A method of press molding a molding material to form a molded part of fiber-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mold tool having a lower mold part and an upper mold part, the upper mold part having a first molding surface for molding a first molded surface of the molded part and the lower mold part having a second molding surface for molding a second molded surface of the molded part;
ii. providing a multilaminar panel of molding material comprising at least one layer of fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces;
iii. locating the molding material in the mold tool;
iv. progressively closing the mold tool to define a substantially closed mold cavity containing the molding material, the closing step including: a. a preliminary closing phase to achieve mutual engagement between the lower and upper mold parts, b. a secondary closing phase after engagement between the lower and upper mold parts with the mold tool partially closed to define a closed intermediate cavity containing the molding material, the closed intermediate cavity being larger than the molded part and the first molding surface of the upper mold part being spaced from the first major surface by a spacing distance, in the secondary phase air being at least partially evacuated from the closed intermediate cavity while the first molding surface of the upper mold part is spaced from the first major surface to provide a vacuum pressure, and c. a tertiary closing phase after the vacuum pressure has been provided in the closed intermediate cavity, the tertiary phase having: I. a first stage prior to both the first molding surface contacting the first major surface and the second molding surface contacting the second major surface, and II. a second compression stage after both the first molding surface has contacted the first major surface and the second molding surface has contacted the second major surface, the closure speed of relative movement between the lower and upper mold parts being higher in the first stage than in the second compression stage;
v. applying pressure to the molding material in the mold cavity to configure the molding material in a fully molded shape; and
vi. substantially fully curing the resin to form a molded part from the molding material.

A method of press molding a molding material to form a molded part of fiber-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mold tool having a lower mold part and an upper mold part, the upper mold part having a first molding surface for molding a first molded surface of the molded part and the lower mold part having a second molding surface for molding a second molded surface of the molded part;
ii. providing a multilaminar panel of molding material comprising at least one layer of fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces;
iii. locating the molding material in the mold tool;
iv. progressively closing the mold tool to define a substantially closed mold cavity containing the molding material, the closing step including: a. a preliminary closing phase to achieve mutual engagement between the lower and upper mold parts, b. a secondary closing phase after engagement between the lower and upper mold parts with the mold tool partially closed to define a closed intermediate cavity containing the molding material, the closed intermediate cavity being larger than the molded part and the first molding surface of the upper mold part being spaced from the first major surface by a spacing distance, in the secondary phase air being at least partially evacuated from the closed intermediate cavity while the first molding surface of the upper mold part is spaced from the first major surface to provide a vacuum pressure, and c. a tertiary closing phase after the vacuum pressure has been provided in the closed intermediate cavity, the tertiary phase having: I. a first stage prior to both the first molding surface contacting the first major surface and the second molding surface contacting the second major surface, and II. a second compression stage after both the first molding surface has contacted the first major surface and the second molding surface has contacted the second major surface, the closure speed of relative movement between the lower and upper mold parts being higher in the first stage than in the second compression stage;
v. applying pressure to the molding material in the mold cavity to configure the molding material in a fully molded shape; and
vi. substantially fully curing the resin to form a molded part from the molding material.

A method of press moulding a moulding material to form a moulded part of fiber-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mould tool having a lower mould part and an upper mould part, the upper mould part having a first moulding surface for moulding a first moulded surface of the moulded part and the lower mould part having a second moulding surface for moulding a second moulded surface of the moulded part; ii. providing a multilaminar panel of moulding material comprising at least one layer of fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces, a surface resin layer of the multilaminar panel being at or adjacent to the first major surface and a dry fiber layer of the multilaminar panel forming the second major surface; iii. locating the moulding material in the mould tool by disposing the second major surface on the second moulding surface of the lower mould part, the lower mould part being at an elevated temperature as compared to the temperature of the moulding material; iv. closing the mould tool to define a substantially closed mould cavity containing the moulding material; v. applying pressure to the moulding material in the mould cavity to configure the moulding material in a fully moulded shape, and after the applying pressure step v the resin in the multilaminar panel fully impregnates the dry fibers; and vi. substantially fully curing the resin to form a moulded part from the moulding material.

A method of press moulding a moulding material to form a moulded part of fiber-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mould tool having a lower mould part and an upper mould part, the upper mould part having a first moulding surface for moulding a first moulded surface of the moulded part and the lower mould part having a second moulding surface for moulding a second moulded surface of the moulded part; ii. providing a multilaminar panel of moulding material comprising at least one layer of fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces, a surface resin layer of the multilaminar panel being at or adjacent to the first major surface and a dry fiber layer of the multilaminar panel forming the second major surface; iii. locating the moulding material in the mould tool by disposing the second major surface on the second moulding surface of the lower mould part, the lower mould part being at an elevated temperature as compared to the temperature of the moulding material; iv. closing the mould tool to define a substantially closed mould cavity containing the moulding material; v. applying pressure to the moulding material in the mould cavity to configure the moulding material in a fully moulded shape, and after the applying pressure step v the resin in the multilaminar panel fully impregnates the dry fibers; and vi. substantially fully curing the resin to form a moulded part from the moulding material.

