Core structure for composite vehicle component

Abstract

A core structure for a composite sandwich panel assembly includes a plurality of walls defining a plurality of open area pores, the plurality of walls joined together to form an array of the plurality of open area pores, the array of the plurality of open area pores having a first face and an opposing second face. The core structure also includes a plurality of break lines formed in at least a portion of the plurality of walls on at least a first face of the core structure.

Description

CORE STRUCTURE FOR COMPOSITE VEHICLE COMPONENTCROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority benefit from U.S. provisional patent application serial number 63 / 719,766, filed November 13, 2024, the contents of which are incorporated by reference herein in their entirety.FIELD OF THE INVENTION

[0002] The present invention in general relates to composites and in particular to a core structure for a composite sandwich with predetermined breaks therein that facilitate controlled, predictable shaping of the composite sandwich as it is molded into a non-planar vehicle component.BACKGROUND

[0003] Weight savings in the automotive, transportation, and logistics based industries has been a major focus in order to make more fuel efficient vehicles both for ground and air transport. In order to achieve these weight savings, light weight composite materials have been introduced to take the place of metal structural and surface body components and panels. Composite materials are materials made from two or more constituent materials with significantly different physical or chemical properties, that when combined, produce a material with characteristics different from the individual components. The individual components remain separate and distinct within the finished structure. A composite material may be preferred for many reasons: common examples include materials which are stronger, lighter, or less expensive when compared to traditional materials.

[0004] A sandwich-structured composite is a special class of composite material that isfabricated by layering different materials together to create one composite that balances the advantages and shortcomings of each individual layer of material, thereby making the resulting sandwich composite greater than the sum of its parts. For example, some sandwich composites are formed by attaching two thin but stiff skins to a lightweight but thick core. The core material is normally a low strength material, but its higher thickness provides the sandwich composite with high bending stiffness with overall low density.

[0005] A problem with such composite sandwich structures is that they are not easily molded into components that have a high aspect ratio, i.e. that are non-planar, given the unpredictable bending and crushing of the core material of the sandwich structure during molding of the non-planar component. This unpredictable nature of the core material as it is molded can lead to other layers of the sandwich structure separating from the core and thus failure of the composite component, leading to a high scrap rate and therefore high manufacturing cost per component.

[0006] In order to form non-planar, high aspect ratio components, such as vehicle hoods, from a composite sandwich material that are less prone to failure, additional machining of the sandwich structure, particularly the core material, must be undertaken prior to molding of the non-planar component. Often these additional machining steps require strict tolerances. This machining, for example, includes machining the core material of the sandwich structure to include non-planar contours of the finished component prior to molding the sandwich structure into the finished component. This introduces an extra manufacturing step that is time consuming and messy and introduces additional complexities into the formation of the composite component, such as strict tolerances when placing the sandwich structure in the mold in order to assure the machined contours are aligned with contours in the mold. Also, this pre-machining prevents preassembly of additional layers onto the sandwich structure, thusrequiring manufacturers to undertake additional steps. As such, existing solutions require long manufacturing times with many complicated steps and significant room for errors, resulting is low throughput and relatively high scrap rates.

[0007] Thus, there exists a need for a core material for a composite sandwich structure that can be easily and predictably formed into a non-planar composite component, such as a vehicle component, without resort to additional highly toleranced machining steps in order to improve throughput and scrap rates.SUMMARY

[0008] A core structure for a composite sandwich panel assembly includes a plurality of walls defining a plurality of open area pores, the plurality of walls joined together to form an array of the plurality of open area pores, the array of the plurality of open area pores having a first face and an opposing second face. The core structure also includes a plurality of break lines formed in at least a portion of the plurality of walls on at least a first face of the core structure.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

[0010] FIG. 1 is a top view of a core structure for a composite sandwich structure that can be easily and predictably formed into a non-planar composite component according to embodiments of the present invention;

[0011] FIG. 2 is a top view of a core structure for a composite sandwich structure that can beeasily and predictably formed into a non-planar composite component according to embodiments of the present invention;

[0012] FIG. 3 is a top view of a core structure for a composite sandwich structure that can be easily and predictably formed into a non-planar composite component according to embodiments of the present invention;

[0013] FIG. 4A is a top view of two un-joined wall portions according to embodiments of the present invention;

[0014] FIG. 4B is a top view of the two wall portions of FIG. 4B joined together to form an open area pore according to embodiments of the present invention;

