Expanded compression molding of composite plastics

Abstract

Composite polymeric articles significantly larger than the size of a compression molding press are produced by providing a plurality of expandable pillows interposed between an upper plate and the upper exterior surface of an outside the press upper mold. The upper plate has a plurality of downwardly extending paired vertical arms attached to opposite sides of the upper plate. Each vertical arm has a lower portion having a eyelet (or aperture), and each pair of vertical arms together forms an aligned pair of eyelets. When the upper and lower mold portions are pressed together, the eyelets reside below the exterior lower surface of the outside the press lower mold portion. Each eyelet is dimensioned to reversibly receive a horizontal or lateral arm that is deployed below the exterior lower surface of the outside the press lower mold portion. A plastic material is introduced onto the interior surface of the lower mold portion, which is compressed between the upper and lower mold portions via a press having a press area that does not extend out over the outside the press portions of the upper and lower mold portions. The lateral arms are extended through the paired and aligned eyelets. The plurality of expandable pillows are expanded, and the lateral arms are brought into compressive abutment with the exterior lower surface of the outside the press lower mold portion. The plastic material residing between the outside the press upper mold portion and the outside the press lower mold portion is then correspondingly compressed.