Method of making a reinforced foam-filled resin-impregnated fiber glass covered vacuum forming mold plug

Claim 1

A method for making a mold suitable for vacuum thermoforming, compressing: a. forming a polyester gel coat on a master pattern; b. applying a rigidizing mixture of a thermosetting resin and glass fiber to said gel coat and curing said resin; c. constructing and bonding on egg crate framework to the rigid layer, said egg crate framework defining spaces in the molds; d. filling the spaces defined by the egg crate framework with a polymeric rigidizing foam; e. forming a vacuum plenum chamber by i. attaching a first cap board to said polymeric foam and said crate framework; and ii. attaching spacers to said first cap board and a second cap board to said spacers, the first and second cap board being of a durable material which remains rigid under vacuum forming conditions; f. securing to said vacuum plenum chamber a means for introducing a vacuum therein; and g. forming air passageways through said gel coat, said rigid layer said polymeric rigidizing foam, said cap board and into said vacuum chamber, including forming some of said passageways adjacent portions of said mold corresponding to sharp angles and indentations in the molded product, thereby making said mold.

Claim 2

A method for making a mold suitable for vacuum thermoforming, compressing: a. forming a polyester gel coat on a master pattern; b. applying a rigidizing mixture of a thermosetting resin and glass fiber to said gel coat and curing said resin; c. constructing and bonding on egg crate framework to the rigid layer, said egg crate framework defining spaces in the molds; d. filling the spaces defined by the egg crate framework with a polymeric rigidizing foam; e. forming a vacuum plenum chamber by i. attaching a first cap board to said polymeric foam and said crate framework; and ii. attaching spacers to said first cap board and a second cap board to said spacers, the first and second cap board being of a durable material which remains rigid under vacuum forming conditions; f. securing to said vacuum plenum chamber a means for introducing a vacuum therein; and g. forming air passageways through said gel coat, said rigid layer said polymeric rigidizing foam, said cap board and into said vacuum chamber, including forming some of said passageways adjacent portions of said mold corresponding to sharp angles and indentations in the molded product, thereby making said mold.