Abstract: A process for producing an object made from plastic material with a mesh structure, wherein the mesh structure is deformed in at least one defined area, in such a manner that the original mesh structure of the area is eliminated and an essentially continuous structure and information can be introduced in this area.

Abstract: A method of manufacturing a honeycomb structure, the method comprising the steps of forming staggered cells through the entire thickness of a fiber fabric, causing loosely held pegs to penetrate into respective ones of the cells, each peg having a cross-section of size smaller than that of the corresponding cell and being made of a material that is suitable for expanding; expanding the pegs so that they fill the cells and exert pressure on the inside faces of the cells; and shrinking the pegs and then withdrawing them.

Abstract: A process for forming a multilayer composite insulator includes: (a) forming an insulator precursor by orienting an insulation insert in a desired location between a first facing layer of and a layer of a polymer based blanket material; (b) closing the insulator precursor in a molding press; (c) heating the insulator precursor in the molding press to a temperature sufficiently high to soften polymer binding fiber in the polymer based blanket material and cause reshaping; and (d) cooling the insulator precursor in the molding press so as to set the insulator precursor in its molded shape and complete formation of the insulator. Other relates processes are also disclosed.

Abstract: A method for manufacture of a hollow complex three-dimensional fiber golf club head having at least one hole. A fluid-removable core is shaped in the general form of the golf club head, placed in a flexible pressurizable bladder around the core, at least one ply of fiber impregnated with a curable resin is wrapped over the core and bladder, and a cured part is formed by pressurizing the bladder while the core, bladder, and impregnated fiber is in a female mold to force the plies against the inner surfaces of the mold. After heating to cure the resin, the bladder and the fluid-removable core is removed from the interior of the cured part by disintegrating core with a fluid sufficient to allow removal of the bladder.

Abstract: This invention relates to a novel apparatus and process for producing thermoplastic articles. In one aspect, the invention pertains to a process for manufacturing fiberglass products using a fiberglass material consisting of fiberglass strands commingled with heat-formable polypropylene strands. A molding apparatus comprising: (a) an air pressure chamber with an open side; (b) a flange plate fitted to the open side of the air pressure chamber, said flange plate having an opening therein for receiving a mold; (c) an upper bladder associated with the flange plate and covering the opening; (d) a base pressure plate; (e) a mold positioned on the base pressure plate; and (f) a locking mechanism for securing the air pressure chamber with the base pressure plate, and balanced air pressure in each chamber during molding.

Abstract: A method for forming composite materials is presented, including providing a composite charge wider than a first surface of a mandrel, and positioning the composite charge across the first surface of the mandrel. The portion of the composite charge overhanging the first surface of the mandrel is supported and urged against the mandrel while supporting the unbent portion of the composite charge substantially parallel to the first surface of the mandrel. The invention also provides a system, using a compression mold of forming bladders and heater plates, to form a composite charge over a mandrel, while supporting the unbent portions of the composite charge during forming substantially parallel to the upper surface of the mandrel. The present invention minimizes the shear zone where plies in the composite laminate charge slide past one another during the forming process reducing or eliminating out-of-plane fiber buckling.

Abstract: A method of making a vehicle interior trim part includes forming an air-permeable substrate into a desired shape; positioning the formed substrate and a cover material on a vacuum mold such that the substrate extends between the cover material and the mold; and vacuum forming the cover material over the substrate.

Abstract: The invention provides a method of manufacturing a part out of reinforced plastics material, the method comprising the following steps: superposing at least one sheet and at least one item of local reinforcement in a mold before the mold is closed, at least one of the sheet and the local reinforcement being constituted by reinforcing fibers and thermoplastic material, the mold having a setback adjacent to the local reinforcement and of width greater than the local reinforcement; and introducing thermoplastic material into the setback in such as a manner as to compact the local reinforcement and an underlying region of the sheet, the mold being shaped so as to compress the sheet on either side of the local reinforcement during closure of the mold.

Abstract: A composite sports racquet frame is made by placing a first prepreg tube into a first mold plate and a second prepreg tube into a second mold plate. A plurality of pin plates, each having a plurality of pins which are at least substantially parallel to one another, are secured to the mold plate so that, when the mold is closed, the pins extend between the two tubes. The tubes are pressurized to assume the shape of the mold and contact one another, and the mold is heated to allow resin to flow between the tubes as they cure, the pins forming pin holes in the frame. Once cured, the frame is removed from the mold, and the pins are withdrawn. If desired, the ends of the tubes forming the handle section can be kept separate from one another during the molding process, by using a removable mold plate. In this manner, not only do the two tubes become integral with one another, at least in the head portion, but string holes do not need to be drilled after the racquet is molded.

