Method of forming an integral fiber reinforced structure

Claim 1

A method of molding in a single operation an integral fiber structure including a sheet-like resin impregnated fiber reinforced region that extends from a hollow resin impregnated fiber reinforced section, said method comprising: (a) providing a mold having a pair of mold pieces disposed to be opened or closed, the mold pieces having first cavity forming surface portions spaced apart from each other by a given distance forming a cavity for defining said hollow section, the mold pieces further including second complementary surface portions having a large area that extend from the first cavity forming surface portions, said complementary surface portions defining said sheet-like region and being spaced apart a distance considerably less than said given distance of the cavity forming surfaces; (b) placing fibrous material on the first cavity forming surface portions and second complementary surface portions of said mold pieces when said mold is open; (c) placing an inflatable member in said cavity; (d) closing said mold so that said fibrous material completely fills the space between said second complementary surface portions that define the sheet-like region; (e) inflating said inflatable member; (f) injecting resin into the fibrous material between the second complementary mold surface portions and causing it to flow towards said cavity to impregnate all of the fibrous material in the mold; and (g) curing said resin to form said fiber reinforced structure with said sheet-like region integrally joined to the hollow section.

Claim 2

A method of molding in a single operation an integral fiber structure including a sheet-like resin impregnated fiber reinforced region that extends from a hollow resin impregnated fiber reinforced section, said method comprising: (a) providing a mold having a pair of mold pieces disposed to be opened or closed, the mold pieces having first cavity forming surface portions spaced apart from each other by a given distance forming a cavity for defining said hollow section, the mold pieces further including second complementary surface portions having a large area that extend from the first cavity forming surface portions, said complementary surface portions defining said sheet-like region and being spaced apart a distance considerably less than said given distance of the cavity forming surfaces; (b) placing fibrous material on the first cavity forming surface portions and second complementary surface portions of said mold pieces when said mold is open; (c) placing an inflatable member in said cavity; (d) closing said mold so that said fibrous material completely fills the space between said second complementary surface portions that define the sheet-like region; (e) inflating said inflatable member; (f) injecting resin into the fibrous material between the second complementary mold surface portions and causing it to flow towards said cavity to impregnate all of the fibrous material in the mold; and (g) curing said resin to form said fiber reinforced structure with said sheet-like region integrally joined to the hollow section.