Composite hybrid component

Abstract

A method of forming a composite hybrid component, the method comprising molding a composite comprising a polymer matrix and an insert in the polymer matrix; and forming an aesthetically pleasing polymeric outer film on the surface of the composite material in the same step as molding the composite material, wherein the aesthetically pleasing polymeric outer film has a thickness of less than 1 mm, from 0.01 to 0.7 mm, from 0.05 to 0.5 mm, or from 0.05 to less than 0.5 mm.

Description

BACKGROUND OF THE INVENTION

[0001] Aesthetically pleasing components, such as vehicle components (e.g., components for motor vehicles such as cars), can avoid additional cladding (which increases weight and cost, two critical-to-quality (CTQ) characteristics). There is an interest in aesthetically pleasing components.

[0002] These and other inefficiencies and improvement opportunities are addressed by the processes, methods, and products (e.g., components) of the present disclosure. SUMMARY OF THE INVENTION

[0003] The present disclosure provides improved processes, methods, and products (e.g., components that include composites and polymer outer layers). More specifically, the present disclosure provides, in various aspects, advantageous methods of forming composite hybrid components.

[0004] The present disclosure provides a method of forming a composite hybrid component, the method comprising molding a composite material that includes a polymer matrix and an insert within the polymer matrix; and forming an aesthetic polymer outer film on a surface of the composite material in the same step as molding the composite material, wherein the aesthetic polymer outer film has a thickness of less than 1 millimeter (mm), is 0.01 to 0.7 mm, 0.05 to 0.5 mm, or 0.05 to less than 0.5 mm.

[0005] The above-described and other features are illustrated by the following detailed description.

[0006] Any combination or arrangement of aspects is contemplated. Additional advantageous features, functions, and applications of the processes, methods, and products (e.g., components) of the present disclosure will become apparent from the following description. DETAILED DESCRIPTION

[0007] Aspects disclosed herein illustrate advantageous methods of forming composite hybrid components. However, it should be understood that the disclosed aspects are merely examples of the present disclosure, which may be implemented in various forms. Accordingly, the details of the exemplary methods disclosed herein should not be construed as limiting.

[0008] The present disclosure provides advantageous methods of forming composite hybrid components. The present disclosure provides the surprising discovery that composite hybrid components can be formed in a single-step process. The single-step process can provide cost benefits, for example, by eliminating separate forming tools.

[0009] The disclosed method of forming a composite hybrid part includes molding a composite material comprising a polymer matrix and an insert material (also referred to herein as an insert), such as continuously reinforced fibers in the polymer matrix; and forming an aesthetic polymer outer film on the surface of the composite material in the same step as molding the composite material, wherein the thickness of the aesthetic polymer outer film is less than 1 mm, being 0.01 to 0.7 mm, 0.05 to 0.5 mm, or 0.05 to less than 0.5 mm. The aesthetic polymer outer film can be formed on one surface of the composite material, or, for example, on opposite surfaces of the composite material.

[0010] The thin thickness of the aesthetic polymer outer film can allow for the formation of a composite hybrid part in a single-step process. The thin thickness of the aesthetic polymer outer film can also allow for the use of a thicker composite material than when using a thicker polymer outer film. In one aspect, the composite web comprises a tape having a matrix material and continuously reinforced fibers embedded in the matrix material, and the thin thickness of the aesthetic polymer outer film can allow for multiple layers of tape to be included in the composite material.

[0011] In one aspect, a composite hybrid part can be manufactured by layering the composite material in an injection mold tool. The layering can be automatic or manual. The injection mold tool can be preheated to reach the glass transition temperature of the polymer matrix of the composite material. The heated layup can then be compressed to consolidate, and then the compressed layup can be cured. The formation of the aesthetic polymer outer film is then completed by injecting a polymer into the injection mold tool. The molding of the composite material and the formation of the aesthetic polymer outer film on the surface of the composite material can be carried out in the cavity of the injection mold tool.

[0012] The outer surface of the aesthetic polymer outer film can include a pattern. The pattern can be an irregular pattern or a regular pattern. The pattern can be formed on the outer surface of the aesthetic polymer outer film in the same step as forming the aesthetic polymer outer film. The formation of the pattern can include printing the pattern into the outer surface of the aesthetic polymer outer film. For example, the aesthetic polymer outer film layer can be pressed against a mold, and by pressing the mold into the aesthetic polymer outer film to imprint a grain, the grain can be imprinted into the aesthetic polymer outer film.