Abstract: A process for producing unmelted fibrous polytetrafluoroethylene (PTFE) resin from which multi-directional planar oriented structures such as sheets and planar shapes can be readily fabricated. Unfilled forms as well as filled and reinforced products are achievable. Novel composite-plied structures or unsintered sheets can be built by layering two (2) or more sheets containing functional fillers or reinforcements and then sintering said layers to provide a homogenous bond between all layered sheets. True reinforcement of formed fluoropolymer structures can be produced with tensile properties, which exceed the strength of virgin products. Microporous asymmetric membranes, which have decreasing pore size in a series of plies can be readily fabricated.

Abstract: A golf club and a primarily non-metallic golf shaft that has an overall light weight are provided. The shaft has a weighting plug located to provide a swingweight similar to a typical steel shafted golf club. A method of making the golf club and golf shaft is simple and efficient, and centers the plug in the golf shaft. The method also provides the advantage of substantially infinitely variable plug density selection within a range of densities. A set of clubs thus made increases playability by providing a range of club weights in the set.

Abstract: A mold to make a plastics material piece includes two parts defining a cavity corresponding to the piece to be made, each part has a peripheral zone for coming into contact with the other part's peripheral zone to define the mold's joint face. One part is made up of two blocks, namely a central block and a peripheral block, the two blocks suitable for sliding relative to each other in the mold closure direction, and the peripheral block capable of movement so as to move the peripheral zone away from the edges of the sheet. A method of making a plastics material piece includes placing a sheet in a part of a mold, moving a peripheral block, closing the mold, and moving the peripheral block to a molding position while keeping the first and second peripheral zones in contact.

Abstract: In a pressware die set, a segmented punch for fabricating a pressed disposable food service article having a substantially planar bottom portion, a sidewall and a rim portion. In one embodiment, the punch is mounted to reciprocate cyclically between an open position and a forming position about an axis of reciprocation and includes outer punch surfaces for forming the sidewall and rim portions of the pressed disposable food service articles, as well as a substantially planar punch surface suitably mounted and dimensioned to engage the substantially planar bottom portion of the disposable food service article. The improved punch includes a knock-out stripper ring juxtaposed with the substantially planar punch surface, defining a knock-out surface and which is reciprocally mounted with respect to the central substantially planar punch surface such that the knock-out surface is contiguous with the substantially planar punch surface when the punch is in a forming position.

Abstract: A method and apparatus for manufacturing a preform component for a golf club head composed of a plurality of plies of pre-preg material is disclosed herein. The preform component is preferably a face component, a crown component or a sole component, composed of a plurality of plies of pre-preg material. The apparatus preferably has a plunger head attached to a pneumatic cylinder for compressing the plies of pre-preg sheets within a mold cavity configured to define a preform component.

Abstract: There is disclosed a molding compound. The molding compound preferably includes a macrocyclic oligoester that reacts with itself, a secondary compound or another macrocyclic oligoester during molding of the molding compound. Exemplary secondary compounds include a cyclic ester, a dihydroxyl-functionalized polymer or the like.

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: A method for the production of a multiple phase composite material, wherein the composite material includes a major phase component and at least one minor phase component. The major and minor phase components are arranged in a desired predefined morphological structure in which the major phase component and the minor phase components have predefined size and shape characteristics. The method involves supplying the major phase component to a chaotic mixer (10) in a controlled manner and supplying the minor phase components to the chaotic mixer (10) in a controlled manner. Within the chaotic mixer (10) the major phase component and minor phase components undergo mixing according to controlled parameters to controllably and progressively develop predefined desired morphologies. Resulting structures are also provided.

Abstract: A carbon material which is an isotropic bulk material in which a rigid aromatic polymer or a reinforcing polymer is dispersed in the matrix polymer finely, homogeneously and sufficiently, and which is excellent in physical characteristics, particularly in conductivity, by mixing a matrix polymer with an aromatic heterocyclic copolymer precursor containing functional groups having heterocycle forming ability in which at least one of said functional groups is substituted by another functional group, in an organic solvent to form a mixed solution, removing the solvent therefrom to form a coagulum, thereby preparing a three-dimensional mesh type molecular composite material, and then burning the resulting composite material.

