Tool and method for manufacturing overmolded structural thermoplastic composite hybrid part having aesthetic integration

Abstract

A process for manufacturing a thermoplastic composite hybrid part having structural and aesthetic features that are injection over-molded on either side of a surface of a composite laminated substrate in a one-step two injection over-molding process is disclosed. The process utilizes a heated CFRTP composite material to laminate a substrate that is injection overmolded with a structural long fiber thermoplastic (LFT) material or resin on one side of the substrate in a first cavity of a dual cavity tool. The structure is injection overmolded on the other side of the substrate in the second cavity of the tool with a thermoplastic material or resin filled with tactile soft chopped staple fibers to achieve a one-piece part with improved aesthetics and tactile sensation with a color representative of the colors inside and outside the automobile. Component manufacturing by means of the one-step two-time thermoplastic composite hybrid injection overmolding technology can be applied in automobiles.

Description

Technical Field

[0001] The present disclosure relates to manufacturing tools, and more particularly, to a multi-cavity tool configured to simultaneously manufacture multiple thermoplastic composite hybrid parts. Background Art

[0002] While developing integrated lightweight components, hybrid solutions that combine continuously fiber-reinforced thermoplastics (CFRTP) composites overmolded with thermoplastic resins are generally considered. These single-shot thermoplastic composite hybrid injection overmolding solutions provide a viable alternative to multi-piece metal systems in vehicles and are used to lightweight many automotive applications. The manufacturing readiness level of this thermoplastic composite hybrid technology has matured, and this thermoplastic composite hybrid technology is used in automotive structural or semi-structural applications. However, since the CFRTP surface is aesthetically unappealing, the use of this technology in applications requiring better surface aesthetics is limited. The aesthetic aspect of thermoplastic composite hybrid parts is obtained through secondary operations such as painting, additional decorative layers, or foaming. For example, the armrest has a foam layer injected with fabric / leather, and the inner surface of the tailgate is covered with an additional decorative panel. These secondary operations may increase the total cost of manufacturing. The thermoplastic composite hybrid technology is currently limited to invisible semi-structural or structural parts. Summary of the Invention

[0003] Embodiments relate to a thermoplastic composite hybrid part that employs a two-shot overmolding tool and process that combines the injection overmolding of structural features (ribbed or honeycombed) and the aesthetic aspect on either side of the CFRTP in a single injection overmolding step.

[0004] One embodiment discloses a tool for manufacturing a part, the part being a co-molded structural thermoplastic composite hybrid part having a substrate or composite insert, a reinforcement structure, and an aesthetic layer, the substrate or composite insert being shaped, the reinforcement structure being formed of a first material injection co-molded onto its inner surface, and the aesthetic layer being formed of a second material injection co-molded onto its outer surface, the tool comprising: a first mold extending from a first mold end to a second mold end, wherein the first mold extends from a first surface of the first mold to a second surface of the first mold; a second mold extending from a first end to a second end, wherein the second mold extends from a first surface of the second mold facing the first surface of the first mold to a second surface of the second mold facing away from the first mold; wherein the first mold includes a first block adjacent to the first end of the first mold and extending outwardly from the first surface, the first block having a first block shape matching the profile of the substrate; wherein the second mold includes a first cavity adjacent to the first end of the second mold and a second cavity adjacent to the second end of the second mold, wherein the first cavity and the second cavity are adjacent to each other and each cavity extends inwardly from the first surface of the second mold toward the second surface; and wherein the first mold is configured to rotate between a first rotational position and a second rotational position, wherein in the first rotational position, the first block is positioned to face the first cavity rather than the second cavity, and in the second rotational position, the first block is positioned to face the second cavity rather than the first cavity.

[0005] Another embodiment provides a method of manufacturing a part using a tool, the part being a co-molded structural thermoplastic composite hybrid part having a substrate or composite insert, a reinforcement structure, and an exterior aesthetic layer, the substrate or composite insert being shaped and having an inner surface and an outer surface, the reinforcement structure being formed of a first material co-molded onto the inner surface, and the exterior aesthetic layer being formed of a second material co-molded onto the outer surface, the method comprising: heating the substrate; positioning the substrate in the tool, wherein the tool has a first mold and a second mold, the first mold extending from a first mold end to a second mold end, the second mold extending from a first end to a second end, wherein the first mold of the tool is in a first rotational position such that the substrate is located between a first block adjacent to the first mold end of the first mold and a first cavity adjacent to the first end of the second mold; closing the tool such that the first mold abuts the second mold and such that the substrate is pressed into a first mold cavity formed between the first block and the first cavity; injecting the first material through a first pouring channel extending from a second surface of the second mold to the first cavity into a reinforcement groove of the first block facing a first surface of the first mold to co-mold the reinforcement structure onto the inner surface of the substrate; opening the tool and moving the first mold from the first rotational position to a second rotational position such that the first block is positioned facing a second cavity adjacent to the second end of the second mold; closing the tool such that the substrate is inserted into a second mold cavity formed between the first block and the second cavity, thereby creating a void between the outer surface of the substrate and the second cavity; injecting the second material into a second pouring channel extending from the second end of the second mold to the second cavity to co-mold the exterior aesthetic layer onto the outer surface of the substrate; and opening the tool and ejecting the part.