[0013] The composite material fits relatively tightly in the mold, which not only allows for the formation of an aesthetic polymer outer film with a thin thickness of less than 1 mm, 0.01 to 0.7 mm, 0.05 to 0.5 mm, or 0.05 to less than 0.5 mm on the composite material, but also helps prevent the composite material from moving in the mold. The tight fit can contribute to a single-step process for forming the composite hybrid part. In contrast, if there is additional cavity volume between the composite material and the mold, the composite material can move within the mold, and the polymer layer may not form properly on the composite material. The additional cavity volume can pose a risk to the correct positioning of the composite material having space to move within the mold.

[0014] The term "aesthetic polymer outer membrane" is used herein for convenience only and may refer to a single-layer aesthetic polymer outer membrane, or a multi-layer aesthetic polymer outer membrane comprising a plurality of layers. In one aspect, the aesthetic polymer outer membrane may comprise a plurality of layers, for example, the aesthetic polymer outer membrane may comprise a surface layer and additional layers. The materials included in the aesthetic polymer outer membrane may be employed in the surface layer, the additional layers, or a combination thereof. If the aesthetic polymer outer membrane comprises additional layers, the additional layers may be compatible with any other layers, composite materials, and any other layers adjacent to the additional layers that make up the aesthetic polymer outer membrane.

[0015] The composite material and the aesthetic polymer outer membrane may comprise the same or different plastic materials that are compatible with each other. As used herein, "compatible" means that the layers can bond and do not interact negatively with each other. The plastic materials may include thermoplastic materials, thermosetting materials, or a combination thereof. Example thermoplastic materials include polypropylene, polycarbonate (PC), polyester, polyetherimide (PEI), polyarylether, or a combination thereof, such as a PC / poly(ethylene terephthalate) (PET) blend. Suitable thermoplastic polyesters include, for example, poly(alkylene dicarboxylates) such as PET, poly(butylene terephthalate) (PBT), poly(propylene terephthalate) (PTT), poly(ethylene naphthalate) (PEN), poly(butylene naphthalate) (PBN), poly(cyclohexanedimethanol terephthalate), poly(cyclohexanedimethanol - co - ethylene terephthalate) (PETA), or poly(1,4 - cyclohexanedimethylene - 1,4 - cyclohexanedicarboxylate) (PCCD); poly(alkylene aryl dicarboxylates); or a combination thereof.

[0016] In one aspect, both the composite material and the aesthetic polymer outer membrane comprise polycarbonate. Linear or branched aromatic polycarbonates may be used. In one aspect, a polycarbonate comprising units derived from the following may be used: 2,2 - bis(4 - hydroxyphenyl)propane ("bisphenol A"), bis(2 - hydroxyphenyl)methane, 1,1 - bis(4 - hydroxyphenyl) - 3,3,5 - trimethylcyclohexane, fluorenone bisphenol, 1,1 - bis(4 - hydroxyphenyl)ethane, 2,6 - dihydroxynaphthalene, bis(3,5 - diethyl - 4 - hydroxyphenyl) sulfone, 2,2 - bis(3,5 - dibromo - 4 - hydroxyphenyl)propane, 4,4'-dihydroxydiphenyl ether, spirobiindane bisphenol, or a combination thereof.

[0017] Example thermosetting materials include thermosetting resins such as epoxy resins, phenolic resins, alkyd resins, polyesters, polyimides, polyurethanes, mineral - filled silicones, bismaleimides, cyanate esters, vinyl resins, and benzocyclobutene resins, as well as blends, copolymers, mixtures, reaction products, and composite materials thereof.

[0018] In one aspect, the aesthetic polymer outer membrane may comprise polyacetal, polyacrylic acid, styrene acrylonitrile, acrylonitrile-butadiene-styrene, polycarbonate, polystyrene, polyethylene, polyphenylene ether, polypropylene, polyethylene terephthalate, polybutylene terephthalate, nylon, polyamideimide, polyarylate, polyurethane, ethylene propylene diene monomer, ethylene propylene diene terpolymer, polyarylsulfone, polyethersulfone, polyphenylene sulfide, polyvinyl chloride, polysulfone, polyetherimide, polytetrafluoroethylene, fluorinated ethylene propylene, perfluoroalkoxy ethylene, polychlorotrifluoroethylene, polyvinylidene fluoride, polyvinyl fluoride, polyether ketone, polyether ether ketone, liquid crystal polymer, or a combination thereof. In one aspect, the polymer matrix and the aesthetic polymer outer membrane each comprise polypropylene.