Abstract: An electric power steering apparatus including a reduction mechanism 5 for transmitting an output of a steering assist motor 1 to a steering mechanism through a worm 3 and a worm wheel 4, in which the worm wheel 4 is formed by a thermosetting synthetic resin filled with a sheet 6 of aramid fibers having a low attacking property to a counter member and an effect of improving the abrasion resistance of the synthetic resin. Even when the reduction mechanism is used in an engine room or the temperature of the reduction mechanism is raised by frictional heat with heightening power, the reduction mechanism is durable, and further the gears have excellent abrasion resistance and toughness and improved durability.

Abstract: A process for the manufacturing of a decorative laminate, which laminate comprises an upper decorative and abrasion resistant thermosetting laminate layer and a carrying core. The upper side of the core is provided with the abrasion resistant thermosetting laminate while the lower side of the core is provided with a balance layer. This balance layer has the purpose of preventing warping of said decorative laminate while at the same time having the purpose of acoustic dampening. The balance layer comprises a layer of a polymer. The balance layer and the thermosetting laminate are joined with said core by means of pressing. Said carrying core further is provided with a dampening foil of an elastomer arranged between the upper side of the core and the abrasion resistant thermosetting laminate. The elastomer and thermosetting laminate are joined with each other and with the core by means of pressing. The achieved laminate is then cut into panels and provided with edges intended for joining.

Abstract: A method for manufacturing fiber-reinforced moldings in a resin mat apparatus. The manufacturing procedure is performed in a continuous manner of operation from the mixing of the components of the resin mixture to the procedure of pressing a molding. The apparatus includes a controlled-temperature, continuous thickening unit for a time-prescribed maturation process of the endless resin mat. Endless felts carry the endless resin mat in a meander or serpentine path through the continuous thickening unit.

Abstract: A method for producing a bicycle wheel rim having an inner peripheral wall, an outer peripheral wall, two lateral walls joining said peripheral walls, and two circumferential wings, for anchoring a tire, is provided. The method providing a rim made of a single part made of structural fiber based material, preferably carbon fiber material.

Abstract: Methods and systems for applying crosslinking agent to a sheet of cellulose fibers are described. The method and system apply crosslinking agent to one or both sides of the sheet and results in a sheet having a high loading of crosslinking agent that is uniformly distributed within the sheet.

Abstract: A method of manufacturing a composite uses a hybrid tool which serves both as a form on which constituent materials are applied for bonding or curing into a part in a desired configuration, and as a fixture for holding the bonded or cured materials in the originally applied position during subsequent machining of a peripheral edge of the part. The method includes fabricating a face sheet of composite material having a facing surface configured to the reverse of a desired shape of one surface of a part to be made on the tool. The materials for the part are applied on the face sheet, debulked, bonded or cured, and edge trimmed thereon, all while on the face sheet in the originally applied position.

Abstract: A method and method to ensure the uniform collapse and diminished loading forces of a prosthesis, the prosthesis having at least one layer of biocompatible material. The device includes a way to stabilize the prosthesis, wherein the prosthesis can be incrementally axially rotated, and a way to manipulate the layer of biocompatible material simultaneously at several distinct points along an axis of the prosthesis so that a set of alterations is formed in the biocompatible layer.

Abstract: A method of producing a non-crimp fabric (10) and a non-crimp fabric comprising a layup of fabric plies (12) stitched together by a thread (18), at least part of which is fusible, is provided. The method can include heating the stitched plies (12) to soften or melt the fusible thread (18). The use of fusible thread (18) can act as an in situ binder within the non-crimp fabric (10) and tension created by the unfused stitching may create channels for matrix resin infusion during manufacture.

Abstract: A process for the production of a panel (7) of composite material with stiffening strips (3), in which a mold (1) is draped with at least one first ply (2) of fibers pre-impregnated with resin, there is emplaced at desired positions on said ply (2) at least one stiffening strip (3), the stiffening strip (3) as well as at least a portion of the remaining surface of the first ply (2) is covered with at least one second ply (4) of fibers pre-impregnated with resin, then a bladder (6) is placed to cover the above elements, the assembly is then placed under vacuum and then in an autoclave to polymerize the resin. Before emplacement of the stiffening strip (3) and/or of the second ply (4), there is interposed at least one layer (5) of a non-adherent material between at least one portion of the surface of the stiffening strip (3) and one and/or the other of the plies (2, 4).

