Consolidating and curing of thermoset composite parts by pressing between a heated rigid mold and customized rubber-faced mold

Abstract

Method and apparatus for consolidating and curing a composite part places and registers a composite laminate layer of thermoset polymer matrix and reinforcing fibers onto the temperature-controlled curing surface of a heated curing mold and provides a base mold with base surface covered by a rubber mask having a mask surface. Three-dimensional surfaces of the curing, base and mask surfaces complement each other so with the curing and base molds adjacent, a pressure space is formed between the base and curing surfaces that contains the compressed rubber mask, a bleeder layer for removing excess air and polymer matrix, and the composite laminate, the pressure space having a perimeter. The base and curing molds are pressed together with a particular force, thereby creating a uniform hydrostatic pressure at the rubber mask and composite laminate interface by virtue of the mold and mask three-dimensional surfaces and rubber mask thickness distribution, to squeeze the composite laminate during consolidation and curing of the part. A vacuum is also applied to the perimeter of the composite laminate during consolidation.