CARBON FIBER CASING HAVING AN INTERNAL ELASTOMER OVERMOLD, AND METHOD FOR MANUFACTURING A CARBON FIBER CASING HAVING AN INTERNAL ELASTOMER OVERMOLD.

Abstract

In one method for manufacturing a composite carcass, carbon fiber is infused with a resin using a first mold to create a carbon fiber shell. A molding material is then injection-molded over the carbon fiber shell using a second mold to create a molded carcass. The molded carcass is then trimmed to create a trimmed carcass. A clear coating can then be applied to the trimmed carcass to create the composite carcass.

Description

CARBON FIBER CASING HAVING AN INTERNAL ELASTOMER OVERMOLD, AND METHOD FOR MANUFACTURING A CARBON FIBER CASING HAVING AN INTERNAL ELASTOMER OVERMOLD. CROSS REFERENCE TO RELATED APPLICATIONS This patent application claims priority over U.S. Provisional Patent Application No. 62 / 791,376, filed on January 11, 2019, which is incorporated herein by reference in its entirety. BACKGROUND This disclosure relates to composite material housings and their manufacture, including carbon fiber housings that have an internal elastomer overmolding. BRIEF DESCRIPTION OF THE DRAWINGS / FIGURES The accompanying drawings, which are incorporated herein and form part of the specification, illustrate the essence of this disclosure and, together with the description, serve to explain the principles of materialization and to enable a person skilled in the relevant technique to make and use the realizations. Figures 1A-1F illustrate a method of manufacturing a carbon fiber shell having an internal elastomer overmolding according to a sample disclosure. Figure 2A illustrates a carbon fiber casing according to a sample example from the disclosure. Figure 2B illustrates a carbon fiber shell with an overmolded interior according to a sample disclosure. Figure 20 illustrates an overmolded carbon fiber housing after trimming according to a sample disclosure. Figure 2D illustrates an overmolded carbon fiber shell after a clear coat application as per a sample disclosure. Figure 3 illustrates a flow diagram of a manufacturing method for a carbon fiber housing that has internal elastomer overmolding according to a sample disclosure. The exemplary samples in this disclosure will be described with reference to the accompanying drawings. In the drawings, identical or similar reference symbols are used for identical or similar components. DETAILED DESCRIPTION The following description sets forth numerous specific details to provide a complete understanding of the materialization of this disclosure. However, it is evident to those skilled in the art that the content of this disclosure, including the structures, systems, and methods, can be practiced without these specific details. The description and representation in this document are the common means used by those experienced or skilled in the art to convey the essence of their work to others skilled in the art. In other cases, known methods, procedures, components, and circuits have not been described in detail to avoid unnecessarily detracting from the purpose of this disclosure. One objective of this disclosure is to provide a process for fabricating a composite material housing. In one embodiment, the composite housing is applicable to motor vehicles, motorcycles, boats, airplanes, trains, or other transportation devices. This disclosure is not limited to transportation-related applications, and the composite material housing may be used in other applications as understood by a person skilled in the art. In one embodiment, the composite shell is a carbon fiber shell with an overmolded elastomer inner body. Advantageously, the one- or multi-element composite shell combines the properties (e.g., appearance, feel, and / or structural properties) of carbon fiber with the properties and benefits of a controlled shape on the inner face of the composite shell to facilitate attachment to other surfaces. In one embodiment, the composite material shell can be applied to a wide variety of parts / areas of, for example, a vehicle and / or an aircraft. In another embodiment, the composite material shell is applied to non-structural parts / areas of, for example, a vehicle, motorcycles, aircraft, and / or other vessels or structures. In yet another embodiment, the composite material shell is used for manufacturing vehicle spoilers. This disclosure is not limited to spoiler applications and may be used on other vehicles, aircraft, and / or marine vessel components (e.g., ships). In other embodiments, the composite material shell can form exterior and / or interior parts of the vehicle / aircraft / vessel. These parts may include, but are not limited to, external and / or internal fittings. Advantageously, the composite material housing, according to the exemplary embodiments, provides high surface strength (e.g., carbon fiber surface) on the outer surface combined with increased flexibility on the inner surface (e.g., overmolded elastomer), facilitating the mounting of the housing onto another surface or component / part. These advantages are not achievable with conventional carbon fiber parts. In one exemplary embodiment, the carbon fiber housing has a thickness of 0.5 to 1 mm, but this is not a limiting factor. With reference to Figs. 1A-1F and the flow diagram shown in Fig. 3, a method for manufacturing a carbon fiber and elastomer composite housing is described according to the exemplary embodiments. Fig. 2 shows the composite housing during various manufacturing operations according to one exemplary embodiment. In operation 305, and as shown in FIG. 1 A, the carbon fiber (B) is placed in a mold (A) (e.g., one-sided mold). After operation 305, and as shown in FIG. 1B, flow