[0015] FIG. 4C is a top view of two open area pores of FIG. 4B joined together to form an array of pores of a core structure according to embodiments of the present invention;

[0016] FIG. 5A is a top view of two un-joined wall portions according to embodiments of the present invention;

[0017] FIG. 5B is a top view of the two wall portions of FIG. 5B joined together to form an open area pore according to embodiments of the present invention;

[0018] FIG. 5C is a top view of two open area pores of FIG. 5B joined together to form an array of pores of a core structure according to embodiments of the present invention;

[0019] FIGS 6A-6F are top views of various open pore structures operative in the present invention that include hexagonal (FIG. 6A), circular (FIG. 6B), rhomboidal (FIG. 6C), triangular (FIG. 6D), parallelogram quadrilateral (FIG. 6E), and regular quadrilateral (FIG. 6F);

[0020] FIGS. 7A-7D are cross sectional view of break lines according to embodiments of the present invention;

[0021] FIG. 8 is a partial cutaway perspective view of a composite sandwich panel assembly according to embodiments of the present invention;

[0022] FIG. 9 is a cross sectional view of a composite sandwich panel assembly according to embodiments of the present invention;

[0023] FIG. 10 is a partially exploded view of a composite component according to embodiments of the present invention;

[0024] FIGS. 11A-11D are cross-sectional views of edges used in the composite component of the present invention;

[0025] FIG. 12 is a photograph showing a top perspective view of a core structure for a composite sandwich structure that can be easily and predictably formed into a non-planar composite component according to embodiments of the present invention, this core structure having a central break line formed therein by leaving gaps between the partially opened open area pores, such as shown in FIG. 3;

[0026] FIG. 13 is a photograph showing a top perspective view of a core structure for a composite sandwich structure that can be easily and predictably formed into a non-planar composite component according to embodiments of the present invention, this core structure having a plurality of break lines formed therein by scoring, such as shown in FIG. 1;

[0027] FIG. 14A is a photograph showing a top perspective view of a non-planar composite component formed using a core structure that does not include any break lines;

[0028] FIG. 14B is a photograph showing a top perspective view of a non-planar composite component formed using a core structure having a plurality of break lines formed therein; and

[0029] FIG. 15 is a photograph of a cross section of the non-planar composite component of FIG. 14B cut along line 15-15 showing how the core structure follows the contours of the non-planar composite component.DETAILED DESCRIPTION

[0030] The present invention has utility as a core material for a composite sandwich structure that can be easily and predictably formed into a non-planar composite component, such as a vehicle component, without resort to additional highly toleranced machining steps in order to improve throughput and scrap rates.

[0031] It is to be understood that in instances where a range of values are provided that the range is intended to encompass not only the end point values of the range but also intermediate values of the range as explicitly being included within the range and varying by the last significant figure of the range. By way of example, a recited range of from 1 to 4 is intended to include 1-2, 1-3, 2-4, 3-4, and 1-4.

[0032] FIGS. 1-3 show embodiments of an inventive open area core structure 10 for a composite sandwich panel assembly 50 that can be easily and predictably formed into a non-planar composite component 100, such as a vehicle component, without resort to additional highly toleranced machining steps. As shown in FIGS. 1-3, embodiments of the core structure 10 include a plurality of walls 12 that are arranged to define a plurality of open area pores 14. The plurality of walls 12 are joined together, for example by glueing, stapling, or welding, in order to form an array 17 of the plurality of open area pores 14. The array of open area pores 14 has a first face 16 and an opposing second face 18. As shown in FIGS. 1-3, embodiments of the core structure 10 additionally include a plurality of break lines 20 formed in at least a portion of the plurality of walls 12 on at least one of a first face 16 or a second face 18 of the core structure 10.

[0033] According to embodiments, the core structure 10 is formed of a lightweight material that defines a plurality of pores 14 so as to reduce the overall density of the core structure 10. An core structure 10 according to the present invention is formed from a variety of materials thatinclude cellulosics such as corrugated fiberboard, paper board, paper stock; thermoplastics such as poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamides, polylactides, polybenzimidazoles, polycarbonates, polyether sulfones, polyethylene, polypropylene, polystyrene, polyvinyl chloride, and block copolymers of any one of the aforementioned where at least one of the aforementioned makes up the majority by weight of the copolymer and regardless of the tacticity of the polymer or copolymer; thermosets such as polyesters, polyureas, polyurethanes, polyurea / polyurethanes, epoxies, vinyl esters; metal such as aluminum, magnesium, , and alloys of any one of the aforementioned where at least one of the aforementioned metals constitutes the majority by weight of the alloy; a foam formed from polyurethane, polyethylene, ethylene vinyl acetate, polypropylene, polystyrene, polyvinyl chloride, oraerogels, regardless of whether the foam is open-celled or closed-celled.

