Patent ID: 7147818

Claim:
A process for forming a fiber reinforced composite structure comprising the steps of: providing a mold having a surface upon which the composite structure is formed; placing a preform upon the mold surface; positioning at least one resin inlet proximate the preform; positioning at least one vacuum outlet proximate the preform; placing at least one vacuum bag over the preform and sealing the vacuum bag to the mold to form a preform assembly, having at least one resin inlet allowing resin to flow therethrough; positioning a means for removing excess resin proximate the preform and further imposing a substantially uniform pressure along the preform; connecting a vacuum system to the at least one vacuum outlet by a vacuum line and drawing a vacuum upon the perform assembly and to the means for removing excess resin; applying resin from the resin feed source through the at least one resin inlet into the preform assembly to fully impregnate the preform; stopping the flow of resin from the resin inlet; applying a vacuum to the perform assembly through the resin inlet, and through at least one vacuum outlet, and through the means for removing excess resin allowing for a sufficient time to remove excess accumulated resin and to compact the fully impregnated preform with a substantially uniform pressure thereover to provide for improved dimensional tolerances and increased fiber volume fraction in the structure; curing the resin in the fully impregnated preform; and removing the cured preform being the fiber reinforced composite structure from the mold.