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Methods and apparatus for forming molded thermal plastic polymer components

  • US 8,673,106 B1
  • Filed: 11/15/2010
  • Issued: 03/18/2014
  • Est. Priority Date: 11/13/2009
  • Status: Active Grant
First Claim
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1. A method of forming a multi-dimensional reinforced composite structure, the method comprising:

  • positioning a first layer of one or more sheets of flexible reinforced thermoplastic against a first mold;

    positioning a first layer of a porous material against the first layer of sheets of reinforced thermoplastic;

    positioning an inflatable bladder against the first layer of porous material;

    positioning a second layer of porous material against the inflatable bladder;

    positioning a second layer of one or more sheets of flexible reinforced thermoplastic against the second layer of porous material and on an opposite side thereof from the inflatable bladder;

    forming a common mold cavity using the first mold and a second mold with the first and second layers of flexible reinforced thermoplastic, the first and second layers of porous material, and the inflatable bladder therebetween;

    applying forming forces of heat, pressure and vacuum to the first layer of sheets and the second layer of sheets to urge the first layer of sheets of reinforced thermoplastic against the first mold, the first layer of porous material against the first layer of sheets with uniform pressure, the second layer of sheets of reinforced thermoplastic against the second mold, and the second layer of porous material away from the first layer of porous material and against the second layer of sheets with uniform pressure to form the reinforced composite structure having a hollow interior with the first and second layers of porous material facing each other, the forming forces causing the first layer of sheets to form to the shape of the first mold and mechanically bond with the first layer of porous material by partially melting into the first layer of porous material and the second layer of sheets to form the shape of the second mold and mechanically bond with the second layer of porous material by partially melting into the second layer of porous material.

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