[0034] As shown in FIGS. 4A and 5A, according to embodiments the walls 12 of the core structure 10 are initially separate C-shaped sections 12’. These wall sections 12’ are joined together, for example by glueing, stapling, or welding, at at least one point 13 to form an open area pore 14, as shown in FIG. 4B and 5B. As shown in FIG. 4B, the wall sections 12’ are joined at two points 13 in order to form a fully encircled open area pore 14; whereas in FIG 5B, the wall sections 12’ are joined at a single point 13 in order to form a partially opened open area pore 14 with gaps 21 therein. As shown in FIGS. 4C and 5C, the formed open area pores 14 are then joined together, for example by glueing, stapling, or welding, at at least one additional point 15 to form the array 17 of open area pores. According to embodiments, the walls 12 have a height of 6 mm to 150 mm, thereby making a height of the core structure 10 from the first face 16 to the second face 18 a corresponding 6 mm to 150 mm. It is appreciated that while pores 14 are depicted as isolated from one another, the wall structures 12 are readilyformed from extended folded strips that define a portion of several pores 14 and when made contiguous with other such folded strips define an array of pores that are intercommunicative along the lines of contact between contiguous strips. In certain inventive embodiments, the ratio of the thickness of a wall 12 to the maximal linear extent between faces 16 and 18 is between 0.01-10:1. A wall thickness ranges from 0.1 mm to 100 mm in such inventive embodiments.

[0035] According to embodiments, as shown in FIGS. 6A-6F, the open area pores 14 have a shape of hexagonal (FIG. 6A), circular (FIG. 6B), rhomboidal (FIG. 6C), triangular (FIG. 6D), parallelogram quadrilateral (FIG. 6E), or regular quadrilateral (FIG. 6F). According to embodiments, the array 17 of open area pores 14 that forms the core structure 10 includes from 2 to 2,000 open area pores 14. The array of pores 14 can be built out to have dimensions that generally correspond to a desired composite component, such as a vehicle component. According to embodiments, the pores 14 of the core structure 10 have an average pore diameter of 6 to 25mm. In some inventive embodiments, the core structure 10 pore 14 diameter is as much as 42mm. As used herein, pore diameter is defined as the average of orthogonal pore dimensions measure at a right angle to the pore axis at the interior wall edge at the face 16. By way of example, a circular pore has identical diameter in x- and y-directions relative to the pore axis.

[0036] According to embodiments, at least some pores 14 of the core structure 10 are in fluid communication with at least one other pore 14. According to embodiments, the fluid communication is established by forming a transverse hole 58 through a side wall 12 of at least some of the pores 14. Such holes can be formed in the wall material 12 before the material is formed into the pores 14 of the open are core structure 10. Alternatively, the transverse holes 58 allowing for fluid communication between the pores can be formed in the walls 12 of thecore 10 after the pores 14 are formed. Fluid communication between at least some of the pores 14 ensures that air that is caught within a pore 14 is able to move to another pore in the event that a given pore is crushed or otherwise deformed, for example during the press molding process. As will be described in greater detail below, in some embodiments the edge region of the core material 10 is crushed to form a sealed edge. In such situations, it is beneficial to provide transverse holes 58 in the walls 12 of at least some of the pores 14, for example those near the edge to be sealed, such that when the seal is formed and the pores 14 near the edge are crushed, the air of those crushed pores is able to move into adjacent pores via the transverse holes.

[0037] According to some inventive embodiments, the pores 14 defined by walls 12 of the core structure 10 extend between faces 16 and 18. In some embodiments, the walls 12 are treated to modify a property thereof such as hydrophobicity or surface energy to promote adhesion thereto. By way of example, cellulosics are prone to moisture uptake and are readily coated with a wax such as a paraffin, or a silicone to render the cellulosic more hydrophobic compared to a native state. Alternatively, the cellulosic is readily alkylated by conventional reactions such as those with chloroacetic acid. Sarymsakov, A. A et al., Chem. Nat. Compd. (1997) 33: 337. Metals are similarly coated with a primer or other corrosion inhibitor. Alternatively, metals or polymers are plasma treated to modify surface energies to facilitate adhesion thereto.