diagram 300 proceeds to operation 310, where a resin infusion operation is performed to create a carbon fiber shell (C) using the mold (A). In one embodiment, the resin infusion operation utilizes an autoclave in which the carbon fiber mold is placed in a chamber configured to generate elevated pressure (e.g., 7 bar) and / or temperature (e.g., 120–230 degrees Celsius) to infuse the resin with the carbon fiber. In another embodiment, the resin infusion is achieved by a resin transfer molding (RTM) process involving a closed mold that is sealed, heated, and placed under a vacuum. In one example, the resin infusion operation takes 1–3 hours, but this is not the duration of this example. One example of carbon fiber used as yarn is HexForce Carbon Fabric x2x Twill 193GSM, but it is not limited to this. One example of carbon fiber-infused resin is PRO-SET Infusion Epoxy (INF-114, INF-211), but it is not limited to this. After operation 310 and as shown in FIG. 1C, flow diagram 300 proceeds to operation 315, where the carbon fiber cover (C) resulting from the resin infusion operation is placed in a mold, such as a multi-part mold (C1 and C2). Mold C1 may be the same as or different from mold A. The multi-part mold may include two mold parts (e.g., C1 and C2), but is not limited to them. After operation 315, as shown in Figure 1D, flow diagram 300 proceeds to operation 320, where the multi-part mold (C1 and C2) is closed with the carbon fiber shell (C) housed within it. In operation 320, the elastomer (D) is molded onto the carbon fiber shell (C) to create a composite shell D1. In one example, an injection molding operation is performed to mold the elastomer (D) onto the carbon fiber shell (C). This injection molding operation (overmolding) bonds the elastomer and the carbon fiber shell. In one embodiment, the elastomer is, for example, RIMLINE SH87930-RUBINATE 8600, but it is not limited to this material. ML / t / zuz i / uyuooy In one embodiment, the elastomer is supplied at a temperature of, for example, 20 to 30°C, and / or the mold has a temperature of, for example, 35 to 40°C. Disclosure is not limited to these exemplary temperatures. In one embodiment, the elastomer is injection molded at a pressure of, for example, 190 bar, but this is not a limitation. The injection molding operation can be performed for 5-10 minutes, but this is not a limitation. After operation 320, as shown in FIG. 1E, flowchart 300 proceeds to operation 325, where the composite shell (D1) is removed from the injection mold and trimmed to provide a trimmed composite shell (D2). In one embodiment, the perimeter of the composite shell (D1), such as portions of the composite shell (D1) without elastomer bonded to it, is trimmed to remove these portions of the composite shell (D1). In one embodiment, the trimming operations may be manual, using, for example, one or more cutting or grinding tools, and / or performed using, for example, one or more cutting or grinding tools, and / or performed using, for example, a numerically controlled (CNC) cutting machine. After operation 325, as shown in FIG. 1F, flow diagram 300 proceeds to operation 330, where the trimmed composite housing (D2) is coated with one or more materials that can provide increased durability. For example, the coating material may provide increased abrasion resistance, UV light blocking, chemical resistance, or similar properties. The coating material may be transparent. The transparent coating may be glossy or matte. The coating material may be applied by a spray system in one embodiment, but is not limited to it. Conclusion The aforementioned description of the specific realizations will fully reveal the general nature of the disclosure, which others may, by applying knowledge within the skill of the art, readily modify and / or adapt for various applications such as specific realizations, without undue experimentation, and without departing from the general concept of the present disclosure. It is therefore intended that such adaptations and modifications be within the meaning and range of equivalents of the described realizations, based on the teaching and guidance presented herein. It should be understood that the phraseology or terminology herein is for descriptive and not limiting purposes, such that the terminology or phraseology of the present specification should be interpreted by the person skilled in the art in light of the teaching and guidance. References in the specification to an embodiment, an embodiment, an example of an embodiment, etc., indicate that the described embodiment may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes that particular feature, structure, or characteristic. Furthermore, such phrases do not necessarily refer to the same embodiment. Additionally, when a particular feature, structure, or characteristic is described in relation to an embodiment, it is stated that it is within the knowledge of a person skilled in the art to affect that feature, structure, or characteristic in relation to other embodiments, whether explicitly described or not. The examples of embodiments described herein are provided for illustrative purposes only and are not exhaustive. Other embodiments are possible, and modifications to the examples are permitted. Therefore, this specification does not purport to limit disclosure. Rather, the scope of disclosure is defined only in accordance with the following claims and their equivalents. Reference List A Resin Transfer Mold B Carbon Fiber C Carbon fiber casing C1 Injection Mold Female Side C2 Injection Mold Male Side D Elastomer MA.tzuz i / uaudoy D1 Composite material housing (without cutout) D2 Composite material housing (with cutout) E Transparent Layer

