A METHOD FOR MOLDING COMPOSITE STRUCTURAL PLASTICS AND OBJECTS MOLDED THEREBY

摘要

A method for molding composite structural plastic components is disclosed wherein such components are cast from a polymerizable thermoset or thermoplastic composition (233) in a conventional metalcasting mold (203). In the instant invention, a low viscosity thermoset or thermoplastic composition having reinforcing fibers distributed therein is poured into conventional metalcasting molds, obviating the need for high heats and pressures associated with injection or compression molding of composite materials as taught in the prior art. Using metalcasting tooling and procedures heretofore used solely in the casting of production metal parts permits 'no pressure' molding without high added heat, with the object to be fabricated being fully cured by the action of a catalyst at relatively low exothermic resin temperatures. This method furthermore enables fabrication of high quality composite structural plastics in traditional soft tool molds and molds produced using rapid prototyping techniques. This economical molding technique permits production of quality structural molded plastics utilizing low cost molds heretofore used only in the prototyping of plastic visual aids.