Sheet, fiber and resin composite material and method and apparatus for forming same

Abstract

A cured resin and fiber part generally can be manufactured by providing a mold that defines a cavity having at least one shape-defining surface. An in-mold paint sheet having a bonding side and a finish side can be positioning in the cavity of the mold such that the finish side of the in-mold paint sheet is positioned adjacent to the shape-defining surface of the mold. A mixture of a thermoset resin and a plurality of reinforcing fibers are then introduced into the cavity of the mold such that the resin and fiber mixture contacts the bonding side of the in-mold paint sheet. The in-mold paint sheet and resin and fiber mixture are then compressed in the mold while being heated causing the resin and fiber mixture to be cured and bonded to the in-mold paint sheet resulting in a part having the finish side of the in-mold paint sheet as a finished surface of the part.

1 . A method of forming a finished composite part comprising: 
 providing a mold, the mold defining a cavity with a shape-defining surface;    providing an in-mold paint sheet, the in-mold paint sheet having a bonding side and a finish side;    installing the in-mold paint sheet in the cavity of the mold such that the finish side of the in-mold paint sheet is positioned adjacent to the shape-defining surface of the mold;    introducing mixture of a resin and a plurality of reinforcing fibers into the cavity of the mold such that the resin and fiber mixture contacts the bonding side of the in-mold paint sheet; and    enclosing the in-mold paint sheet and resin and fiber mixture in the mold;    cooling the in-mold paint sheet while at least some of the resin is curing;    wherein the resin and fiber mixture is cured and bonded to the in-mold paint sheet to form a part having the finish side of the in-mold paint sheet as a finished surface of the part.    
     
     
         2 . The method of  claim 1 , wherein the part is formed as a one-piece assembly having three dimensional reinforcing structures integral to the part integral with the part.  
     
     
         3 . The method of  claim 1 , wherein the mold has a shear edge comprising: 
 an upper surface;    a lower surface spaced from the upper surface, defining an interior portion between the lower surface and the upper surface where the part is to be formed, and an exterior portion between the lower and upper surface configured to remain free of the paint sheet and the resin and fiber mixture during molding,    wherein an interior portion is configured to contain the paint sheet and the mixture of resin and fiber and an exterior portion of the mold shear edge is configured to operate with a spacing between the upper surface and the lower surface to allow evolved gasses to escape and allow the paint sheet to protrude from the mold.    
     
     
         4 . The method of  claim 1 , wherein the resin is a thermoset polyurethane resin.  
     
     
         5 . The method of  claim 1 , wherein the reinforcing fiber is a carbon fiber.  
     
     
         6 . The method of  claim 5 , wherein the carbon fibers are about 10-50 millimeters in length.  
     
     
         7 . The method of  claim 5 , wherein the carbon fibers are about 20-30 millimeters in length.  
     
     
         8 . The method of  claim 1 , wherein the resin substantially completely wets substantially all of the reinforcing fibers.  
     
     
         9 . The method of  claim 5 , wherein the carbon fibers are about 25 millimeters in length.  
     
     
         10 . The method of  claim 1 , wherein the paint sheet is maintained at a temperature of about 70° F. to 150° F.  
     
     
         11 . The method of  claim 1 , wherein the paint sheet is at least one and a half millimeters thick.  
     
     
         12 . The method of  claim 1 , wherein a reinforcing member is introduced into the mold and the reinforcing member is incorporated into the part to provide a one piece assembly by the curing of the resin.  
     
     
         13 . The method of  claim 1 , wherein installing the paint sheet comprises pre-forming the paint sheet using a billow form/male form thermoforming process.  
     
     
         14 . A finished composite part comprising: 
 a paint sheet, the paint sheet having a bonding side and a finish side;    a cured resin and fiber composite integrally bonded to the paint sheet wherein the paint sheet's bonding layer is integrally bonded to the composite and the paint sheet's finish side comprises a finished surface of the finished composite part.    
     
     
         15 . The part of  claim 14  wherein the resin is a polyurethane resin.  
     
     
         16 . The part of  claim 14  wherein the reinforcing fiber is a carbon fiber.  
     
     
         17 . The part of  claim 16  wherein the carbon fibers are about 10-50 millimeters in length.  
     
     
         18 . The part of  claim 16  wherein the carbon fibers are about 20-30 millimeters in length.  
     
     
         19 . The part of  claim 14 , wherein the paint sheet is at least about one and a half millimeters thick.  
     
     
         20 . A method of forming a finished composite part comprising: 
 providing a mold, the mold defining a cavity with a shape-defining surface; the mold having a shear edge, the shear edge having an upper surface, a lower surface spaced from the upper surface, defining an interior portion between the lower surface and the upper surface where the part is to be formed, and an exterior portion between the lower and upper surface configured to remain free of the paint sheet and the resin and fiber mixture during molding, wherein an interior portion is configured to contain the paint sheet and the mixture of resin and fiber and an exterior portion of the mold shear edge is configured to operate with a spacing between the upper surface and the lower surface to allow evolved gasses to escape;    providing an in-mold paint sheet, the in-mold paint sheet having a bonding side and a finish side;    installing the in-mold paint sheet in the cavity of the mold by preforming the paint sheet to the mold so that that the finish side of the in-mold paint sheet is conformed adjacent to the shape-defining surface of the mold;    introducing mixture of a polyurethane thermoset resin and a plurality of carbon reinforcing fibers with a length of about 25 millimeters, wherein the resin substantially completely wets substantially all of the fibers, into the cavity of the mold such that the resin and fiber mixture contacts the bonding side of the in-mold paint sheet;    enclosing the in-mold paint sheet and resin and fiber mixture in the mold;    heating the resin and fiber mixture;    cooling the paint sheet to a temperature of about 70° F. to 150° F. ;    wherein the resin and fiber mixture is cured and bonded to the in-mold paint sheet in a one-shot process to form a one piece assembly having the finish side of the in-mold paint sheet as a finished surface of the part.