Patent ID: 7533626

Claim:
A method for molding an article having an upper portion, a lower portion, and an insert located between the upper portion and the lower portion, wherein the article is molded as a single, unitary piece with no seams or discontinuities located between the upper portion and the lower portion, the method comprising: arranging in a spaced apart opposed relationship a first mold section comprising a first semi-rigid membrane removably mounted to a first rigid housing to define a first fluid tight chamber therein and a second mold section comprising a second semi-rigid membrane removably mounted to a second rigid housing to define a second fluid tight chamber therein; defining a mold plenum between the first and second semi-rigid membranes when the first and second mold sections are closed together to mold the article; filling the first and second fluid tight chambers with a substantially non-compressible backing fluid to support each membrane during injection of resin; positioning the insert in the mold plenum defined between the first and second semi-rigid membranes; providing fibrous reinforcing material that surrounds the insert within the mold plenum, the fibrous reinforcing material including portions positioned between the first semi-rigid membrane and the insert, the fibrous reinforcing material also including portions positioned between the second semi-rigid membrane and the insert, each of the fibrous reinforcing material portions positioned between the first and second semi-rigid membranes and the insert being in contact with the insert; closing the first and second mold sections towards each other to sandwich the fibrous reinforcement material around the insert; retaining the first and second mold sections together; injecting resin under pressure into the mold plenum such that the resin envelops the fibrous reinforcing material and the insert; distributing a resulting injection pressure by the backing fluid; and curing the resin by heating at least one of the backing fluid to produce the molded article.