Membrane structure for vacuum assisted molding fiber reinforced article

1. A method of manufacturing a fiber reinforced article, the method comprising the steps of:

providing a fiber structure defining voids therein;

providing a first membrane assembly having a first fabric and having a first microporous membrane laminated to at least a portion of the first fabric such that the first membrane assembly has a membrane side and a fabric side, and the fabric side and the membrane side both have an oil resistance rating of at least a number 8 determined by AATCC 118 testing;

providing a second membrane assembly having a second fabric and having a second microporous membrane adjacent to at least a portion of the second fabric, the second microporous membrane has an oil resistance rating of at least a number 8 determined by AATCC 118 testing;

applying the first membrane assembly over at least a portion of the fiber structure; applying the second membrane assembly over at least a portion of the first membrane assembly;

providing a resin and hardener mix at a temperature up to 180° C.; and

infusing the resin and hardener mix into voids of the fiber structure by applying a vacuum to the fiber structure and the first and second membrane assemblies wherein the first and second membrane assemblies inhibit the flow of resin therethrough.

2. The method of claim 1 wherein at least one of the first and second microporous membranes is made from expanded polytetrafluoroethylene.

3. The method of claim 1 wherein at least one of the first and second microporous membranes further includes an oleophobic treatment.

4. The method of claim 1 wherein the resin and hardener mix includes diglycidyl ether of bisphenol-A.

5. The method of claim 1 wherein at least one of the first and second membrane assemblies has an air permeability therethrough of at least 0.005 CFM/ft 2 as determined by ASTM D737 testing.

6. The method of claim 1 wherein the second membrane assembly has the second fabric layer laminated to the second microporous membrane.

7. The method of claim 1 wherein the first and second membrane assemblies resist wetting by resin and hardener mix with a surface tension as low as about 13 dynes/cm.

8. The method of claim 1 wherein at least one of the first and second membrane assemblies includes at least two microporous membranes and at least one fabric.

9. A method of manufacturing a fiber reinforced article, the method comprising the steps of:

providing a fiber structure defining voids therein;

providing a first membrane assembly having a first fabric and having a first microporous membrane laminated to at least a portion of the first fabric such that the first membrane assembly has a membrane side and a fabric side, and the fabric side and the membrane side both have an oil resistance rating of at least a number 8 determined by AATCC 118 testing and having an air permeability of at least 0.005 CFM per square foot determined by ASTM D737 testing;

providing a second membrane assembly having a second fabric and having a second microporous membrane adjacent to at least a portion of the second fabric, the second microporous membrane has an oil resistance rating of at least a number 8 determined by AATCC 118 testing and has an air permeability of at least 0.005 CFM per square foot determined by ASTM D737 testing;

applying the first membrane assembly over at least a portion of the fiber structure; applying the second membrane assembly over at least a portion of the first membrane assembly;

providing a resin at a temperature up to 180° C.; and

infusing the resin into voids of the fiber structure by applying a vacuum to the fiber structure and the first and second membrane assemblies wherein the first and second membrane assemblies inhibit the flow of resin therethrough.

10. The method of claim 9 wherein the first and second membrane assemblies resist wetting by resin with a surface tension as low as about 13 dynes/cm.

11. The method of claim 9 wherein at least one of the first and second microporous membranes is made from expanded polytetrafluoroethylene.

12. The method of claim 9 wherein at least one of the first and second microporous membranes further includes an oleophobic treatment.

13. The method of claim 9 wherein the resin includes diglycidyl ether of bisphenol-A.

14. The method of claim 9 wherein at least one of the first and second membrane assemblies includes at least two microporous membranes and at least one fabric.