A method of press molding a molding material to form a molded part of fiber-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mold tool having a lower mold part and an upper mold part, the upper mold part having a first molding surface for molding a first molded surface of the molded part and the lower mold part having a second molding surface for molding a second molded surface of the molded part;
ii. providing a multilaminar panel of molding material comprising at least one layer of dry fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces;
iii. locating the molding material in the mold tool;
iv. progressively closing the mold tool to define a substantially closed mold cavity containing the molding material, the closing step having: I. a first stage prior to both the first molding surface contacting the first major surface and the second molding surface contacting the second major surface and II. a second compression stage after both the first molding surface has contacted the first major surface and the second molding surface has contacted the second major surface, the second compression stage causing resin impregnation of the dry fibers,
the closure speed of relative movement between the lower and upper mold parts being higher in the first stage than in the second compression stage;
v. applying pressure to the molding material in the mold cavity to configure the molding material in a fully molded shape; and
vi. substantially fully curing the resin to form a molded part from the molding material.

A method of press molding a molding material to form a molded part of fiber-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mold tool having a lower mold part and an upper mold part, the upper mold part having a first molding surface for molding a first molded surface of the molded part and the lower mold part having a second molding surface for molding a second molded surface of the molded part;
ii. providing a multilaminar panel of molding material comprising at least one layer of dry fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces;
iii. locating the molding material in the mold tool;
iv. progressively closing the mold tool to define a substantially closed mold cavity containing the molding material, the closing step having: I. a first stage prior to both the first molding surface contacting the first major surface and the second molding surface contacting the second major surface and II. a second compression stage after both the first molding surface has contacted the first major surface and the second molding surface has contacted the second major surface, the second compression stage causing resin impregnation of the dry fibers,
the closure speed of relative movement between the lower and upper mold parts being higher in the first stage than in the second compression stage;
v. applying pressure to the molding material in the mold cavity to configure the molding material in a fully molded shape; and
vi. substantially fully curing the resin to form a molded part from the molding material.

A method of press molding a molding material to form a molded part of fiber-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mold tool having a lower mold part and an upper mold part, the upper mold part having a first molding surface for molding a first molded surface of the molded part and the lower mold part having a second molding surface for molding a second molded surface of the molded part; ii. providing a multilaminar panel of molding material comprising at least one layer of fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces, a surface resin layer of the multilaminar panel being at or adjacent to the first major surface; iii. locating the molding material in the mold tool; iv. closing the mold tool to define a substantially closed mold cavity containing the molding material, the closing step including the sub-steps of: a. partially closing the mold tool to define a closed intermediate cavity containing the molding material, the closed intermediate cavity being larger than the molded part and the first molding surface of the upper mold part being spaced from the first major surface, the upper mold part being at an elevated temperature as compared to the temperature of the molding material; and b. at least partially evacuating air from the closed intermediate cavity while the first molding surface of the upper mold part is spaced from the first major surface; v. applying pressure to the molding material in the mold cavity to configure the molding material in a fully molded shape; and vi. substantially fully curing the resin to form a molded part from the molding material.

A method of press molding a molding material to form a molded part of fiber-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mold tool having a lower mold part and an upper mold part, the upper mold part having a first molding surface for molding a first molded surface of the molded part and the lower mold part having a second molding surface for molding a second molded surface of the molded part; ii. providing a multilaminar panel of molding material comprising at least one layer of fibers and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces, a surface resin layer of the multilaminar panel being at or adjacent to the first major surface; iii. locating the molding material in the mold tool; iv. closing the mold tool to define a substantially closed mold cavity containing the molding material, the closing step including the sub-steps of: a. partially closing the mold tool to define a closed intermediate cavity containing the molding material, the closed intermediate cavity being larger than the molded part and the first molding surface of the upper mold part being spaced from the first major surface, the upper mold part being at an elevated temperature as compared to the temperature of the molding material; and b. at least partially evacuating air from the closed intermediate cavity while the first molding surface of the upper mold part is spaced from the first major surface; v. applying pressure to the molding material in the mold cavity to configure the molding material in a fully molded shape; and vi. substantially fully curing the resin to form a molded part from the molding material.

An insulating structure for an appliance includes an outer layer and an inner layer, wherein an insulating cavity is defined therebetween. A plurality of hollow nano-spheres are disposed within the insulating cavity, wherein each of the hollow nano-spheres includes a diameter in the range of from approximately 50 nanometers to approximately 1000 nanometers and has a wall that defines the internal space, and wherein the wall of each hollow nano-sphere has a thickness that is in a range of from approximately 0.5 nanometers to approximately 100 nanometers. A fill material is disposed in the insulating cavity and wherein the fill material is disposed in the space defined between the plurality of hollow nano-spheres, and wherein the fill material includes at least one of powdered silica, granulated silica, other silica material, aerogel and insulating gas.

An insulating structure for an appliance includes an outer layer and an inner layer, wherein an insulating cavity is defined therebetween. A plurality of hollow nano-spheres are disposed within the insulating cavity, wherein each of the hollow nano-spheres includes a diameter in the range of from approximately 50 nanometers to approximately 1000 nanometers and has a wall that defines the internal space, and wherein the wall of each hollow nano-sphere has a thickness that is in a range of from approximately 0.5 nanometers to approximately 100 nanometers. A fill material is disposed in the insulating cavity and wherein the fill material is disposed in the space defined between the plurality of hollow nano-spheres, and wherein the fill material includes at least one of powdered silica, granulated silica, other silica material, aerogel and insulating gas.