초록 ▼

A flexible molding component used with a base mold improves on existing methods of forming fiber reinforced composite parts. The molding component is formed of a flexible body structure having an interfacing surface and a perimeter region including a perimeter seal configured for sealing engagement

A flexible molding component used with a base mold improves on existing methods of forming fiber reinforced composite parts. The molding component is formed of a flexible body structure having an interfacing surface and a perimeter region including a perimeter seal configured for sealing engagement with the base mold. Resin and vacuum distribution channels are formed in the interfacing surface to deliver resin to a fiber lay up disposed on the base mold and draw the resin across and through the lay up, respectively, to properly mix the resin/fiber combination which forms the desired part. Application of the vacuum causes the perimeter seal of the flexible body structure to sealingly engage with the base mold to enclose materials between the body structure and the mold, as well as causing the interfacing surface to draw against the resin/fiber combination and the mold to shape the combination into the desired part.

대표청구항 ▼

What is claimed is: 1. A mold component configured for use with a base mold in a closed molding process to form a fiber-reinforced composite part, the mold component comprising: a flexible body structure including a perimeter region and an interfacing surface, at least a portion of said interfacing

What is claimed is: 1. A mold component configured for use with a base mold in a closed molding process to form a fiber-reinforced composite part, the mold component comprising: a flexible body structure including a perimeter region and an interfacing surface, at least a portion of said interfacing surface configured to contact said part disposed on said base mold, and said flexible body structure having integrally formed therewith: at least one resin distribution channel extending across the interfacing surface and at least one vacuum distribution channel; a perimeter seal extending from said body structure for sealing engagement with said base mold to enclose the part between said body structure and said base mold and wherein said perimeter seal defines at least a portion of said vacuum distribution channel; and at least one vacuum output port in fluid communication with each of said vacuum distribution channel and said perimeter seal vacuum distribution portion thereby providing a first vacuum along said seal to assist said sealing engagement and an independent second vacuum across said interfacing surface to assist resin distribution between said body structure and said base mold. 2. The mold component of claim 1, further comprising: a standoff extending from said interfacing surface of said body structure; and a plurality of passages formed in said standoff to facilitate fluid communication between said at least one resin distribution channel and an enclosed space formed between said body structure and said base mold wherein said fiber-reinforced composite part may be formed. 3. The mold component of claim 1, wherein said flexible body structure is formed by spraying a material on a pattern, said material being selected from the group consisting of polyurea, polyurethane, a polyurea/polyurethane compound, and mixtures thereof. 4. The mold component of claim 3, wherein said material is further selected from the group consisting of aliphatic compounds, aromatic compounds, and polyaspartic compounds. 5. The mold component of claim 1, wherein said perimeter seal comprises a grid of sidewall flanges. 6. The mold component of claim 1, wherein said body structure further comprises first regions formed at said resin or vacuum distribution channels having increased rigidity as compared to the remainder of said body structure. 7. The mold component of claim 6, wherein said first regions include a reinforcing material bonded with said body structure. 8. The mold component of claim 1, wherein said body structure is formed of one or more materials thereby providing regions in said body structure with different physical properties. 9. The mold component of claim 8, said physical properties being selected from the group consisting of density, rigidity, compression, elongation, and combinations thereof. 10. The mold component of claim 1, further comprising at least one resin input port extending through said body structure and in fluid communication with at least one of said at least one resin distribution channel. 11. The mold component of claim 1, wherein said perimeter seal comprises a plurality of perimeter seals extending downwardly from said body structure and defining a vacuum distribution channel therebetween. 12. A mold component configured for use with a base mold in a closed molding process to form a fiber-reinforced composite part, the mold component comprising: a flexible body structure including a perimeter region and an interfacing surface, at least a portion of said interfacing surface configured to contact said part disposed on said base mold, and said flexible body structure having integrally formed therewith: at least one resin distribution channel and at least one vacuum distribution channel extending across the interfacing surface; a perimeter seal extending from said body structure for sealing engagement with said base mold to enclose the part between said body structure and said base mold and wherein said perimeter seal defines a vacuum distribution channel; and at least one vacuum output port in fluid communication with each of said interfacing surface vacuum distribution channel and said perimeter seal vacuum distribution channel thereby providing a first vacuum along said seal to assist said sealing engagement and an independent second vacuum across said interfacing surface to assist resin distribution between said body structure and said base mold. 13. The mold component of claim 12, wherein said perimeter seal comprises a plurality of perimeter seals extending downward from said body structure and defining a vacuum distribution channel therebetween. 14. The mold component of claim 12 wherein at least a portion of said interfacing surface is configured to contact said part disposed on said base mold, said mold component further comprising: a standoff extending from the interfacing surface of said body structure; and a plurality of passages formed in said standoff to facilitate fluid communication between said at least one resin distribution channel and an enclosed space formed between said body structure and said base mold wherein said fiber-reinforced composite part may be formed. 