[0019] The composite material, the aesthetic polymer outer membrane, or a combination thereof may comprise additives for providing or enhancing visual effects. Such visual additives include, but are not limited to, pigments and decorative materials such as metal flakes, dyes, and luminescent compounds. Specific examples of suitable additives include metal oxides (such as titanium dioxide and iron oxide); metal hydroxides; metal flakes (such as aluminum flakes); chromates (such as lead chromate); sulfides; sulfates; carbonates; carbon black; silica; talc; kaolin; phthalocyanine blue and phthalocyanine green; organic red; organic maroon, and other organic pigments and dyes, or a combination thereof. In one aspect, pigments that are stable at high temperatures are used, i.e., pigments that do not degrade or change significantly at a temperature of 350 °C or higher than 350 °C.

[0020] Lightfast additives may also be present in the composite material, the aesthetic polymer outer membrane, or a combination thereof. For example, the composite material, the aesthetic polymer outer membrane, or a combination thereof may further comprise lightfast compounds, lightfast antioxidants, lightfast antiozonants, or a combination thereof. Examples of lightfast compounds include dilauryl-3,3'-thiodipropionate, tris(4-tert-butyl-3-hydroxy-2,6-dimethylbenzyl) isocyanurate, 1,3,5-trimethyl-2,4,6-tris(3,5-di-tert-butyl-4-hydroxybenzyl) benzene, N,N'-β,β'-naphthalene-4-phenylene diamine, 4,4'-methylene-bis(dibutyldithiocarbamate), or 2,2,4-trimethyl-1,2-dihydroquinoline.

[0021] Additionally or alternatively to the disclosed additives, performance additives may be included in composite materials, aesthetic polymer outer membranes, or combinations thereof. Exemplary performance additives include impact modifiers, ultraviolet (UV) absorbers, flame retardants, fillers, stabilizers, transesterification inhibitors, adhesion promoters such as bisphenol derivatives, aminosilanes or their derivatives, mold release agents, or combinations thereof. Examples of ultraviolet light absorbers (UVA) include benzotriazoles, benzophenones, triazines, cyanoacrylates, dibenzoylmethane, benzoxazinones, and hindered amine light stabilizers (HALS) such as 2-(benzotriazol-2-yl)-4-(1,1,3,3-tetramethylbutyl)phenol, 2-(benzotriazol-2-yl)-4-methylphenol, 2-hydroxy-4-octyloxybenzophenone, 2-hydroxy-4-methoxybenzophenone, ethyl 2-cyano-3,3-diphenylacrylate, 2-(2'-hydroxy-4'-octyloxy)bis-4,6-(2',4'-dimethylphenyl)triazine, 2-ethyl-2'-ethoxyoxanilide, or bis[2-hydroxy-5-methyl-3-(benzotriazol-2-yl)phenyl]-methane. Combinations of additives may also be used.

[0022] In one aspect, the aesthetic polymer outer membrane does not include insert materials such as reinforcing fibers. In one aspect, the aesthetic polymer outer membrane includes insert materials such as reinforcing fibers.

[0023] Inserts may include metal inserts such as metal layers or composite laminated inserts. In one aspect, the metal inserts may include, for example, coated or uncoated stainless steel or non-stainless steel, coated or uncoated aluminum, coated or uncoated magnesium, coated or uncoated titanium, coated or uncoated chromium, coated or uncoated zinc, or combinations thereof.

[0024] Inserts may include fibrous materials such as processed mineral fibers such as those derived from blends, including aluminosilicates, alumina, magnesia, or hemihydrate calcium sulfate; natural fibers including wood flour, cellulose, cotton, sisal, jute, starch, cork flour, lignin, ground nut shells, corn or rice husks; synthetic reinforcing fibers, including polyester fibers such as polyethylene terephthalate fibers, polyvinyl alcohol fibers, aramid fibers, polybenzimidazole fibers, polyimide fibers, polyphenylene sulfide fibers, polyether ether ketone fibers, boron fibers, ceramic fibers such as silicon carbide or fibers from mixed oxides of aluminum, boron, or silicon; single crystal fibers or "whiskers", including silicon carbide fibers, alumina fibers, boron carbide fibers, iron fibers, nickel fibers, or copper fibers; glass fibers, including textile glass fibers such as E, A, C, ECR, R, S, D, or NE glass, or quartz; or treated or untreated carbon fibers such as vapor grown carbon fibers, including those having an average diameter of about 3.5 to about 500 nanometers.