[0006] Another embodiment provides a method of manufacturing a part using a tool, the part being a co-molded structural thermoplastic composite hybrid part having a first substrate or composite insert, a reinforcement structure, and an exterior aesthetic layer, the first substrate or composite insert having an inner surface and an outer surface and being shaped, the reinforcement structure being formed of a first material co-molded onto the inner surface, and the exterior aesthetic layer being formed of a second material co-molded onto the outer surface, the method comprising: heating the first substrate; positioning the first substrate in the tool, wherein the tool has a first mold and a second mold, the first mold extending from a first mold end to a second mold end, the second mold extending from a first end to a second end, wherein the first mold of the tool is in a first rotational position such that the first substrate is located between a first block adjacent to the first end of the first mold and a first cavity adjacent to the first end of the second mold, a second block adjacent to the second mold end of the first mold being positioned to face a second cavity adjacent to the second end of the second mold; closing the tool such that the first mold abuts the second mold and the first substrate is pressed into a first mold chamber formed between the first block and the first cavity and the second block is positioned in the second cavity; injecting the first material via a first pouring channel into a first reinforcement groove of the first block to co-mold the reinforcement structure onto the inner surface of the first substrate; opening the tool and moving the first mold from the first rotational position to a second rotational position such that the first block is positioned to face the second cavity and the second block is positioned to face the first cavity; heating a second substrate; positioning the second substrate between the second block and the first cavity; closing the tool such that the first substrate is inserted into a second mold chamber formed between the first block and the second cavity, thereby creating a void between the outer surface of the first substrate and the second cavity, and the second substrate is pressed into the first mold chamber formed between the second block and the first cavity; injecting the second material into the second pouring channel to co-mold the exterior aesthetic layer onto the outer surface of the first substrate, and injecting the first material through the first pouring channel into a second reinforcement groove in the second block to co-mold the reinforcement structure onto the inner surface of the second substrate; and opening the tool and ejecting the part. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The present disclosure is illustrated by way of example and is not limited in the figures, in which like reference numerals indicate similar elements.

[0008] Figure 1AShows a tool according to an embodiment, the tool having two mold cavities and a single mold part for manufacturing a thermoplastic composite hybrid part having an internal reinforcement structure and an external aesthetic layer, wherein the tool has a first mold and a second mold, wherein the first mold is in a first position such that a first mold part of the first mold faces a first cavity of two cavities of a second block, the tool is closed, and the first mold part is in the first cavity.

[0009] Figure 1A1 Shows a perspective view of the first mold, wherein the first mold is cut along line A-A to provide Figure 1A the image shown in

[0010] Figure 1A2 Shows a perspective view of a formed substrate laminate having a central opening that allows material to pass through when a reinforcement structure is formed on the substrate laminate.

[0011] Figure 1B Shows a Figure 1A thermoplastic composite hybrid part having an internal reinforcement structure and an external aesthetic layer manufactured with the tool of

[0012] Figure 1C Shows Figure 1A the tool of , wherein the first mold and the second mold are separated from each other.

[0013] Figure 1D Shows Figure 1A the tool of , wherein the first mold is in a second rotational position in which the mold part faces a second cavity of the two cavities.

[0014] Figure 2 Shows Figure 1A the tool of , wherein the tool is closed and the mold part is in the second cavity.

[0015] Figure 3 Shows the tool as Figure 1C shown in , wherein additional feature parts of the tool are identified.

[0016] Figure 4A Shows the tool as Figure 1A shown in , wherein additional feature parts of the tool are identified.

[0017] Figure 4B Shows the tool as Figure 1C shown in , wherein additional feature parts of the tool are identified.

[0018] Figure 5 Shows the tool as Figure 1A shown in , wherein additional feature parts of the tool are identified.

[0019] Figure 6Shows another tool according to an embodiment, the tool having two mold cavities and two mold parts for manufacturing a thermoplastic composite hybrid part having an internal reinforcement structure and an external aesthetic layer, wherein the tool is closed, and the first mold part is in the first of the two cavities, and the second mold part is in the second of the two cavities.

[0020] Figures 7A to 7H Shows a process according to an embodiment, the process for manufacturing an injection-molded structural thermoplastic composite hybrid part with an aesthetic integration part by using a single-core and double-cavity tool in a two-shot injection molding in a single step with an in-mold formed substrate, wherein multiple parts can be manufactured in series relative to each other.

[0021] Figure 8 Is a diagram showing Figures 7A to 7H the process shown in

[0022] Figures 9A to 9C Shows a process according to an embodiment, the process for manufacturing an injection-molded structural thermoplastic composite hybrid part with an aesthetic integration part by using a single-core and double-cavity tool in a two-shot injection molding in two steps with a pre-formed substrate, wherein multiple parts can be manufactured in series relative to each other.

[0023] Figure 10 Is a diagram showing Figures 9A to 9C the process shown in

[0024] Figures 11A to 11J Shows another process according to an embodiment, the another process for manufacturing an injection-molded structural thermoplastic composite hybrid part with an aesthetic integration part by using a double-core and double-cavity tool in a two-shot injection molding in a single step with an in-mold formed substrate, wherein multiple parts can be manufactured in series relative to each other.

