Patent ID: 6638466
Filing Date: 2003-10-28
Classification: B29C,B29L

Abstract:
A method of forming a composite structure, comprising:positioning first and second material pieces adjacent each other within a mold cavity and with a separating film disposed between said first and second material pieces, said first material piece comprising an impregnable fiber material piece; introducing a first resin into said mold cavity to contact and substantially impregnate said first material piece with said first resin; allowing said first resin that substantially impregnates said first material piece to cure within said mold cavity to form a first part of said composite structure; and wherein said separating film is substantially impermeable to said first resin; wherein said second material piece comprises fiber material pre-impregnated with a second resin; wherein said separating film is substantially impermeable to said second resin; and wherein said method further comprises allowing said second resin to cure within said mold cavity to form a second part of said composite structure; wherein said first and second resins substantially do not adhere to said separating film during said curing of said resins so that said separating film is substantially separable from each of said composite structure first and second parts; and wherein said method further comprises: removing said composite structure first and second parts from said mold cavity, separating said first and second composite structure parts from each other and removing said separating film, and then refitting said first and second composite structure parts together; and forming an open area within a surface of said composite structure first part after separating said first and second composite structure parts; wherein said open area is formed so as to be covered by said second composite structure part when said first and second composite structure parts are refitted together.