Method for making a dial table

Abstract

A method of making a dial table is provided. A foam layout is interposed between a base assembly and a top assembly to form a composite layout. The base assembly includes a first segmented carbon fiber layout therein and the top assembly includes a second segmented carbon fiber layout therein. A caul plate is then placed adjacent to the composite layout. The caul plate includes a plurality of caul plate apertures. A vacuum is thereafter generated proximate the composite layout. A resin is drawn through the plurality of caul plate apertures using the generated vacuum until the composite layout is infused with the resin. The caul plate is removed from adjacent the composite layout and the resin-infused composite layout is baked. Thus, the dial table is made.

1 . A dial table comprising: 
 a top assembly including a first segmented carbon fiber layout therein;    a base assembly including a second segmented carbon fiber layout therein;    a foam layout interposed between the base assembly and the top assembly; and    a resin infused into the base assembly, the top assembly, and the foam layout.    
   
   
       2 . The dial table of  claim 1 , wherein the first and second segmented carbon fiber layouts are formed from a unidirectional carbon fiber and the base assembly and the top assembly each further include a glass cloth layout formed from a bi-directional carbon fiber.  
   
   
       3 . The dial table of  claim 1 , wherein the first and second segmented carbon fiber layouts are formed from a plurality of segmented carbon fiber layers.  
   
   
       4 . The dial table of  claim 3 , wherein each of the plurality of segmented carbon fiber layers is offset from an adjacent layer.  
   
   
       5 . The dial table of  claim 1 , wherein the base assembly and the top assembly each further include a carbon fiber twill layout.  
   
   
       6 . The dial table of  claim 1 , wherein the foam layout includes a plurality of grooves and a plurality of holes to promote infusion of the resin.  
   
   
       7 . A method of making a dial table, the method comprising the steps of: 
 interposing a foam layout between a base assembly and a top assembly to form a composite layout, the base assembly including a first segmented carbon fiber layout therein and the top assembly including a second segmented carbon fiber layout therein;    placing a caul plate adjacent to the composite layout, the caul plate including a plurality of caul plate apertures;    generating a vacuum proximate the composite layout;    drawing a resin through the plurality of caul plate apertures using the generated vacuum until the composite layout is infused with the resin;    removing the caul plate from adjacent the composite layout; and    curing the resin-infused composite layout and thereby forming the dial table.    
   
   
       8 . The method of  claim 7 , wherein the method further comprises the step of forming at least one of the first and second segmented carbon fiber layouts from one or more layers of radial unidirectional carbon fiber segments.  
   
   
       9 . The method of  claim 8 , wherein the method further comprises the step of arranging each of the layers of radial unidirectional carbon fiber segments such that adjacent layers are offset from each other.  
   
   
       10 . The method of  claim 7 , wherein at least one of the top assembly and the base assembly further include one of a glass cloth layout and a carbon fiber twill layout, the glass cloth layout formed from a bi-directional carbon fiber fabric and the carbon fiber twill layout formed from a carbon fiber twill fabric.  
   
   
       11 . The method of  claim 7 , wherein the curing step is performed by baking the resin-infused composite layout.  
   
   
       12 . The method of  claim 7 , wherein the method further comprises the step of forming a plurality of radially inward serrating cuts in at least one of the base assembly, the top assembly, and the foam layout to promote infusing of the resin.  
   
   
       13 . The method of  claim 7 , wherein the method further comprises the step of bonding a first washer to the top assembly and a second washer to the base assembly with the resin.  
   
   
       14 . The method of  claim 7 , wherein the method further comprises the step of sequentially placing the top assembly, the foam layout, and the base assembly in a mold.  
   
   
       15 . The method of  claim 7 , wherein the method further comprises the step of placing a sleeve adjacent to an inner periphery of the composite layout, the sleeve including a plurality of grooves and an infusion port therein to promote distribution of the resin through the composite layer.  
   
   
       16 . A method of making a dial table, the method comprising the steps of: 
 arranging selected ones of a plurality of carbon fiber segments to form a first segmented carbon fiber layout;    interposing the first segmented carbon fiber layout between first and second glass cloth layouts to form a base assembly;    arranging selected ones of a plurality of carbon fiber segments to form a second segmented carbon fiber layout;    interposing the second segmented carbon fiber layout between third and fourth glass cloth layouts to form a top assembly;    sequentially placing the top assembly, the foam layout, and the base assembly into a mold such that the foam layout is interposed between the top assembly and the bottom assembly to form a composite layout;    placing a caul plate adjacent to the composite layout, the caul plate including a plurality of caul plate apertures;    generating a vacuum proximate the composite layout;    drawing a resin through the plurality of caul plate apertures using the generated vacuum until the composite layout is infused with the resin;    removing the caul plate from proximate the composite layout; and    baking the resin-infused composite layout thereby curing the resin and forming the dial table.    
   
   
       17 . The method of  claim 16 , the method further comprising the step of folding an outer base assembly periphery portion over an outer top periphery portion.  
   
   
       18 . The method of  claim 16 , wherein the method further comprises securing a first washer and a second washer to the composite layout using the resin.  
   
   
       19 . The method of  claim 16 , wherein the method further comprises the step of forming a plurality of radially inward serrating cuts in the top assembly to promote infusing of the resin and adhering a carbon fiber capping strip to an outer foam periphery of the foam layout.  
   
   
       20 . The method of  claim 16 , wherein the plurality of carbon fiber segments are formed from a unidirectional carbon fiber fabric and at least one of the first, second, third, and fourth glass cloth layouts are formed from a bi-directional carbon fiber fabric and the method further comprises the step of dispensing an adhesive upon the plurality of carbon fiber segments prior to at least one of the arranging selected ones steps.