Abstract: The invention relates to the formation of a smooth attractive surface on a composite molded article. More particularly, the invention relates to combining materials in a mold to result in a composite article having a finished surface. The invention relates to a method having improved efficiency and reduced emissions of hazardous air pollutants used in making composite molded articles comprising a reinforced thermosetting material having a thermoplastic exterior layer.

Abstract: The invention relates to the formation of a smooth attractive surface on a composite molded article. More particularly, the invention relates to combining materials in a mold to result in a composite article having a finished surface. The invention relates to a method having improved efficiency and reduced emissions of hazardous air pollutants used in making composite molded articles comprising a reinforced thermosetting material having a thermoplastic exterior layer.

Abstract: The invention relates to the formation of a smooth attractive surface on a composite molded article. More particularly, the invention relates to combining materials in a mold to result in a composite article having a finished surface. The invention relates to a method having improved efficiency and reduced emissions of hazardous air pollutants used in making composite molded articles comprising a reinforced thermosetting material having a thermoplastic exterior layer.

Abstract: A method and apparatus for molding composite articles can include a pair of opposed hollow mold sections having first and second molding membranes which define a mold plenum therebetween. Each mold section can be filled with a substantially noncompressible, thermally conductive fluid. The temperature of the mold plenum can be controlled by regulating the temperature of the thermally conductive fluid. Sensing of various parameters during the injection and curing processes of the molding fluid, for example pressure, flowrate, temperature and filling of the plenum can be used to optimize the molding process.

Abstract: A method of molding composite articles including arranging a pair of matched-tool mold sections in an opposed relationship, each mold section having a rigid housing and a thin, semi-rigid membrane removably and sealably mounted on the housing so as to define a fluid-tight chamber; filling the fluid-tight chambers with a non-compressible backing fluid; and accommodating thermal expansion of the backing fluid by an expansion chamber in fluid communication with the fluid tight chambers. The method further includes defining a mold plenum between the semi-rigid membranes when the mold sections are closed together; inserting reinforcement materials between the semi-rigid membranes prior to closing the mold sections; and injecting and curing a molding fluid after closing the mold sections.

Abstract: An apparatus for molding composite articles includes a pair of opposed matched-tool mold sections, each having a rigid housing and a thin, semi-rigid membrane removably and sealably mounted on the housing so as to define a fluid-tight chamber therein. The chamber of each mold section is filled with a noncompressible heat-conductive fluid to provide fluid backing to the portions of each membrane defining the molding surfaces of each mold section. A system of temperature control coils extending within each chamber are connected to an external heater/chiller unit to permit circulation therethrough of a suitable temperature control fluid, whereby positive control of the temperature of the backing fluid and, correlatively, the molding surfaces of the membranes.

Abstract: A method and apparatus for molding composite articles can include a pair of opposed hollow mold sections having first and second molding membranes which define a mold plenum therebetween. Each mold section can be filled with a substantially noncompressible, thermally conductive fluid. The temperature of the mold plenum can be controlled by regulating the temperature of the thermally conductive fluid. Sensing of various parameters during the injection and curing processes of the molding fluid, for example pressure, flowrate, temperature and filling of the plenum can be used to optimize the molding process.