[0025] Figure 12 Is a diagram showing Figures 11A to 11J the process shown in

[0026] Figures 13A to 13H Shows yet another process according to an embodiment, the yet another process for manufacturing an injection-molded structural thermoplastic composite hybrid part with an aesthetic integration part by using a double-core and double-cavity tool in a two-shot injection molding in two steps with a pre-formed substrate, wherein multiple parts can be manufactured in series relative to each other.

[0027] Figure 14 Is a diagram showing Figures 13A to 11H the process shown in

[0028] Figure 15An internal view of an overmolded structural thermoplastic composite part having an aesthetic integration portion, manufactured according to an embodiment, is shown.

[0029] Figure 16 An external view of an overmolded structural thermoplastic composite hybrid part having an aesthetic integration portion, manufactured according to an embodiment, is shown. DETAILED DESCRIPTION

[0030] Turning now to Figure 1A , a tool 100 for manufacturing a thermoplastic composite hybrid part 110 ( Figure 1B ) is disclosed herein. The part 110 has a formed substrate laminate (or substrate) 120, which can be C-shaped, i.e., having a C-shaped cross-section with an inner surface 130 and an outer surface 140. A reinforcement structure 150 is overmolded on the inner surface 130 of the substrate, and an external aesthetic layer 160 is overmolded on the outer surface 140 of the substrate. The reinforcement structure 150 can be a long fiber-filled thermoplastic material, and the external aesthetic layer 160 can be a short chopped fiber thermoplastic material with a soft touch.

[0031] The tool 100 extends along a first axis A1 from a first end 180 to a second end 190 and along a second axis A2 perpendicular to the first axis A1 from a first side 200 to a second side 210. The tool 100 includes a first die (also referred to as a male mold, a core mold, or generally as a first platen) 220 and a second template or second die (also referred to as a female mold or a mold or generally as a second platen) 230 that are parallel to each other along the first axis A1. The first die 220 or the second die 230 is configured to move along the second axis A2 from a first translation position (FIG. 1c) to a second translation position (FIG. 1a), in the first translation position, the first die 230 and the second die 240 are spaced apart from each other, and in the second translation position, the first die 230 and the second die 240 are engaged with each other. This movement can be achieved by an appliance 250, which can be a motor, a robot, etc.

[0032] The first die 220 extends along the first axis A1 from a first end 222 (or a first die end) to a second end 224 (or a second die end). The second die 230 extends along the first axis A1 from a first end 232 to a second end 234. The first die 220 extends along the second axis A2 from a first surface 220A facing the second die 230 to a second surface 220B facing away from the second die 230. The second die 230 extends along the second axis A2 from a first surface 230A facing the first die 220 to a second surface 230B facing away from the first die 220.

[0033] The first mold 220 includes a first block (also referred to as a projection or core) 240 having a first block shape, which may be a rectangular shape, that matches the inner surface of the formed substrate of the composite part. In Figure 1A1 a perspective view of the first block 240 of the first mold 220 is shown. That is, Figure 1A the cross-section in Figure 1A1 is obtained by cutting the first block 240 of the first mold 220 along line A-A in Figure 1A2 A perspective view of the formed substrate laminate 120 having a central opening H1 is shown, which allows material to pass through when a reinforcing structure is formed on the substrate laminate 120. The first block 240 extends outwardly from the first surface 220A of the first mold 220. The second mold 230 includes a first cavity 250 formed adjacent to the first end 232 of the second mold 230 and a second cavity 260 formed adjacent to the second end 234 of the second mold. Each cavity 250, 260 extends inwardly from the first surface 230A of the second mold 230 toward the second surface 230B of the second mold 230. The first cavity 250 and the second cavity 260b are adjacent to each other along a first axis A1.

[0034] The first mold 220 is configured to rotate (or pivot) about its center CL (i.e., its central axis along the second axis A2) between a first rotational position (Figure 1c) and a second rotational (or pivoting) position (Figure 1d). Such rotation can be achieved by rotating the first mold 220 180 degrees about its center CL by means of an appliance 250 such as those described above. In the first rotational position (Figure 1d), the first block 240 is configured to be inserted into the first cavity 250 rather than the second cavity 260. In the second rotational position (Figure 1d), the first block is configured to be inserted into the second cavity 260 rather than the first cavity 250 ( Figure 2 ).

[0035] Turning to Figure 3 , the first mold 220 extends a first mold length DL1 along the first axis A1. The second mold 230 extends a second mold length DL2 along the first axis A1, and the second mold length DL2 may be the same as the first mold length DL1. The first block 240 extends outwardly from the first surface 220A of the first mold 220 along the second axis A2 by a first block depth PD. The first block 240 extends a first block length PL along the first axis A1, and the first block length PL is less than half of the first mold length DL1. The first block 240 is adjacent to the first end 180 of the first mold 220 and is accommodated between the first end 180 of the first mold 220 and the center CL of the first mold 220.