[0038] According to certain inventive embodiments, the core structure 10 and composite sandwich panel assembly 50 provides sound damping, fire retardancy, thermal insulation, or a combination thereof by placing a sound and / or heat absorbing material within the pores 14 of the core structure 10. According to embodiments, the pores 14 of the core structure 10 are at least partially filled with a fill 49. The fill illustratively includes foam pellets, fireretardant, and / or a phase change material. Phase change materials operative herein include waxes or an inorganic salt hydrates. In a specific inventive embodiment the flame retardant alumina trihydrate (ATH) may be used as a fill material.

[0039] According to embodiments, the break lines 20 that are formed in at least a portion of the plurality of walls 12 on the first face 16 or the second face 18 of the core structure 10 are scores, cuts, slashes, or other openings that are introduced or formed in the core structure 10 so as to create a weak point that facilitates predictable molding of the core structure 10 with other layers to form a molded non-planar composite component 100, such as a vehicle component, without resort to additional highly toleranced machining steps. As shown in FIG.1, the break lines 20 are a plurality of scores, cuts, slashes, or other openings that are formed in the core structure 10 by cutting or scoring. For example, the break lines 20 are formed by slashing, burning, laser etching, or cutting material of the walls 12 away from the core structure 10. According to embodiments, as shown in FIGS. 7A-7D, the break lines have a cross section of a triangle, a trapezoid, a semi-circle, or a square or rectangle. It is noted that while the formation of the break lines 20 by cutting or scoring the core structure 10 is a post formation machining step, this machining step is fast and does not require precise, highly toleranced machining or subsequent alignment within a mold for forming the composite component. FIG.13 is a photograph showing a top perspective view of a core structure 10 that has a plurality of break lines 20 formed therein by scoring.

[0040] According to other embodiments, the plurality of break lines 20 are formed by leaving gaps 21 between the plurality of walls 12 when forming the array of the plurality of open area pores 14, as shown in FIGS. 2 and 3. That is, when the wall sections 12’ are joined at a single point 13 in order to form a partially opened open area pore 14, as shown in FIG. 5B, the un-joined portions of the walls 12’ form gaps 21 in the walls 12 that create break lines 20.According to such embodiments, the break lines 20 are formed in the core structure 10 during the formation of the core structure 10 itself, thus not requiring any additional post-formation machining. FIG. 12 is a photograph showing a top perspective view of a core structure 10 that has a central break line 20 formed therein by leaving gaps 21 between a partially opened open area pores 14.

[0041] According to embodiments, the core structure 10 includes a conduit 40 embedded in the array 17 of the plurality of open area pores 14. The conduit 40 can be used for ventilation or for electrical wires. According to embodiments, the conduit 40 comprises tubing or wires that are embedded into the core structure 10 before the vehicle component 100 is molded. According to some embodiments, the conduit 40 is a hollow tube that is fully enclosed but for the open ends. According to other embodiments, the conduit 40 is a channel that has an additional opening therein in addition to the open ends, such as an open top, as shown in FIG.8. According to still other embodiments, the conduit 40 is a receptacle 41, as shown in FIGS.3 and 8, that has only one open side. According to embodiments, the conduit 40 is configured to act as a ventilation duct, enables electrical wiring 60 with or without connectors 62 thereon and / or heating elements 64 to be placed therethrough (such as shown in FIG. 3) or is configured to receive circuitry 66 printed on or attached to a backside of a resin layer 52, 54 to be placed therein (such as shown in FIG. 8). Accordingly, embodiments of the composite component 100 are capable of including features such as speakers, lights, air vents for regulating the climate within the vehicle, and defrosting elements for removing ice or snow present on the vehicle component. The conduit 40 of various vehicle components is configured to align with a conduit of another vehicle component to form a single connected conduit system throughout the vehicle to connect electrical wiring 60, ventilation ducts, and / or heating elements 64 of each of an inventive vehicle component with like electrical wiring, ventilation ducts, and / or heatingelements of the vehicle to function. According to embodiments, the core structure 10 includes a hard point 42 embedded in at least one of the plurality of open area pores 14. According to embodiments, the hard point 42 is an attachment point for attaching various elements, such as hinges or locks, to the composite component 100 with a fastener. Alternatively, the hard point 42 is an element, such as a hinge or lock, that is placed in the mold and molded with and thereby embedded into the composite component 100.