[0025] Non-limiting examples of fibrous materials include short inorganic fibers, including processed mineral fibers such as those derived from blends, including aluminosilicates, alumina, magnesia, or hemihydrate calcium sulfate, boron fibers, ceramic fibers such as silicon carbide or fibers from mixed oxides of aluminum, boron, or silicon. Also included are single crystal fibers or "whiskers", including silicon carbide, alumina, boron carbide, iron, nickel, or copper. Fibrous materials such as glass fibers, basalt fibers, including textile glass fibers or quartz, may also be included.

[0026] Also included are natural organic fibers, including wood flour or fibrous products obtained by grinding wood such as cellulose, cotton, sisal, jute, cloth, linen, felt, or natural cellulose fabrics such as kraft paper, cotton paper, or paper containing glass fibers, starch, cork powder, lignin, ground nut shells, corn, rice husks, or combinations thereof.

[0027] Organic reinforcing fibrous materials or synthetic reinforcing fibers may be used, such as organic polymers capable of forming fibers, such as polyethylene terephthalate, polybutylene terephthalate, or other polyesters, polyarylates, polyethylene, polyvinyl alcohol, polytetrafluoroethylene, acrylic resins, high-strength fibers with high thermal stability, including aromatic polyamides, polyaramid fibers such as Kevlar (a product of DuPont), polybenzimidazole, polyimide fibers such as polyimide 2080 or PBZ fibers (both products of Dow Chemical Company); or polyphenylene sulfide, polyetheretherketone, polyimide, polybenzoxazole, aromatic polyimide, or polyetherimide, or combinations thereof.

[0028] In one aspect, the composite material may comprise, for example, at least one layer of a tape having a matrix material and continuous reinforcing fibers embedded in the matrix material. The matrix material may be a thermoplastic material, such as a polyolefin. The continuous reinforcing fibers may be oriented in the longitudinal direction of the tape. The term "continuous fiber" may refer to a fiber having the same length as the tape, such as a fiber extending the length of the tape.

[0029] The composite material may be made of two or more layers of tape. The continuous fibers in each layer may be oriented in different directions relative to the longitudinal direction of the tape. The orientation of the fibers in one layer relative to the fibers in another layer may be from -90° to +90°. The angle between the longitudinal direction of the continuous fibers in the first layer and the longitudinal direction of the continuous fibers in the second layer may be from -45° to +45°. The thickness of the composite material may be from 0.1 to 6.0 mm. The thickness of one layer may be from 0.1 to 0.3 mm. Multilayer composite materials may be used, having a thickness of 1.5 to 4.5 mm or 2.0 to 4.0 mm. The thickness of the composite material may be varied in its width direction, longitudinal direction, or a combination thereof to locally increase reinforcement.

[0030] In one aspect, the composite material includes a first layer comprising a first polymer matrix having a first insert, such as a first continuous reinforcing fiber embedded in the first polymer matrix; and a second layer comprising a second polymer matrix having a second insert, such as a second continuous reinforcing fiber embedded in the second polymer matrix.

[0031] The composite material may comprise or consist of a combination of polypropylene (PP) reinforced with long fibers. In one aspect, the composite material may comprise PP and 30 to 60 weight percent (wt%) based on the total weight of the composite material, such as 40 wt% of long glass fibers, such as STAMAX manufactured by SABIC. TM As used herein, the term "long glass fiber" refers to glass fibers having a length of at least 10 mm, such as 10 to 55 mm, 10 to 40 mm, 10 to 30 mm, or 10 to 20 mm. In one aspect, the composite material may comprise short glass fibers having a length of less than 10 mm, or less than 1 mm, or less than 0.5 mm, such as 0.1 to 2 mm, 0.1 to 1 mm, 0.1 to 0.5 mm, 2 to 7 mm, or 3 to 5 mm. The length of the glass fibers is then measured and melt mixed with the polyolefin.

[0032] The composite material may comprise polypropylene reinforced with continuous fibers, such as continuous glass fibers. In one aspect, the composite material may comprise two or more layers of unidirectional tapes laminated on top of each other at a specific laminate angle or lay-up angle. Each layer of the tape may comprise 30 to 60 volume percent (vol%) based on the total volume of the layer of the tape, such as 45 vol% of continuous glass fibers.