Claims

CLAIMS 1. A method of manufacturing a composite material shell, comprising: infusing carbon fiber with a resin using a first mold to create a carbon fiber shell; injection molding a molding material onto the carbon fiber shell using a second mold to generate a molded shell; trimming the molded shell to create a trimmed shell; and applying the clear coating to the trimmed shell to create the composite shell.

2. The method according to statement 1, where the first mold is a single-sided mold.

3. The method according to statement 1, where the second mold is different from the first mold.

4. The method according to statement 1, where the second mold is a multi-part mold having at least two mold parts.

5. The method according to statement 1, wherein infusing the carbon fiber with the resin comprises subjecting the carbon fiber and the resin to a temperature elevated relative to ambient temperature and / or a pressure higher relative to ambient pressure.

6. The method according to statement 1, wherein the first mold is a one-sided mold and the second mold is a multi-part mold having at least two mold parts.

7. The method according to statement 1, wherein the resin is infused with the carbon fiber using an autoclave.

8. The method according to statement 1, wherein the resin is infused with the carbon fiber using a resin transfer molding (RTM) process.

9. The method according to claim 5, wherein the raised temperature is 120-230 degrees Celsius and the raised pressure is at least 7 bar. MA.tzuz i / uyuóoy 10. The method according to statement 1, wherein the resin infused with the carbon fiber is epoxy.

11. The method according to statement 1, wherein the molding material is an elastomer.

12. The method according to statement 1, wherein the injection mold is worked at a temperature of 35 to 40sC, the molding material is injected at a temperature of 20 to 30sC, and / or the molding material is injected at a pressure of 190 bar.

13. The method according to statement 1, wherein the injection molding is carried out at a temperature of 35 to 402C, the molding material is injected at a temperature of 20 to 30eC and the molding material is injected at a pressure of 190 bar.

14. The method in accordance with statement 1, wherein the trimming removes parts of the molded casing that include only the carbon fiber casing.

15. The method in accordance with statement 1, wherein the trimming removes parts of the molded housing along the perimeter.

16. The method in accordance with statement 1, wherein the transparent coating at least partially blocks ultraviolet light and / or provides greater chemical resistance.

17. The method according to statement 1-16, wherein the composite material shell is a carbon fiber shell having an inner elastomer overmolding.

18. A computer-readable non-transient storage medium with an executable program stored therein, wherein the program instructs a processor to perform the method of any of statements 1-16.

19. A composite material housing, comprising: A carbon fiber housing; an elastomer overmolding within the carbon fiber housing.

20. The composite material shell of statement 19, wherein the elastomer is overmolded onto the inner surface of the carbon fiber shell.