15. The mold component of claim 12, wherein said flexible body structure is formed by spraying a material on a pattern, said material being selected from the group consisting of polyurea, polyurethane, a polyurea/polyurethane compound, and mixtures thereof. 16. The mold component of claim 15, wherein said material is further selected from the group consisting of aliphatic compounds, aromatic compounds, and polyaspartic compounds. 17. The mold component of claim 12, wherein said perimeter seal comprises a grid of sidewall flanges. 18. The mold component of claim 12, wherein said body structure further comprises first regions formed at said distribution channels having increased rigidity as compared to the remainder of said body structure. 19. The mold component of claim 18, wherein said first regions include a reinforcing material bonded with said body structure. 20. The mold component of claim 12, wherein said body structure is formed of one or more materials thereby providing regions in said body structure with different physical properties. 21. The mold component of claim 20, said physical properties being selected from the group consisting of density, rigidity, compression, elongation, and combinations thereof. 22. The mold component of claim 12, further comprising: at least one resin input ports extending through said body structure and in fluid communication with at least one of said at least one resin distribution channel. 23. A reusable mold component configured for use with a base mold in a closed molding process to form a fiber-reinforced composite part, the mold component comprising: a flexible body structure formed by spraying material selected from the group consisting of polyurea, polyurethane, and polyurea/polyurethane on a pattern, said body structure including a perimeter region and an interfacing surface, at least a portion of said interfacing surface configured to contact said part disposed on said base mold, and said flexible body structure having integrally formed therewith: at least one resin distribution channel extending across the interfacing surface and at least one vacuum distribution channel; a perimeter seal extending from said body structure for sealing engagement with said base mold to enclose the part between said body structure and said base mold and wherein said perimeter seal defines at least a portion of said vacuum distribution channel; and at least one vacuum output port in fluid communication with each of said vacuum distribution channel and said perimeter seal vacuum distribution portion thereby providing a first vacuum along said seal to assist said sealing engagement and an independent second vacuum across said interfacing surface to assist resin distribution between said body structure and said base mold. 24. The mold component of claim 23, further comprising: a standoff extending from said interfacing surface of said body structure; and a plurality of passages formed in said standoff to facilitate fluid communication between said at least one resin distribution channel and an enclosed space formed between said body structure and said base mold wherein said fiber-reinforced composite part may be formed. 25. The mold component of claim 23, wherein said material is further selected from the group consisting of aliphatic compounds, aromatic compounds, and polyaspartic compounds. 26. The mold component of claim 23, wherein said perimeter seal comprises a grid of sidewall flanges. 27. The mold component of claim 23, wherein said body structure further comprises first regions formed at said resin or vacuum distribution channels having increased rigidity as compared to the remainder of said body structure. 28. The mold component of claim 27, wherein said first regions include a reinforcing material bonded with said body structure. 29. The mold component of claim 23, wherein said body structure is formed of one or more materials thereby providing regions in said body structure with different physical properties. 30. The mold component of claim 29, said physical properties being selected from the group consisting of density, rigidity, compression, elongation, and combinations thereof. 31. The mold component of claim 23, further comprising at least one resin input port extending through said body structure and in fluid communication with at least one of said at least one resin distribution channels. 32. The mold component of claim 23, wherein said vacuum distribution channel extends across said interfacing surface. 33. The mold component of claim 23, wherein said perimeter seal comprises a plurality of perimeter seals extending downwardly from said body structure and defining a vacuum distribution channel therebetween. 34. A mold component configured for use with a base mold in a closed molding process to form a fiber-reinforced composite part, the mold component comprising: a flexible body structure including a perimeter region and an interfacing surface, at least a portion of said interfacing surface configured to contact said part disposed on said base mold, and said flexible body structure having integrally formed therewith: at least one resin distribution channel extending across the interfacing surface and at least one vacuum distribution channel; a plurality of perimeter seals extending downwardly from said body structure for sealing engagement with said base mold to enclose the part between said body structure and said base mold and wherein said perimeter seals define at least a portion of said vacuum distribution channel; and at least one vacuum output port in fluid communication with each of said vacuum distribution channel and said perimeter seal vacuum distribution portion thereby providing a first vacuum along said seal to assist said sealing engagement and an independent second vacuum across said interfacing surface to assist resin distribution between said body structure and said base mold. 35. The mold component of claim 34, further comprising: a standoff extending from said interfacing surface of said body structure; and a plurality of passages formed in said standoff to facilitate fluid communication between said at least one resin distribution channel and an enclosed space formed between said body structure and said base mold wherein said fiber-reinforced composite part may be formed. 36. The mold component of claim 34, wherein said flexible body structure is formed by spraying a material on a pattern, said material being selected from the group consisting of polyurea, polyurethane, a polyurea/polyurethane compound, and mixtures thereof. 