Process for forming composite article

Claim 2

A process for forming a hollow, cured composite article comprising the steps of: preparing a meltable plug having external dimensions equal to the internal shape of the cured composite article; placing a polymerizable material about that portion of the plug which corresponds to the interior of the composite article to be formed; inserting the polymerizable-material-covered plug into a cavity formed in a thermally-expansive and heat-resistant polymer and placing the polymer and plug assembly into a rigid container; affixing the cover over the container and heating the contents of the container thereby causing the thermally-expansive polymer to expand and the polymerizable polymer to crosslink; cooling the contents of the container; removing the plug and its cross-linked covering from the container and from the cavity; and heating the plug and its composite material part to a temperature sufficient to melt the plug thereby leaving a cured composite part.

Claim 3

The process of claim 1 further including, after said preparing step, the steps of: covering that portion of the plug which corresponds to the interior of the composite article to be formed with a removable substance about the thickness of the cured composite article thereby forming a covered plug; placing the covered plug into a closeable, rigid container which does not significantly deform at an internal pressure of 700 psig; filling the rigid container with a curable, thermally-expansive and heat-resistant polymer to an extent so that when the rigid container is closed, it will be filled between 90% and 100%; curing the thermally-expansive polymer; separating the cured polymer into sufficient parts so that the covered plug can be removed without tearing the cured polymer; removing the covered plug from the polymer thereby leaving a cavity in the polymer; and removing the removable substance from the covered plug.

Claim 4

The process of claim 1 wherein said rigid container has removable sides.

Claim 5

The process of claim 1 wherein said thermally-expansive polymer is a silicone polymer.

Claim 6

The process of claim 1 wherein said polymerizable matter is an epoxy resin.

Claim 7

The process of claim 5 wherein said polymerizable material further includes reinforcing fibers.

Claim 8

The process of claim 6 wherein said reinforcing fibers are graphite fibers.

Claim 9

The process of claim 1 wherein said meltable plug is fabricated from a metallic alloy.

Claim 10

A process for forming a mold form forming a cured composite article comprising the steps of: preparing a meltable plug having external dimensions equal to the internal shape of the cured composite article; covering that portion of the plug which corresponds to the interior of the composite article to be formed with a removable substance about the thickness of the cured composite article thereby forming a covered plug; placing the covered plug into a closeable, rigid container which does not significantly deform at an internal pressure of 700 psig; filling the rigid container with a curable, thermally-expansive and heat-resistance polymer to an extent so that when the rigid container is closed, it will be filled between 90% and 100%; curing the thermally-expansive polymer; separating the cured polymer into sufficient parts so that the covered plug can be removed without tearing the cured polymer; removing the covered plug from the polymer thereby leaving a cavity in the polymer; and removing the removable substance from the covered plug.

Claim 11

A process for forming a mold form forming a cured composite article comprising the steps of: preparing a meltable plug having external dimensions equal to the internal shape of the cured composite article; covering that portion of the plug which corresponds to the interior of the composite article to be formed with a removable substance about the thickness of the cured composite article thereby forming a covered plug; placing the covered plug into a closeable, rigid container which does not significantly deform at an internal pressure of 700 psig; filling the rigid container with a curable, thermally-expansive and heat-resistance polymer to an extent so that when the rigid container is closed, it will be filled between 90% and 100%; curing the thermally-expansive polymer; separating the cured polymer into sufficient parts so that the covered plug can be removed without tearing the cured polymer; removing the covered plug from the polymer thereby leaving a cavity in the polymer; and removing the removable substance from the covered plug.

Claim 12

The process of claim 9 wherein said removable substance is fabricated from a wax.

Claim 13

The process of claim 9 wherein said thermally-expansive polymer is a silicone polymer.

Claim 14

The process of claim 9 wherein said rigid container has removable sides.