Title: Apparatus for forming composite articles

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Abstract: Apparatus for forming a composite article including an inflatable center adapted to retain a predetermined shape covered with a covering of molded material and preferably an inflatable composite article such as a game ball with a covering of more uniform thickness. Surfaces of complementary elements of a mold are adapted to define, when the mold is closed, a molding cavity corresponding to the outer surface of a desired composite article. Said surfaces are electrostatically sprayed with a molding material to form a layer of molding material over said surfaces. Preferably, electrostatic spraying is performed while heating the mold preferably to a temperature above 135.degree.C. and most desirably between 150.degree. and 190.degree.C. An inflatable center is then inserted into the mold and the mold is closed to define the molding cavity with the inflatable center therein. Thereafter, the inflatable center is inflated preferably to a pressure greater than 600 kilopascals and most desirably between 1100 and 1250 kilopascals to compress the molding material against the surfaces of the molding cavity to produce mold details. The mold is then heated preferably to a temperature greater than 135.degree.C. and most desirably to a temperature between 150.degree. and 190.degree.C. to fuse the molding material to the desired covering for the inflatable composite article. Subsequently, the mold is cooled and the composite article is removed from the mold.


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