Abstract: A process for manufacturing a dressing for an inner lining comprising molding an intermediate layer of a semi-rigid fibrous blanket, applying onto each surface of the layer a thermosetting resin and then a reinforcement layer made of fibrous material; applying at least one protective sheet on one side, covering one of the reinforcement layers defining a concealed surface; and applying onto the opposite side of the lining the decorative lining layer defining an exposed surface; and finally subjecting the layer thus obtained to a shaping or molding process in a hot press, and also polymerizing the thermosetting resin. The invention also relates to the product obtained by the process.

Abstract: The present invention discloses a method of fabricating a composite material hockey stick shaft using internal bladder pressure molding technology. The bladder is inserted over a mandrel and composite materials are disposed on the bladder forming a soft, uncured piece. The mandrel is removed and the piece is disposed in a mold following which air pressure is applied to the bladder which deforms the piece to conform to the shape of the cavity. The addition of pressure and heat cures the composite materials and produces a finished hockey stick shaft.

Abstract: Floor coverings and methods of producing same, are provided. A vehicle floor covering includes a barrier layer of polymeric material and a sound-absorbing backing layer bonded to the barrier layer. The barrier layer exposed surface includes various aesthetic and/or functional features. The barrier layer has variable thickness. Thicker portions are formed by adding additional layers of barrier material to selected portions prior to molding.

Abstract: A molded wood flake or strand part (14) is shown, having a densified and/or thinner perimeter surrounding a hole (15) in the part. The method of making such part includes narrowing the mold cavity surrounding the hole, and/or providing a hole punch (17) with a shoulder which projects beyond the surface of the mold, to further compress the wood flakes or strands near the hole.

Abstract: A machine and a method for forming composite materials are provided. The machine includes a frame and at least one forming beam attached to the frame, the at least one beam being arranged to align with a mandrel. The forming beam is pivotally segmented into at least two segments to conform to the shape of the mandrel, or alternately is bendable to conform to the shape of the mandrel. The mandrel is receivable within the frame in alignment with the forming beam. An apparatus is also provided to position a composite charge over the mandrel, and to position the mandrel within the frame. A further apparatus is provided to transport the mandrel, and to urge the mandrel toward the forming beam, forming a composite charge.

Abstract: A method and apparatus for conditioning a fibrous material. The conditioning arrangement includes a moisturizing chamber having two series of opposed rollers arranged to accept a fiber batt into a pressing space therebetween. The pressing space tapers from a batt entrance toward a batt exit. This tapered configuration is affected for compressing a fiber batt as it is rolled therethrough. As illustrated, before entering the conditioner, the cotton batt has a greater thickness than after compaction and processing through the moisturizing chamber. A moisture infusion assembly is provided within the moisturizing chamber and has an air distributor configured to dispense moisture laden air adjacent to a fiber batt being processed through the pressing space. An air collector is configured to pull exhaust air away from the fiber batt being processed through the pressing space.

Abstract: A method for making a hockey stick shaft by a double pressing process, and an apparatus for making the same. The double pressing process consists of pulling resin soaked rovings through heated mold cavities. A core is inserted between upper and lower rovings, the press is closed, and upper and lower laminates are molded on simultaneously, using heat and pressure. The hockey stick shaft made therefrom has two opposite surfaces, each of the surfaces being provided with a fiberglass roving reinforcement along each opposite edge and a graphite roving reinforcement fiber between the two fiberglass roving means.

Abstract: A method for producing a composite component having a variable thickness includes placing a caul member over a plurality of laid-up prepreg plies supported by a mold. The mold includes a cavity for receiving the lay-up that is defined by a bottom surface, a plurality of walls extending upwardly from the bottom surface, and an open upper face surrounded by a mold edge. A support flange extends inwardly toward the center of the cavity from each of the walls at a predetermined distance from the bottom surface. The caul is made from an anisotropic material so that the caul is basically rigid about lateral axis and flexible about a longitudinal axis. During an autoclave curing process, the caul applies pressure along the length of the lay-up to draw the caul into engagement with the support flange, which serves as a stop to prevent further movement of the caul.