[0033] The composite material may comprise tapes of unidirectional continuous fibers in a matrix material. Woven fibers, such as fabrics from reinforcing fibers, may be used. Continuous length fiber composites, i.e., where the length of the fibers matches the length of the tape, may provide excellent stiffness and strength compared to woven fiber composites and long discontinuous fiber filled materials.

[0034] The fiber type, size, or amount may vary with the matrix material employed in the manufactured composite. Example fiber types include, but are not limited to, glass fibers (such as E-glass ("electrical glass", such as borosilicate glass) or S-glass ("structural glass", such as magnesia / alumina / silicate glass)), mineral fibers, polymer fibers, natural fibers, or combinations thereof. The fiber diameter (width) may be from 6 microns to 25 microns. The fiber length may be from 2 to 75 mm. In one aspect, the continuous reinforcing fibers include glass fibers, carbon fibers, aramid fibers, thermoplastic fibers, basalt fibers, or combinations thereof.

[0035] The composite material may comprise 25 to 75 wt%, 35 to 65 wt% or 40 to 60 wt% of a matrix material. The composite material may comprise 25 to 75 wt%, 35 to 65 wt% or 40 to 60 wt% of fibers. The weight percentages are based on the total weight of the composite material.

[0036] In one aspect, the aesthetic polymer outer film is directly on the surface of the composite material. In one aspect, an adhesive layer may optionally be provided between the composite and the aesthetic polymer outer film.

[0037] The use of an adhesive layer can provide enhanced adhesion by increasing the amount of resin at the interface and / or by improving the compatibility between the aesthetic polymer outer film and the composite material (e.g., when the composite material and the aesthetic polymer outer film contain different resins). The adhesive layer may comprise a material selected to be compatible with the aesthetic polymer outer film and the composite material. Specific examples of compatible materials for use in the adhesive layer include polycarbonate; polyesters such as PET, PBT, PTT, PEN, PBN, PETA, and PCCD; polyetherimide; polyamide; polyalkylene aryl dicarboxylate; resins containing polyacrylonitrile, such as acrylonitrile - butadiene - styrene (ABS), acrylonitrile - butadiene - acrylate (ASA), or acrylonitrile - (ethylene - propylene diamine modified) - styrene (AES); polyphenylene sulfide; polymethyl methacrylate (PMMA); copolyester carbonate; poly(alkylene dicarboxylate); or combinations thereof. In one aspect, the adhesive layer comprises a blend of the resin from the aesthetic polymer outer film and the resin from the composite material.

[0038] Polycarbonate and blends of polycarbonate and polyester can be used in the adhesive layer, for example, in combination with an aesthetic polymer outer film comprising an aryl polyester resin. Suitable polycarbonate resins include linear aromatic polycarbonate resins, such as those containing units derived from bisphenol A, and branched aromatic polycarbonate resins.

[0039] Polyesters and blends containing two or more polyesters can also be used in the adhesive layer, for example, in combination with an aesthetic polymer outer film comprising an aryl polyester resin. For example, one blend suitable for use in the adhesive layer comprises 10 to 50 wt% of PBT, PET, glycolated poly(ethylene terephthalate), or poly(cyanoparaphenylene) (PCT) and 50 to 90 wt% of an aryl polyester resin, such as a resorcinol polyester resin and 50 to 90 wt% of a resin containing resorcinol aryl ester units, based on the weight of the blend.

[0040] Composite hybrid components formed by the disclosed methods can include vehicle body panels. As used herein, the term "vehicle" includes conventional motor vehicles such as passenger vehicles including sport utility vehicles (SUVs), buses, trucks, various commercial vehicles, watercraft including various boats and ships, aircraft, etc., and also includes hybrid vehicles, electric vehicles, plug-in hybrid electric vehicles, hydrogen-powered vehicles, and other alternative fuel vehicles (e.g., fuels derived from resources other than petroleum). As mentioned herein, a hybrid vehicle is a vehicle having two or more energy sources, such as a gasoline-powered and an electric-powered vehicle.

[0041] The compositions, methods, and articles of manufacture optionally include, consist of, or consist essentially of any suitable materials, steps, or components disclosed herein. The compositions, methods, and articles of manufacture may additionally or alternatively be formulated to be lacking or substantially free of any materials (or substances), steps, or components that are otherwise unnecessary to achieve the functions or objectives of the compositions, methods, and articles of manufacture.