[0036] The first cavity 250 has a first cavity shape, which may be a cup shape that is complementary to the shape of the first block and extends inwardly from the first surface 220B of the second mold 230 along a second axis A1 by a first cavity depth CD1 that is greater than the first block depth PD. The first cavity 250 extends along a first axis A1 by a first cavity length CL1 that is greater than the first block length PL. As Figure 4A shown, when forming a substrate 120 or encapsulating a previously formed substrate 120, a first mold cavity MC1 is defined between the first block 240 and the first cavity 250 when the first mold 220 is positioned against the second mold 230 during operation of the tool 100.

[0037] The second cavity 260 is larger than the first cavity 250. The second cavity 260 has a second cavity shape that is complementary to the shape of the first block. The second cavity 260 extends inwardly from the first surface 230A of the second mold 230 along a second axis A2 by a second cavity depth CD2 that is greater than the first cavity depth CD1. The second cavity 260 extends along the first axis A1 by a second cavity length CL2 that is greater than the first cavity length CL1. As Figure 4B shown, when the first mold 220 is positioned against the second mold 230 for overmolding a cosmetic layer 160 around the outer surface 140 on the part 110, a second mold cavity MC2 that is larger than the first mold cavity MC1 is defined between the first block 240 and the first cavity 250.

[0038] Turning to Figure 5 , a block outer surface 270 is defined along the first block 240 by the first surface 220A of the first mold 220. A (first) reinforcing groove 280 is defined in the first block 240 and extends from the block outer surface 270 along the second axis A1 toward the second surface 220B of the first mold 220. The reinforcing groove 280 may be formed as a rib structure or a honeycomb structure, i.e., having a rib shape or a honeycomb shape. A first pouring channel 290 is defined in the second mold 230 and extends from the second surface 230B of the second mold 230 to the first cavity 250. According to this configuration, a liquid material is configured to flow into the reinforcing groove 280 to form a reinforcing structure 150 against the inner surface 130 of the substrate 120 of the composite part. The reinforcing groove 280 may be a (first) plurality of reinforcing grooves 280 that extend from the block outer surface 270 along the second axis A2 toward the second surface 220A of the first mold 220.

[0039] The first surface 220A of the first mold 220 defines a first outer lip 310 except at the location where the first piece 240 is located. That is, the first outer lip 310 surrounds the first piece 240. The first surface 230A of the second mold 230 defines a second outer lip 320 except at the locations where the block cavities 250, 260 are located. That is, the second outer lip 320 surrounds the block cavities 250, 260. When the first mold 220 is positioned against the second mold 230, the first outer lip 310 and the second outer lip 320 face each other and abut against each other.

[0040] A second pouring channel 330 is defined in the second mold 230, and the second pouring channel 330 extends from the second end 234 of the second mold 20 to the second cavity 260, which enables liquid material to flow into the second mold chamber MC2 when the first piece 240 is disposed in the second cavity 260, as will be described below.

[0041] With the tool 100 disclosed above, the first mold 220 has only one piece, which is the first piece 240, such that the tool 100 can process a single part 110 in each operation of the tool 100. Turning to Figure 6 , the tool 100A has all the same features and functions as the tool 100 disclosed above, except that the first mold 220 includes a second piece 350 that protrudes outward from the first surface 220A of the first mold 220. The second piece 350 is configured to be the same as the first piece 240, and has the same dimensions as the first piece 240, and is adjacent to the first piece 240 along a second axis A2. For example, a (second) reinforcing groove 370 is formed in the second piece 350, and the (second) reinforcing groove 370 extends inwardly from the outer block surface 375. Like the first piece 240, the reinforcing groove 370 can be a (second) plurality of reinforcing grooves. The first outer lip 310 surrounds the first piece 240 and the second piece 350. In the first rotational position of the first mold 220, the second protrusion 350 is configured to be inserted into the second cavity 260 instead of the first cavity 250. In the second rotational position, the second piece 350 is configured to be inserted into the first cavity 250 instead of the second cavity 260.

[0042] Turning to FIGS. 7 and Figure 8 , a method of manufacturing a part 110 using the tool 100 is shown. As Figure 7A and block 810 show, the method includes heating a substrate 120 with a heating appliance 500, and the heating appliance 500 can be a typical lamination heater, which is a flat sheet as Figure 7A shown. That is, the substrate 120 can have a planar cross-section and is a thermoplastic composite laminate blank, which is a continuous fiber reinforced thermoplastic (CFRTP) composite laminate. As Figure 7BAs shown in block 820, the method includes positioning a substrate 120 in a tool 100 with a first mold 220 in a first rotational position such that the substrate 120 is located between a first block 240 and a first cavity 250. As Figure 7C As shown in block 825, the method includes closing the tool 100 such that the first mold 220 abuts a second mold 230 and such that the substrate 120 is pressed into a first mold chamber MC1 formed between the first block 240 and the first cavity 250. This process thermoforms the substrate 130 into a C-shaped insert.

