Patent ID: 9114570
Filing Date: 2015-08-25
Classification: A43B,B29C,B29D,B29K,B29L,B32B,Y10T

Abstract:
1. A method of producing a three-dimensional flexible composite part, the method comprising: providing a male mold and a female mold having compatible configurations; shaping a first composite layup of at least one fiber-reinforced scrim and optional first surface layer over the male mold, each scrim comprising two or more layers of unidirectional fibers placed at different configurations; transferring the first shaped layup from the male mold into conformity with the female mold; shaping a second composite layup of at least one fiber-reinforced scrim and optional second surface layer over the male mold, each scrim comprising two or more layers of unidirectional fibers placed at different configurations; transferring the second shaped layup from the male mold into the female mold over the first transferred layup; folding peripheral first layup material so as to overlap the periphery of the second transferred layup; and curing the first and second layups in the female mold to form a three-dimensional part having a seam formed only from the overlap thereby leaving a hollow space between remaining first and second cured layup material.