Composite molding techniques

Abstract

A molded component and method of molding such a component having one or more features. At least one fibrous substrate is located in a mold. A matrix-forming material is also provided in the mold. Heat is applied to melt the matrix-forming material to form a matrix and to integrally mold the one or more features.

1 . A molded component comprising:
 at least one fibrous substrate; and   a matrix;   wherein the component further comprises at least one integrally molded feature formed contemporaneously with the matrix from the same material.   
     
     
         2 . A molded component as claimed in  claim 1 , wherein said molded feature is formed at least substantially completely from the same material as the matrix. 
     
     
         3 . A vehicle comprising the molded component of  claim 1 . 
     
     
         4 . A molded component comprising:
 at least one fibrous substrate that includes a substrate matrix-forming material and a plurality of fibers; and   a feature-forming material that includes a feature matrix-forming material;   wherein the substrate matrix-forming material and the feature matrix-forming material together form a matrix having at least one feature that is integrally molded while forming the matrix by applying pressure to combine the substrate matrix-forming material and the feature matrix-forming material together in a mold.   
     
     
         5 . A vehicle comprising the molded component of  claim 4 . 
     
     
         6 . A molded component formed by a method comprising the steps of:
 locating a first fibrous substrate in a mold, the mold including two recesses and the first fibrous substrate comprising a substrate matrix-forming material and a plurality of fibers;   providing a feature-forming material in the mold, the feature forming material comprising a feature matrix-forming material;   locating, in the mold, a second fibrous substrate at least partially overlapping the first fibrous substrate, wherein the feature-forming material is provided between the first and second fibrous substrates to form a core; and   applying pressure to combine the first and second fibrous substrates substrate and feature matrix-forming material to form a matrix and to integrally mold the at least one feature,   wherein the mold comprises a first mold part comprising at least one of said recesses, whereby at least the feature matrix-forming material flows through one of the first and second fibrous substrates before flowing into the at least one recess during the application of pressure, and   further wherein the feature matrix-forming material is provided as two or more discrete portions of material, each of said two or more discrete portions being positioned in the mold adjacent to a respective one of the recesses, and   the feature-forming material forming the core between the first and second fibrous substrates further comprising a plurality of short fibers, wherein the short fibers are shorter than the plurality of fibers in the first fibrous substrate.   
     
     
         7 . A vehicle comprising the molded component of  claim 6 .