[0043] As Figure 7D As shown in block 830, the method includes injecting a first material via a first pouring channel 290 into a strengthening groove 280 to overmold a strengthening structure 150 onto an inner surface 130 of the substrate 120. This process is also referred to as the 1K (or first) time, which may utilize SABIC STAMAX® 40YM240 material for the strengthening structure 150 or any long fiber-filled thermoplastic resin. The fibers may be carbon fibers, glass fibers, or any other strengthening material. The material flows from the first pouring channel 290 of the second mold 230 through a hole H1 in the substrate 120 to the strengthening groove 280 of the first block 240 of the first mold 220. As Figure 7E As shown in block 840, the method includes opening the tool 100 and moving the first mold 220 from the first rotational position to a second rotational position such that the first block 240 is configured to engage (e.g., face) a second cavity 260. Figure 7F As shown in block 850, the method includes closing the tool 100 such that the substrate 120 is inserted into a second mold chamber MC2 formed between the first block 240 and the second cavity 260. Since the second mold chamber MC2 is larger than the first mold chamber MC1, a gap G1 is formed between an outer surface 140 of the substrate 120 and the second cavity 160. Figure 7G As shown in block 860, the method includes injecting a second material into a second pouring channel 330 to overmold an outer aesthetic layer 160 onto the outer surface 140 of the substrate 120. This process is also referred to as the 2K (or second) time, which may utilize a SABIC HAPSOFT™ PP compound with a desired color as the material for the aesthetic layer 160 or any chopped (short) fiber-filled tactilely soft thermoplastic resin. The fibers may be carbon fibers, glass fibers, or any other strengthening material. Thereby, a composite hybrid part 110 is formed. As Figure 7G As shown in block 870, the method includes opening the tool 100 and ejecting the part 110. This process is repeated from block 810 to 870, e.g., as Figures 7A to 7H shown, to form multiple parts 110.

[0044] Turning to FIGS. 9 and Figure 10, showing another method of manufacturing part 110 using tool 100. At block 1010, the method includes heating substrate 120, which has been previously formed into a C-shaped insert as Figure 9A shown. This forming can be achieved by using separate or combined methods. As Figure 9B and block 1020 show, the method includes positioning substrate 120 in tool 100 with the first die 220 in a first rotational position such that substrate 120 is located between the first block 240 and the first cavity 250. As Figure 9C and block 1030 show, the method includes closing tool 100 such that the first die 220 abuts the second die 230, and substrate 120 is disposed in a first mold chamber MC1 formed between the first block 240 and the first cavity 250. The remaining processing is the same as Figures 7D to 7H and that shown in blocks 830 to 870.

[0045] Turning to FIGS. 11 and Figure 12 , showing a method of manufacturing part 110 using tool 100A. As Figure 11A and block 1210 show, the method includes heating substrate (or first substrate) 120, which is a flat sheet as Figure 11A shown. As Figure 11B and block 1220 show, the method includes positioning substrate 120 in tool 100A with the first die 220 in a first rotational position such that substrate 120 is located between the first block 240 and the first cavity 250 and the second block 350 faces the second cavity 260. As Figure 11C and block 1225 show, the method includes closing tool 100A such that the first die 220 abuts the second die 230, and causing substrate 120 to be pressed into a first mold chamber MC1 formed between the first block 240 and the first cavity 250. Simultaneously, the second block 350 is positioned in the second cavity 260. This processing thermoforms substrate 130 into a C-shaped insert.

[0046] As Figure 11D and block 1230 show, the method includes injecting a first material into the reinforcement groove 280 via the first pouring channel 290 to overmold the reinforcement structure 150 onto the inner surface 130 of substrate 120. As Figure 11E and block 1240 show, the method includes opening tool 100A and moving the first die 220 from the first rotational position to a second rotational position. In this configuration, the first block 240 faces the second cavity 260 and the second block 350 faces the first cavity 250.

[0047] As Figure 11FAs shown in block 1244, the method includes heating a second substrate 120A, where the second substrate 120A is a flat sheet as Figure 11F shown. As Figure 11G shown in block 1246, the method includes positioning the second substrate 120A between a second block 350 and a first cavity 250.

[0048] As Figure 11H shown in block 1250, the method includes closing tool 100A such that a first block 240 is inserted into a second mold chamber MC2 formed between the first block 240 and a second cavity 260. Since the second mold chamber MC2 is larger than the first mold chamber MC1, a gap G1 is formed between the outer surface 140 of the substrate 120 and the second cavity 160. Simultaneously, the second substrate 120A is pressed into the first mold chamber MC1 formed between the second block 350 and the first cavity 250. This process thermoforms the second substrate 120A into a C-shaped insert that matches the shape of the substrate 120, such that the second substrate 120A has an inner surface 130A and an outer surface 140A.

[0049] As Figure 11I shown in block 1260, the method includes injecting a second material into a second pouring channel 330 to overmold an external aesthetic layer 160 onto the outer surface 140 of the substrate 120. Thereby, a composite part 110 is formed. Simultaneously, the material is injected through a first pouring channel 290 and a reinforcing groove 380 in the second block 350 to overmold a reinforcing structure 150 onto the inner surface 130A of the second substrate 120A. As Figure 12 shown in block 1270, tool A is opened and the part 110 is removed from tool 100A. This process is repeated from block 1240 to 1270, for example, as Figures 11E to 11J shown, to form multiple parts 110. As can be understood, this process enables the production of multiple parts 110 to be faster.

