System and method for producing moulded structure

A method of manufacturing a moulded component having at least two unidirectional fibre portions 104 comprising positioning the unidirectional fibre portions in a network in a jig 101 such that they meet or join at one or more nodal points 106, preferably using clamps 102; joining the nodal points by...

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Bibliographische Detailangaben
Hauptverfasser: Alex Lakic, Pete Kitchen
Format: Patent
Sprache:eng
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Beschreibung
Zusammenfassung:A method of manufacturing a moulded component having at least two unidirectional fibre portions 104 comprising positioning the unidirectional fibre portions in a network in a jig 101 such that they meet or join at one or more nodal points 106, preferably using clamps 102; joining the nodal points by over-moulding with a first material (fig 2: 204, 206, 208); positioning the network of unidirectional fibres in a mould tool (fig 5A; 502) comprising at least one recess (fig 5A; 506) to receive and constrain the nodal point(s); over-moulding the network with a second moulding material (fig 5A; 510) to form the component. The first moulding material may be in the form of disks comprising embedded aligned fibres. The second moulding material preferably comprises a sheet moulding compound, a metal or metal alloy, a matrix material containing glass fibres or a mixture thereof. A moulded component having at least two unidirectional fibre portions meeting at nodal point(s) wherein a majority of the volume of the component is formed from a second moulding material and is formed from a first moulding material in the vicinity of the nodal point(s). A vehicle comprising a moulded component such as parts of a body shell, a battery casing, sub-frame or an automobile seat are further provided.