37. The mold component of claim 36, wherein said material is further selected from the group consisting of aliphatic compounds, aromatic compounds, and polyaspartic compounds. 38. The mold component of claim 34, wherein said perimeter seal comprises a grid of sidewall flanges. 39. The mold component of claim 34, wherein said body structure further comprises first regions formed at said resin or vacuum distribution channels having increased rigidity as compared to the remainder of said body structure. 40. The mold component of claim 39, wherein said first regions include a reinforcing material bonded with said body structure. 41. The mold component of claim 34, wherein said body structure is formed of one or more materials thereby providing regions in said body structure with different physical properties. 42. The mold component of claim 41, said physical properties being selected from the group consisting of density, rigidity, compression, elongation, and combinations thereof. 43. The mold component of claim 34, further comprising at least one resin input port extending through said body structure and in fluid communication with at least one of said at least one resin distribution channel. 44. The mold component of claim 1, wherein said perimeter seals define a vacuum distribution channel therebetween. 45. A mold component configured for use with a base mold in a closed molding process to form a fiber-reinforced composite part, the mold component comprising: a flexible body structure including a perimeter region and an interfacing surface, at least a portion of said interfacing surface configured to contact said part disposed on said base mold, and said flexible body structure having integrally formed therewith: at least one resin distribution channel extending across the interfacing surface and at least one vacuum distribution channel; a plurality of perimeter seals extending downwardly from said body structure for sealing engagement with said base mold to enclose the part between said body structure and said base mold and wherein said perimeter seals define a vacuum distribution channel therebetween; and at least one vacuum output port in fluid communication with each of said vacuum distribution channel and said perimeter seal vacuum distribution portion thereby providing a first vacuum along said seal to assist said sealing engagement and an independent second vacuum across said interfacing surface to assist resin distribution between said body structure and said base mold. 46. The mold component of claim 45, further comprising: a standoff extending from said interfacing surface of said body structure; and a plurality of passages formed in said standoff to facilitate fluid communication between said at least one resin distribution channel and an enclosed space formed between said body structure and said base mold wherein said fiber-reinforced composite part may be formed. 47. The mold component of claim 45, wherein said flexible body structure is formed by spraying a material on a pattern, said material being selected from the group consisting of polyurea, polyurethane, a polyurea/polyurethane compound, and mixtures thereof. 48. The mold component of claim 47, wherein said material is further selected from the group consisting of aliphatic compounds, aromatic compounds, and polyaspartic compounds. 49. The mold component of claim 45, wherein said perimeter seal comprises a grid of sidewall flanges. 50. The mold component of claim 45, wherein said body structure further comprises first regions formed at said resin or vacuum distribution channels having increased rigidity as compared to the remainder of said body structure. 51. The mold component of claim 50, wherein said first regions include a reinforcing material bonded with said body structure. 52. The mold component of claim 45, wherein said body structure is formed of one or more materials thereby providing regions in said body structure with different physical properties. 53. The mold component of claim 52, said physical properties being selected from the group consisting of density, rigidity, compression, elongation, and combinations thereof. 54. The mold component of claim 45, further comprising at least one resin input port extending through said body structure and in fluid communication with at least one of said at least one resin distribution channel. 55. A process involving a closed molding tooling technique to form a fiber-reinforced composite part against a base mold with a flexible body structure having an interfacing surface upon which at least one resin distribution channel and at least one vacuum distribution channel are formed and extend thereacross, and at least one perimeter seal, the process comprising: placing a fiber lay up on the base mold applying resin to the fiber lay up; moving the body structure onto the base mold such that the fiber lay up is covered by the interfacing surface of the body, thereby forming an enclosed space between the body structure and the base mold, the fiber lay up being located in the enclosed space; and drawing a first vacuum at said perimeter seal to cause said perimeter seal to sealingly engage the base mold; and drawing a second vacuum independent from said first vacuum through said enclosed space thereby urging the resin to travel through the resin distribution channel and across and through the fiber lay up generally in the direction of the second vacuum draw to thereby form the composite part upon curing. 56. A process of forming a boat involving closed molding tooling techniques to form a fiber-reinforced composite boat against a base mold with a flexible body structured having an interfacing surface corresponding to the shape of said composite boat upon which at least one resin distribution channel and at least one vacuum distribution channels are formed and extend thereacross and at least one perimeter seal, the process comprising: forming a reusable unitary body structure by spraying material selected from the group consisting of polyurea, polyurethane, and polyurea/polyurethane on a pattern; placing a fiber lay up on the base mold; applying resin to the fiber lay up; moving the unitary integral body structure onto the base mold such that the fiber lay up/resin combination is covered by the interfacing surface of the unitary integral body structure; and drawing a first vacuum at said perimeter seal to cause said perimeter seal to sealingly engage the base mold; and drawing a second vacuum independent from said first vacuum through said enclosed space thereby urging the resin to travel through the resin distribution channel and across and through the fiber lay up generally in the direction of the second vacuum draw to thereby form a composite boat upon curing.