[0050] Turning now to FIGS. 13 and Figure 14 , another method of manufacturing a part 110 using tool 100A is shown. As Figure 13A shown in block 1410, the method includes heating a substrate 120, where the substrate 120 has been formed into a C-shaped profile as Figure 13A shown, similar to Figure 9A shown. As Figure 13B shown in block 1420, the method includes positioning the substrate 120 with the first mold 220 in a first rotational position such that the substrate 120 is located between the first block 240 and the first cavity 250 and the second block 350 faces the second cavity 260. As Figure 13CAs shown in and box 1425, the method includes closing tool 100A such that the first mold 220 abuts against the second mold 230, and such that the substrate 120 is positioned within a first mold cavity MC1 formed between the first block 240 and the first cavity 250 and the second block 350 is positioned within the second cavity 260.

[0051] As Figure 13D As shown in and box 1430, the method includes injecting a first material through a first pouring channel 290 into a reinforcing groove 280 to overmold a reinforcing structure 150 onto an inner surface 130 of the substrate 120. As Figure 13E As shown in and box 1440, the method includes opening tool 100A and moving the first mold 220 from a first rotational position to a second rotational position such that the first block 240 faces the second cavity 260 and the second block 350 faces the first cavity 250.

[0052] As Figure 13F As shown in and box 1444, the method includes heating a second substrate 120A, which has been formed as a C-shaped insert as Figure 13E shown. As Figure 13G As shown in and box 1446, the method includes positioning the second substrate 120A between the second block 350 and the first cavity 250.

[0053] As Figure 13H As shown in and box 1450, the method includes closing tool 100A such that the first block 240 is inserted into a second mold cavity MC2 formed between the first block 240 and the second cavity 260. Since the second mold cavity MC2 is larger than the first mold cavity MC1, a gap G1 is formed between an outer surface 140 of the substrate 120 and the second cavity 160. Simultaneously, the second substrate 120A is positioned within the first mold cavity MC1 formed between the second block 350 and the first cavity 250. The remaining processing is the same as Figures 11I to 11J that shown in and boxes 1260 to 1270 to form the part 110. The processing can be Figure 13E repeated starting from and box 1440 to simultaneously produce multiple parts 110.

[0054] The above disclosed process provides for the manufacture of thermoplastic composite hybrid parts having structural and aesthetic features which are injection overmolded on either side of the surface of a composite laminate substrate in a two-shot injection overmolding process in one step. The automated process utilizes a preformed CFRTP composite laminate substrate which is injection overmolded on one side of the substrate with a structural long fiber thermoplastic (LFT) resin in the first cavity of a two-cavity tool. The resulting structure is then injection overmolded on the other side of the substrate in the second cavity of the two-cavity tool with a thermoplastic resin filled with tactilely soft chopped (short) fibers to achieve a single-piece solution which potentially achieves improved aesthetics and haptics having the desired color representative of automotive interior and exterior colors. This one-step two-shot injection overmolding process can be achieved within an acceptable cycle time making it potentially suitable for mass production. The final finished part meets both the structural requirements and aesthetic requirements for automotive applications thus avoiding any secondary operations and reducing the manufacturing cost of the part. Part manufacture by means of this one-step two-shot thermoplastic composite hybrid injection overmolding technique can be applied to many automotive applications such as, for example, tailgate, armrest, seat structure, instrument panel, etc.

[0055] Example:

[0056] Referring instead to Figure 15 , an internal rib structure or honeycomb structure 1520 is obtained by injection overmolding onto a part 1510 through a first injection overmolding process, or 1K times can contribute to improving the buckling resistance and flexural properties of the injection overmolded structural thermoplastic composite hybrid part 1510. It also contributes to a higher energy absorption efficiency for improved crashworthiness. The combination of the composite laminate substrate and the 1K times injection overmolding resin can provide the required amount of stiffness / strength by means of functional integration. The internal rib structure or honeycomb structure 1520 is obtained from SABIC STAMAX® 40YM240, which is a black long glass fiber thermoplastic resin, or any long fiber filled thermoplastic resin. The fibers can be carbon fibers, glass fibers or any other reinforcing material. The first cavity of a single-core two-cavity tool and a two-core two-cavity tool is used for injection overmolding the rib structure or honeycomb structure. The external aesthetic layer 1530 is obtained by blending a thermoplastic resin filled with tactilely soft chopped (short) fibers with a representative desired color (e.g., blue) for automotive applications during the second injection overmolding process.

[0057] Referring instead to Figure 16, the outer layer 1530 of the material with a soft touch is obtained through a second injection overmolding process, or 2K, for aesthetics and haptics. The SABIC HAPSOFT™ PP compound is a natural-colored short glass fiber thermoplastic resin, or any short (short) fiber-filled soft-touch thermoplastic resin. The fiber can be carbon fiber, glass fiber, or any other reinforcing material. This allows the SABIC HAPSOFT™ PP compound to be blended with other color masterbatches and thus create representative automotive interior and exterior colors. For example, blue, beige, gray, black, red, and gray can be blended with the SABIC HAPSOFT™ PP compound. The second cavity of the single-core double-cavity tool and the double-core double-cavity tool is used for injection overmolding the soft-touch outer layer.