[0042] All ranges disclosed herein include the endpoints, and the endpoints can be combined independently of each other (e.g., "up to 25 wt% or more specifically 5 to 20 wt%", including the endpoints of the range "5 to 25 wt%" and all intermediate values, etc.). "Combination" includes blends, mixtures, alloys, reaction products, etc. The terms "first", "second", etc. do not denote any order, quantity, or importance, but are used to distinguish one element from another. The terms "a" and "an" and "the" do not denote a limitation of quantity and should be construed to cover both the singular and the plural unless otherwise indicated herein or clearly contradicted by the context. "Or" means "and / or" unless otherwise expressly stated. Throughout the specification, reference to "aspects", "embodiments", "examples", etc. means that a particular element described in connection with the example is included in at least one example described herein, and may or may not be present in other examples. Additionally, it should be understood that the described elements may be combined in any suitable manner in the various aspects. The phrase "a combination thereof" or "a combination comprising at least one of the foregoing" is open-ended and includes one or more of the listed items, and may include other similar unlisted items.

[0043] Unless stated to the contrary herein, all test standards are the latest standards effective as of the filing date of the present application, or if priority is claimed, the filing date of the earliest priority application in which the test standard appears. Unless otherwise elucidated, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0044] Compounds are described using standard nomenclature. Unless otherwise defined herein, the term "hydrocarbon" means a compound containing carbon and hydrogen and optionally having from 1 to 3 heteroatoms.

[0045] Although specific aspects have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are presently unforeseen may be made by the applicant or others skilled in the art. Accordingly, the appended claims and their possible modifications are intended to embrace all such alternatives, modifications, variations, improvements, and substantial equivalents.

Claims

1. A method of forming a composite hybrid component, the method comprising: molding a composite material comprising a polymer matrix and inserts in the polymer matrix; and forming an aesthetic polymer outer film on the surface of the composite material in the same step as molding the composite material, wherein the thickness of the aesthetic polymer outer film is less than 1 mm, being 0.01 to 0.7 mm, 0.05 to 0.5 mm or 0.05 to less than 0.5 mm.

2. The method according to claim 1, wherein the inserts comprise continuous reinforcing fibers.

3. The method according to claim 1 or 2, wherein the outer surface of the aesthetic polymer outer film comprises a pattern.

4. The method according to claim 3, wherein the pattern comprises an irregular pattern.

5. The method according to claim 3, wherein the pattern comprises a regular pattern.

6. The method according to claim 1, the method further comprising forming a pattern on the outer surface of the aesthetic polymer outer film in the same step as forming the aesthetic polymer outer film, wherein the formation of the pattern comprises printing the pattern in the outer surface of the aesthetic polymer outer film.

7. The method according to any one of the preceding claims, wherein the composite material comprises: a first layer comprising a first polymer matrix and a first insert embedded in the first polymer matrix; and a second layer comprising a second polymer matrix and a second insert embedded in the second polymer matrix.

8. The method according to any one of the preceding claims, wherein the aesthetic polymer outer film comprises polyacetal, polyacrylic acid, styrene acrylonitrile, acrylonitrile-butadiene-styrene, polycarbonate, polystyrene, polyethylene, polyphenylene ether, polypropylene, polyethylene terephthalate, polybutylene terephthalate, nylon, polyamideimide, polyarylate, polyurethane, ethylene propylene diene monomer, ethylene propylene monomer, polyarylsulfone, polyethersulfone, polyphenylene sulfide, polyvinyl chloride, polysulfone, polyetherimide, polytetrafluoroethylene, fluorinated ethylene propylene, perfluoroalkoxy ethylene, polychlorotrifluoroethylene, polyvinylidene fluoride, polyvinyl fluoride, polyether ketone, polyether ether ketone, liquid crystal polymer or a combination thereof.

9. The method according to any one of the preceding claims, wherein the polymer matrix and the aesthetic polymer outer film each comprise polypropylene.

10. The method according to any one of the preceding claims, wherein the aesthetic polymer outer film does not comprise an insert material.

11. The method according to any one of claims 1 to 9, wherein the aesthetic polymer outer film comprises an insert material.

12. The method according to any one of the preceding claims, wherein the aesthetic polymer outer film is directly located on the surface of the composite material.

13. The method according to any one of claims 1 to 11, the method further comprising an adhesive layer between the aesthetic polymer outer film and the composite material.

14. The method according to any one of the preceding claims, wherein the molding of the composite material and the formation of the aesthetic polymer outer film on the surface of the composite material are carried out in a cavity of an injection molding tool.

15. A composite hybrid component formed by the method according to any one of the preceding claims.