Patent ID: 7638084
Filing Date: 2009-12-29
Classification: B29C

Abstract:
1. A method for forming a hollow composite material part having one or more selectively positioned core, structural insert, or veneer pieces integrally associated therewith, wherein the composite part defines a first shape, and wherein the method comprises at least the following steps: providing a dissolvable solid mandrel having an exterior surface and a second shape that is substantially the same as but sized smaller than the first shape of the composite material part, wherein the mandrel has one or more selectively positioned recesses that are complementary to the one or more core, structural insert, or veneer pieces: forming an elastic layer about the mandrel to define an elastic bladder; applying a vacuum in between the bladder and the mandrel to thereby force and conform the bladder against the exterior surface of the mandrel; applying a resin and a fiber material about and immediately adjacent to the bladder, and positioning at least one of the one or more core, structural insert, or veneer pieces adjacent and proximate to one of the one or more selectively positioned recesses to define an uncured part; placing the uncured part into a split mold, wherein the split mold has an interior surface and a third shape that is substantially the same as the first shape of the composite material part; applying a fluid or gas pressure in between the mandrel and the uncured part to thereby force and conform the uncured part against the interior surface of the split mold; heating the split mold to a temperature and for a period of time sufficient to cure the resin to thereby define the composite material part; liquefying and removing the mandrel from within the composite material part; and optionally removing the bladder from within the composite material part.