Abstract: Large composite structures are produced using a vacuum assisted resin transfer molding process incorporating a resin distribution network. The resin distribution network is provided by a textured sheet of metal formed as an integral vacuum bag and mold. The texture is formed by upraised portions on one side of the sheet which correspond with depressions on the other side. Valleys between the upraised portions form the resin distribution network. A fiber lay up is placed against the textural sheet with the upraised portions facing the lay up. Main feeder grooves are also formed directly in the sheet. Resin is supplied under vacuum to the main feeder grooves, from where it travels through the valleys of the textured sheet to impregnate the lay up.

Abstract: Large composite structures are produced using a vacuum assisted resin transfer molding process incorporating a resin distribution network. The structure includes cores each having a main feeder groove or channel therein. A resin distribution network is provided adjacent the core surface in fluid communication with the feeder groove. In a first embodiment, the resin distribution network comprises a plurality of microgrooves formed in each core surface. In a second embodiment, the resin distribution network comprises a separate distribution medium surrounding each core. Each core and associated resin distribution network is covered with a fiber material. The dry lay-up is placed against a mold and encapsulated in a vacuum bag. Uncured resin is fed under vacuum directly into the main feeder groove in each core via a fitting through the bag. The resin flows from the main feeder groove through the resin distribution network and outwardly into the fiber material and is allowed to cure.

Abstract: Large composite structures are produced using a vacuum assisted resin transfer molding process incorporating a resin distribution network. The structure includes cores each having a main feeder groove or channel therein. A resin distribution network is provided adjacent the core surface in fluid communication with the feeder groove. In a first embodiment, the resin distribution network comprises a plurality of microgrooves formed in each core surface. In a second embodiment, the resin distribution network comprises a separate distribution medium surrounding each core. Each core and associated resin distribution network is covered with a fiber material. The dry lay-up is placed against a mold and encapsulated in a vacuum bag. Uncured resin is fed under vacuum directly into the main feeder groove in each core via a fitting through the bag. The resin flows from the main feeder groove through the resin distribution network and outwardly into the fiber material and is allowed to cure.

Abstract: Apparatus for the production of high strength fiber reinforced plastic structures via an improved vacuum assisted technique. A fluid impervious outer sheet is marginally sealed upon a mold to provide an enclosure, or chamber, in which a fiber lay up can be placed. The fluid impervious outer sheet is provided with a vacuum outlet, and the mold is provided with a resin inlet. Primary distribution media are provided one located on one side of the fiber lay up and the other on the opposite side of the fiber lay up. Each is of character which facilitates on application of a vacuum the ready, continuous flow of resin via the resin inlet into the chamber to the marginal edges of said resin distribution medium and flow through of the resin through the fiber lay up.

Abstract: A process, and apparatus for the production of fiber reinforced plastic structures, particularly high strength fiber reinforced plastic structures via an improved vacuum assisted technique. In apparatus which includes a fluid impervious outer sheet, or bag, provided with a resin inlet, marginally sealed upon a mold to provide a chamber in which can be place a fiber lay up and which in turn is provided with a vacuum outlet there is provided a resin distribution medium for location on one side of the fiber lay up of character which permits on application of a vacuum the ready, continuous flow of resin via the resin inlet into the chamber to the marginal edges of said resin distribution medium. Closure of the outer sheet, or bag, with the fiber lay up is prevented by the presence of the resin distribution medium while the flow of resin is continued throughout the resin distribution medium, the resin applied to one side of the fiber lay up, and the resin cured.

Abstract: The hull of a wooden vessel is laminated and provided with an outer plastic skin which provides a hull of high structural strength, and protects the wood interior against rot and attack by marine organisms. In its preferred aspects, a skin of fabric-like fiberglass is chemically bonded (and preferably chemically and mechanically bonded) to a wooden hull constituted of wooden planking at least three-fourths inch in thickness by use of an elastomeric adhesive which, after curing, is capable of stretching at least twice, and preferably from about 3 to about 5 times its length, and the outer surface of the fabric-like fiberglass is saturated with resin, covered with a chopped fiberglass mat, cured, a fairing compound is applied to the exterior of the skin, and the surface is sanded and painted.

Abstract: A new and further improved multi-ply fabric, and process for the manufacture of such fabric, particularly useful in boat building wherein the fabric must fit or assume the shape of compound-curved surfaces to suitably serve as a base or support for resin or liquefied plastics added thereon and cured or hardened as an initial step in the formation of, e.g., a fiberglass reinforced plastic boat hull. The fabric is characterized generally as of a two-ply construction embodying an upper and lower ply between which is "sandwiched" and secured a series of parallel aligned, spaced apart, springy elements of specific character between which can be placed yarns or rovings to impart tensile strength.