Moulding composite panels

A method of manufacturing a composite panel comprising locating in a moulding cavity 66 of a press mould 68 an assembly 60 of a panel part 62 and a reinforcement part 64 which is disposed at one or more locations on a surface of the panel part to provide primary structural area(s) adjacent to at lea...

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Bibliographische Detailangaben
1. Verfasser: Daniel Thomas Jones
Format: Patent
Sprache:eng
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Zusammenfassung:A method of manufacturing a composite panel comprising locating in a moulding cavity 66 of a press mould 68 an assembly 60 of a panel part 62 and a reinforcement part 64 which is disposed at one or more locations on a surface of the panel part to provide primary structural area(s) adjacent to at least one secondary structural area of the panel part; the panel part comprising of a first ply including a first fibrous layer 88 of randomly oriented non-woven carbon fibres and the reinforcement part comprising at least one second fibrous layer 94; the panel and reinforcement part being provided with a resin. Press moulding the assembly to form a composite panel in which the reinforcement portion is integrally moulded with the panel portion wherein the mold tool applies a higher compressive pressure to the primary structural area(s) than to at least one secondary structural area. The higher compressive pressure preferably provides a higher volume fraction of fibres in the primary structural area (e.g. 30-55vol%) than in the secondary structural area (e.g. 15-30vol%). A thickness ratio of the gap of the cavity and the thickness of the moulded part is preferably higher in the secondary structural area (e.g from 75-100%) than in the primary structural area (e.g. 45-75%). The composite panel may be a vehicle body panel.