US 11,052,619 B1
Fabrication apparatuses and methods
Travis Kieffer, Spragueville, IA (US); Ben Clarke, Clinton, IA (US); Mike Rederer, Maquoketa, IA (US); Jason Gregorich, Preston, IA (US); and Terry Kieffer, Preston, IA (US)
Assigned to Plastics Unlimited, Inc., Preston, IA (US)
Filed by Plastics Unlimited, Inc., Preston, IA (US)
Filed on Sep. 21, 2017, as Appl. No. 15/711,914.
Application 15/711,914 is a continuation in part of application No. 14/265,047, filed on Apr. 29, 2014, granted, now 10,807,320.
Claims priority of provisional application 62/397,627, filed on Sep. 21, 2016.
Claims priority of provisional application 61/816,905, filed on Apr. 29, 2013.
Int. Cl. B29C 70/44 (2006.01); B29C 70/54 (2006.01); B29C 70/34 (2006.01); B29C 43/36 (2006.01); B29C 43/12 (2006.01)
CPC B29C 70/44 (2013.01) [B29C 43/12 (2013.01); B29C 43/3642 (2013.01); B29C 70/342 (2013.01); B29C 70/543 (2013.01); B29C 2043/3644 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method for forming a part, said method comprising:
a. providing a table, said table comprising:
i. a top surface, a table contour formed in said top surface;
ii. a cavity formed in said top surface;
b. positioning a bag on said table, said bag comprising:
i. a bag contour corresponding to said table contour in a shape, a size, and a relative position of said table contour;
ii. a seat having a relative position corresponding to said cavity in said table with respect to a relative position of said cavity; and,
iii. a bag inlet formed as an aperture extending through said bag, wherein a resin is introduced into said space via said bag inlet;
c. ensuring said table contour is positioned adjacent said bag contour;
d. ensuring said seat is positioned adjacent said cavity;
e. positioning a caul plate on said bag, said caul plate comprising:
i. a first side constituting a resin side;
ii. a second side constituting a bag side, wherein said bag side is positioned adjacent said bag during use;
iii. an aperture extending through said caul plate from said resin side to said bag side, wherein a relative position of said aperture corresponds to said relative position of said seat;
iv. a caul plate inlet;
v. a contour, wherein said contour corresponds to said bag contour in said shape, said size, and said relative position of said table contour;
f. positioning an extending portion of an embedded member through said aperture and into said seat;
g. positioning a frame of said embedded member adjacent said resin side of said caul plate;
h. placing a first portion of substrate lay-up on said caul plate;
i. positioning an outer member over said first portion of substrate lay-up, wherein said outer member is formed with a flange around a periphery thereof;
j. positioning a cover over said outer member, wherein said cover and said bag are configured to seal an area therebetween from an external environment;
k. reducing the pressure within a space between said outer member and said resin side of said caul plate to an amount less than ambient pressure;
l. introducing said resin into said space;
m. controlling the temperature between said cover and said bag;
n. allowing said resin and said first portion of substrate lay-up to cure into a substrate lay-up/resin medium;
o. allowing the pressure within said space to return to approximately ambient pressure; and,
p. removing said caul plate from said part.