compression molded at a pressure of 500-3000 p.s.i. (35 to 210 kg. per sq. cm.) and a temperature of 100.degree.-165.degree. C., and cured into an article. The fabric used has a grab break strength of at least 10 lbs. (4.5 kg.

Abstract: The formation of a composite formed by spreading a liquid thermosetting resin over a continuously moving plastic film or sheet is disclosed. Chopped fiber is added and a fabric or veil, such as a dacron polyester cloth, is continuously laid over the top to form a reinforced composite. This continuously produced thermosetting resin composite is rolled into a coil. After a maturation period, the plastic film or sheet may be removed from the SMC composite and sections of appropriate size and weight are cut from the coil and placed over the die of a compression molding machine, veil side down, up or both. The material is then compression molded at a pressure of 500-3000 p.s.i (35 to 210 kg. per sq. cm.) and a temperature of 100.degree.-165.degree. C., and cured into an article. In another embodiment, the fabric or veil may be first placed on one of the die elements, e.g., the bottom die. SMC is then placed over the fabric to make up the total charge.