Method of Making Reinforced Composite Articles with Reduced Fiber Content in Local Areas and Articles Made by the Method

Abstract

A composite part including a resin matrix and fibers reinforcing the resin matrix in a first portion of the matrix. A second portion of the resin matrix is substantially devoid of fibers. The fibers may be in the form of a woven mat that defines an opening. Alternatively, the fibers may be loose fibers that are deposited in a mold that includes predetermined areas that are shielded from the deposit of the loose fibers. A method of making the composite part is disclosed in which a woven mat having an opening is filled with resin. Another method is also disclosed in which loose fibers are shielded from being deposited in a portion of the mold that is subsequently filled with resin.

What is claimed is: 
     
         1 . A method of making a fiber reinforced composite part comprising:
 providing a fiber mat defining an opening;   inserting the fiber mat into a mold with the opening in a predetermined location in the mold;   supplying a liquid resin to the mold that envelopes the fiber mat; and   hardening the resin in the mold, wherein the resin fills the opening to provide a fastener receptacle area on the fiber reinforced composite part at the predetermined location.   
     
     
         2 . The method of  claim 1  further comprising:
 assembling a second part to the fiber reinforced composite part; and 
 joining the fiber reinforced composite part and the second part together at the predetermined location. 
 
     
     
         3 . The method of  claim 2  wherein the step of joining the fiber reinforced composite part and the second part further comprises:
 forming a clinch joint in the second part and the fastener receptacle area in the fiber reinforced composite part. 
 
     
     
         4 . The method of  claim 2  wherein the step of joining the fiber reinforced composite part and the second part further comprises:
 inserting a fastener through the second part and the fastener receptacle area in the fiber reinforced composite part. 
 
     
     
         5 . The method of  claim 4  wherein during the inserting step the fastener is selected from the group consisting of:
 a rivet; 
 a self-piercing rivet; 
 a self-tapping screw; and 
 a flow drill screw. 
 
     
     
         6 . A method of making a fiber reinforced composite part comprising:
 shielding a predetermined portion of a mold;   depositing a loose fiber reinforcement material into the mold, wherein the loose fiber material is not deposited in the predetermined portion; and   supplying a liquid resin to a mold that encapsulates the loose fiber reinforcement material and fills the predetermined portion of the mold; and   hardening the resin to form a fastener receptacle area in the fiber reinforced composite part.   
     
     
         7 . The method of  claim 6  further comprising:
 assembling a second part to the fiber reinforced composite part; and 
 joining the fiber reinforced composite part and the second part together at the fastener receptacle area. 
 
     
     
         8 . The method of  claim 7  wherein the step of joining the fiber reinforced composite part and the second part further comprises:
 forming a clinch joint in the second part and the fastener receptacle area in the fiber reinforced composite part. 
 
     
     
         9 . The method of  claim 7  wherein the step of joining the fiber reinforced composite part and the second part further comprises:
 inserting a fastener through the second part and into the fastener receptacle area in the fiber reinforced composite part. 
 
     
     
         10 . The method of  claim 9  wherein during the inserting step the fastener is selected from the group consisting of:
 a rivet; 
 a self-piercing rivet; 
 a self-tapping screw; and 
 a flow drill screw.