[0058] The terms used herein are for the purpose of describing particular embodiments only and are not intended to limit the present disclosure. As used herein, unless the context clearly dictates otherwise, the singular forms "a", "an", and "the" are also intended to include the plural forms. It will be further understood that when used in this specification, the terms "comprises" and / or "comprising" specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0059] Those skilled in the art will understand that various example embodiments are shown and described herein, each having certain features in a particular embodiment, but the present disclosure is not limited thereto. On the contrary, the present disclosure can be modified to include any number of variations, changes, substitutions, combinations, sub-combinations, or equivalent arrangements not heretofore described but commensurate with the scope of the present disclosure. In addition, while various embodiments of the present disclosure have been described, it should be understood that aspects of the present disclosure may include only some of the described embodiments. Therefore, the present disclosure should not be considered limited by the foregoing description, but only by the scope of the appended claims.

Claims

1. A tool for manufacturing a part, which is a overmolded structural thermoplastic composite hybrid part having a substrate or composite insert, a reinforcing structure, and an aesthetic layer, the substrate or composite insert being shaped, the reinforcing structure being formed of a first material injection overmolded onto its inner surface, and the aesthetic layer being formed of a second material injection overmolded onto its outer surface, the tool comprising: A first mold extending from a first mold end to a second mold end, wherein the first mold extends from a first surface of the first mold to a second surface of the first mold; A second mold extending from a first end to a second end, wherein the second mold extends from a first surface of the second mold facing the first surface of the first mold to a second surface of the second mold facing away from the first mold; Wherein the first mold includes a first block adjacent to the first end of the first mold and extending outwardly from the first surface, and the first block has a first block shape matching the profile of the substrate; Wherein the second mold includes a first cavity adjacent to the first end of the second mold and a second cavity adjacent to the second end of the second mold, wherein the first cavity and the second cavity are adjacent to each other, and wherein each cavity extends inwardly from the first surface of the second mold towards the second surface; and Wherein the first mold is configured to rotate between a first rotational position and a second rotational position, wherein in the first rotational position, the first block is positioned to face the first cavity rather than the second cavity, and in the second rotational position, the first block is positioned to face the second cavity rather than the first cavity.

2. The tool according to claim 1, wherein: The first mold extends a first mold length from the first mold end of the first mold to the second mold end; Wherein the first block extends outwardly from the first surface of the first mold by a first block depth, the first block has a first block length smaller than half of the first mold length, and the first block is adjacent to the first end of the first mold; Wherein the first cavity has a first cavity shape complementary to the first block shape, the first cavity extends inwardly from the first surface of the second mold by a first cavity depth, the first cavity depth is greater than the first block depth, and the first cavity has a first cavity length greater than the first block length; and Wherein when the first mold is positioned against the second mold during operation of the tool, a first mold chamber is defined between the first block and the first cavity.

3. The tool according to claim 1 or 2, wherein The second mold extends a second mold length equal to the first mold length.

4. The tool according to any one of the preceding claims, wherein, The second cavity is larger than the first cavity.

5. The tool according to any one of the preceding claims, wherein: The second cavity has a second cavity shape complementary to the shape of the first block, the second cavity extending inwards from the first surface of the second mold by a second cavity depth, the second cavity depth being greater than the first cavity depth, and the second cavity having a second cavity length greater than the first cavity length, and when the first mold is positioned against the second mold, a second mold cavity larger than the first mold cavity is defined between the first block and the first cavity.

6. The tool according to any one of the preceding claims, wherein: The first surface of the first mold defines a block outer surface at the first block; wherein a reinforcing groove extending from the block outer surface towards the second surface of the first mold is defined in the first block; and wherein a first pouring channel is defined in the second mold, the first pouring channel extending from the second surface of the second mold to the first cavity, whereby the first material is configured to flow into the reinforcing groove to form the reinforcing structure against the inner surface of the substrate of the part; and optionally, wherein the reinforcing groove is a plurality of reinforcing grooves extending from the block outer surface towards the second surface of the first mold.

7. The tool according to any one of the preceding claims, wherein: The first surface of the first mold defines a first outer lip except at the location where the first block is located; wherein the first surface of the second mold defines a second outer lip except at the locations where the first cavity and the second cavity are located; wherein when the first mold abuts against the second mold, the first outer lip and the second outer lip are positioned against each other; and wherein a second pouring channel is defined in the second mold, the second pouring channel extending from the second end of the second mold to the second cavity, whereby the second material is configured to flow into the second mold cavity.

8. The tool according to any one of the preceding claims, wherein: The first mold includes a second block, the second block being configured to be the same as and adjacent to the first block; and wherein in the first rotational position of the first mold, the second block is positioned to face the second cavity rather than the first cavity, and in the second rotational position, the second block is positioned to face the first cavity rather than the second cavity.