Abstract: There is presented a method of connecting a plurality of mandrels to one another to constitute an integral mandrel 10, forming a fabric 1 on the surface of the integral mandrel, and infiltrating the formed fabric with matrix. A plurality of products can simultaneously be manufactured, and this can remarkably reduce fiber loss and enhance productivity.

Abstract: A pleating machine (20) is provided which allows extremely rapid, uniform pleating of flexible, tubular bodies (28), thereby eliminating the arduous and time-consuming task of manual pleating. The machine (20) includes an upper, stationary, female tubular jaw (90) and a lower, reciprocal, male tubular pleating jaw (92) which are oriented in superposed, substantially axial alignment, along with a drive assembly (26) serving to vertically reciprocate lower jaw (92). An elongated rod-type body support (24) extends downwardly through the upper jaw (90) and presents a pleating surface (88a), so that upon reciprocation of lower jaw (92), the jaw lugs (105) successively engage the body (28) to form pleats (162, 164). The pleats (162, 164) are retained by keeper structure including inwardly extending female jaw segments (98) and weighted slide (89) mounted on support (24).

Abstract: A method and system for co-molding a thermoplastic material with a thermoplastic sandwich material to form a thermoplastic sandwich article having a thermoplastic inner portion are provided. An inner male die forces the thermoplastic composite material and the sandwich material within the peripheral edge portion together at a temperature and pressure sufficient to fuse the materials together to form a thermoplastic composite inner portion of the sandwich material.

Abstract: A method and system for molding thermoplastic sandwich material to form a deep-drawn article utilizing a unique clamping technique and mechanism are described. The method includes the steps of positioning a blank of thermoplastic sandwich material having a cellular core over a female die having an article-defining cavity defined by inner surfaces of the female die. Then, an inner portion of the blank is forced into the female die along a substantially vertical axis and against the inner surfaces of the female die to obtain deep-drawn material. During the step of forcing at least one outer portion of the blank immediately adjacent the female die is clamped to guide the at least one outer portion of the blank to travel into the article-defining cavity at an acute angle with respect to the vertical axis. Thickness of at least one side wall of the deep-drawn material is substantially the same as thickness of the blank of thermoplastic sandwich material.

Abstract: Methods and apparatus for compressing and processing a mat of lignocellulose material into the form of a board are disclosed. The apparatus includes a pair of compression rolls, at least one of which has a perforated shell surface, a channel within that roll for injecting a processing medium into the mat through a restricted sector of the roll, a processing medium supply for the channel including a slide shoe which is sealingly attached to one end of the roll, and the channel includes a number of channels associated with portions of the axial width of the roll so that the processing medium can be supplied through step-wise variable portions of the width of the roll.

Abstract: A composite formed of a polymer matrix phase having a reinforcement phase including polymeric microfibers. The microfibers are preferably formed of a highly oriented polymer, having a high modulus value and a large surface area. The large surface area can serve to tightly bind the microfibers to the polymer matrix phase. The microfibers can be provided as a fully- or partially-microfibrillated film, as a non-woven web of entangled microfibers, or as a pulp having free fibers. The microfibers can be embedded in, or impregnated with, a polymer or polymer precursor. Some composite articles are formed from thermoset resins cured about a highly oriented polypropylene microfiber reinforcement phase, providing a strong, tough, moisture resistant article. One composite includes a matrix and reinforcement formed of the same material type and having substantially equal refractive indices, allowing the composite to be optically clear.

Abstract: A composite riser for an archery bow formed from fibers embedded in resin in such a way that resin rich areas, dry fibers and voids are eliminated, providing consistent risers of high quality. The location of structural fibers, such as a carbon fibers or fiberglass composite materials, is ensured within a mold used to form the riser and relative to the resin which bonds the fibers together. Various processes may be used to form the riser with control of the fibers and resin maintained. For example, structural reaction injection molding, liquid composite molding, continuous fiber molding, modified compression molding, resin transfer molding and variable infusion molding processes can be used.