9. The tool according to any one of the preceding claims, wherein, The substrate is a thermoplastic composite laminate blank, which is a continuous fiber reinforced thermoplastic (CFRTP) composite laminate, the first material is a long fiber filled thermoplastic material, and the second material is a short chopped fiber thermoplastic material with a soft touch; and optionally, wherein the reinforcing structure is formed in a rib shape or a honeycomb shape.

10. A method of manufacturing a part using a tool, the part being a co-molded structural thermoplastic composite hybrid part having a substrate or composite insert, a reinforcement structure, and a cosmetic layer, the substrate or composite insert being shaped and having an inner surface and an outer surface, the reinforcement structure being formed of a first material co-molded onto the inner surface, and the outer cosmetic layer being formed of a second material co-molded onto the outer surface, the method comprising: heating the substrate; positioning the substrate in the tool, the tool having a first mold and a second mold, the first mold extending from a first end to a second end, the second mold extending from a first end to a second end, the first mold of the tool being in a first rotational position such that the substrate is located between a first block adjacent to the first end of the first mold and a first cavity adjacent to the first end of the second mold; closing the tool such that the first mold abuts the second mold and the substrate is pressed into a first mold cavity formed between the first block and the first cavity; injecting the first material through a first pouring channel extending from a second surface of the second mold to the first cavity into a reinforcement groove of the first block facing a first surface of the first mold to co-mold the reinforcement structure onto the inner surface of the substrate; opening the tool and moving the first mold from the first rotational position to a second rotational position such that the first block is positioned to face a second cavity adjacent to the second end of the second mold; closing the tool such that the substrate is inserted into a second mold cavity formed between the first block and the second cavity, thereby creating a void between the outer surface of the substrate and the second cavity; injecting the second material into a second pouring channel extending from the second end of the second mold to the second cavity to co-mold the outer cosmetic layer onto the outer surface of the substrate; and opening the tool and ejecting the part.

11. The method according to claim 10, wherein: the substrate has a C-shaped cross-section before being heated; or wherein the substrate has a planar cross-section before being heated and is formed into the C-shaped cross-section when pressed into the first mold cavity.

12. The method according to claim 10 or 11, wherein The substrate is a thermoplastic composite laminate blank, which is a continuous fiber reinforced thermoplastic (CFRTP) composite laminate, the first material is a long fiber filled thermoplastic material, and the second material is a short chopped fiber thermoplastic material with a soft touch; and optionally, wherein the reinforcement structure is formed in a rib shape or a honeycomb shape.

13. A method of manufacturing a part using a tool, the part being a co-molded structural thermoplastic composite hybrid part having a first substrate or composite insert, a reinforcement structure, and an outer aesthetic layer, the first substrate or composite insert being shaped and having an inner surface and an outer surface, the reinforcement structure being formed of a first material co-molded onto the inner surface, and the outer aesthetic layer being formed of a second material co-molded onto the outer surface, the method comprising: Heating the first substrate; Positioning the first substrate in the tool, wherein the tool has a first mold and a second mold, the first mold extending from a first mold end to a second mold end, the second mold extending from a first end to a second end, wherein the first mold of the tool is in a first rotational position such that the first substrate is located between a first block adjacent to the first mold end of the first mold and a first cavity adjacent to the first end of the second mold, and a second block adjacent to the second mold end of the first mold is positioned to face a second cavity adjacent to the second end of the second mold; Closing the tool such that the first mold abuts the second mold and such that the first substrate is pressed into a first mold chamber formed between the first block and the first cavity and the second block is positioned in the second cavity; Injecting the first material via a first pouring channel into a first reinforcement groove of the first block to co-mold the reinforcement structure onto the inner surface of the first substrate; Opening the tool and moving the first mold from the first rotational position to a second rotational position such that the first block is positioned to face the second cavity and the second block is positioned to face the first cavity; Heating a second substrate; Positioning the second substrate between the second block and the first cavity; Closing the tool such that the first substrate is inserted into a second mold chamber formed between the first block and the second cavity, thereby creating a void between the outer surface of the first substrate and the second cavity, and the second substrate is pressed into the first mold chamber formed between the second block and the first cavity; Injecting the second material into a second pouring channel to co-mold the outer aesthetic layer onto the outer surface of the first substrate and injecting the first material through the first pouring channel into a second reinforcement groove in the second block to co-mold the reinforcement structure onto the inner surface of the second substrate; and Opening the tool and ejecting the part.

14. The method according to claim 13, wherein: The first substrate has a C-shaped cross-section before being heated; or wherein the first substrate has a planar cross-section before being heated and the first substrate is formed into the C-shaped cross-section when pressed into the first mold chamber; and Optionally, wherein the second substrate has the C-shaped cross-section before being heated; or wherein the second substrate has the planar cross-section before being heated, and the second substrate is formed into the C-shaped cross-section when being pressed into the first die cavity.

15. The method according to any one of claims 14 or 15, wherein The first substrate is a thermoplastic composite laminate blank, which is a continuous fiber reinforced thermoplastic (CFRTP) composite laminate, the first material is a long fiber filled thermoplastic material, and the second material is a short cut short fiber thermoplastic material with a soft touch; And Optionally, wherein the reinforcing structure is formed into a rib shape or a honeycomb shape.

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