Abstract: Method of manufacturing a ribbed structure with fiber-reinforced composite material is provided. A mold for the structure is prepared having a mold surface. Non-hardened resin containing reinforcing fibers are placed on the mold surface of the structure mold. A mold for a rib is formed by using a material containing biodegradable polymers. Non-hardened resin containing reinforcing fibers are laminated on the rib mold, and then the rib mold is placed in a predetermined position on the non-hardened resin containing the reinforcing fibers tin the mold surface of the structure mold. The non-hardened resins are hardened and the rib mold is biochemically degraded wherein in the hardening of the resins, the resin hardened on the rib mold and the resin hardened on the mold surface of the structure mold are united with each other.

Abstract: A metal mold is machined via a computer numerically controlled wire-cut electrical discharge technique so as to describe a fractally profiled parallel grooves-and-ridges configuration. Fibers are placed along the mold's grooves. Using the mold combined with the fibers situate in its grooves, a first composite portion is resin transfer molded so as as to describe a complementary fractally profiled parallel grooves-and-ridges configuration, and to include, in its ridges, the fibers situate in the mold's grooves. Fibers are placed along the first composite portion's grooves. Using the first composite portion combined with the fibers situate in its grooves, a second composite portion is resin transfer molded so as as to describe a complementary fractally profiled parallel grooves-and-ridges configuration, and to include, in its ridges, the fibers situate in the first composite portion's grooves, and to effect secondary bonding of the first and second composite portions.

Abstract: A method of manufacturing a rear shelf trim and speaker grill panel (12) for an automotive vehicle (10) includes steps of punching a substrate layer (16) of a polypropylene and flax material with a punch set (46) to form a grill section (60) and placing a decorative carpet layer (18) over the substrate layer (16) and molding the two layers into a combined speaker grill and rear shelf trim panel (12).

Abstract: The present invention refers to a process for manufacturing a nonwoven fabric of synthetic fiber with scented matter. The process consists of producing a molten mass of thermoplastic resin, inserting a base mixture into the mass containing microcapsules of a scented substance, extruding the mass and drawing the extruded filaments, and using the extruded threads to create a web of nonwoven fabric.

Abstract: A molding method and an impact resistant automotive part such as a bumper beam resulting from the molding method are obtained wherein a thermoplastic reinforced fiber structure at least partially forms a pair of attachment portions of the part and continuously extends between the attachment portions to link the attachment portions. The method includes the steps of providing a plurality of blanks, heating the plurality of blanks, and stacking the plurality of blanks to form a stack of blanks. The stack is then stamped to form the part including the pair of attachment portions spaced a predetermined distance apart. The thermoplastic reinforced fiber structure has tows of fibers wetted by a resin material such as polypropylene. Preferably, the fibers are woven glass fibers.

Abstract: A continuous loop polishing pad that is reinforced by a reinforcing filler and a method for fabricating the polishing pad are described. The reinforced polishing pad is constructed by a sub-layer and a top layer, wherein the sub-layer defines an inner diameter of the polishing pad and contains a reinforcing filler with an aspect ratio of at least 10 oriented substantially in a circumferential direction of the continuous loop polishing pad. The top layer is laminated to the sub-layer with a top surface defining an outer diameter of the polishing pad, while both the sub-layer and the top layer are formed of a polymeric material. The invention further describes a method for fabricating the reinforced polishing pad in a continuous loop.

Abstract: A method for fabricating fiber reinforced plastic structures includes a mold surface upon which can be supported a lay-up of one or more layers of a fibrous material, and over which can be placed a fluid impervious outer sheet with an inlet port and having its edges marginally sealed upon the mold surface to form a chamber. A vacuum outlet is connected to the chamber for drawing a vacuum there from. A resin distribution system is positioned between the lay-up and the fluid impervious sheet. The resin distribution system includes a resin distribution medium for receiving resin from the inlet port and a resin containment layer between the resin distribution medium and lay-up for preventing resin flowing from the resin distribution medium into the lay-up until the resin distribution medium is substantially filled with resin.

Abstract: An apparatus for fabricating fiber reinforced plastic structures is provided. The apparatus includes a mold surface upon which can be supported a lay-up of one or more layers of a fibrous material, and over which can be placed a fluid impervious outer sheet with an inlet port and having its edges marginally sealed upon the mold surface to form a chamber. A vacuum outlet is connected to the chamber for drawing a vacuum therefrom. A resin distribution system is positioned between the lay-up and the fluid impervious sheet. The resin distribution system includes a distribution sheet for receiving resin from the inlet port and at least one flat resin distribution line connected to the inlet port.