[0042] According to embodiments, a veil 44 is provided on at least one of the first face 16 or the second face 18 of the array 17 of the plurality of open area pores 14 of the core structure 10, thereby forming a composite sandwich panel assembly 50, as shown in FIG. 8. According to embodiments, the veils 44 are each independently a sheet of non-oriented glass fibers. According to embodiments, the veils 44 are each independently a fiber mat formed of glass fibers. According to certain inventive embodiments, the fiber mat forming the veil 44 includes non-oriented, non- woven fibers, unidirectional, or woven fibers. According to embodiments, the at least one veil 44 is adhered to at least one of the first face 16 or the second face 18 by an adhesive that is either sprayed on or by tack points where the adhesive is applied between the face 16, 18, and the veil 44. According to embodiments, the adhesive is a sprayed on liquid adhesive or a glue such as hot glue. According to embodiments, the adhesive is a polyurethane or polyurethane prepolymer adhesive, which may be in the form of glue, a moisture cure adhesive, a reactive hot melt adhesive, or a polyurethane resin.

[0043] According to embodiments, the veils are independently woven or nonwoven yet having sufficient porosity to allow a resin layer 52, 54, described below, to penetrate therethrough (penetrated layers shown as 52’ and 54’ in FIG. 9. The veils 44 provide not only a larger surface area for the application of the resin layer 52, 54 and strength to the molded composite component 100, but also the veil 44 is believed to function to mitigate surfacetension differences relative to various layers of the composite sandwich panel assembly 50 and resulting composite component 100 that may arise such as the manufacturing process, temperature differences in a use environment, and differential force loading during usage. According to embodiments, the veils 44 each independently illustratively include fibers of thermoplastic materials such as poly(methyl methacrylate) (PMMA), acrylonitrile butadiene styrene (ABS), polyamides, polylactides, polybenzimidazoles, polycarbonates, polyether sulfones, polyethylene, polypropylene, polystyrene, polyvinyl chloride, and block copolymers of any one of the aforementioned where at least one of the aforementioned makes up the majority by weight of the copolymer and regardless of the tacticity of the polymer or copolymer; carbon fibers; polyaramids; glass fibers in the form as a woven, roving, or lofted sheet; and mixtures of the various fibers. The veil 44 has a mesh size of 10 to 1000, that is, the mesh layer has 10 to 1000 opening per square inch.

[0044] Once the composite sandwich panel assembly 50 is formed with the inventive core structure 10 and at least one veil 44 on a face 16, 18 thereof, the composite sandwich panel assembly 50 can be used to form a non-planar composite component 100. According to embodiments, the present invention is suitable for any components made of composite material, but in particular for vehicle composite components, and even more particularly vehicle composite components that have a high aspect ratio, i.e. components that have out of plane contours or bends in them, such as vehicle roofs, vehicle doors, vehicle hoods, luggage compartment covers, and rear-end modules, as shown in FIG. 10. According to embodiments, forming such a non-planar composite component 100 includes applying a first layer of resin 52 to the first veil 44 on the first face 16 of the core structure 10. Next, a second layer of resin 54 is applied to the second veil 44 on the second face 18 of the core structure 10. Next, the composite sandwich panel assembly 50 with the resin layers 52,54 applied are placed in a press mold having a non-planar contour and pressed in the mold to form the non-planar composite component. According to embodiments, the resin layers 52, 54 are each independently a polyurethane resin. According to embodiments, the resin layers 52, 54 are sprayed or rolled on.

[0045] FIG. 14A is a photograph showing a top perspective view of a non-planar composite component formed using a core structure that does not include any break lines. As can beobserved in this photograph, the non-planar composite component formed without the core break lines has several readily apparent defects where the core material did not properly conform to the contours of the non-planar mold. In contrast, FIG. 14B is a photograph showing a top perspective view of a non-planar composite component having the same shape as that of FIG. 14A formed using a core structure having a plurality of break lines formed therein. Notably the non-planar composite component of FIG. 14B is defect free, with the cross sectional view of the same component shown in FIG. 15 confirming that the core having break lines according to embodiments of the present invention conforms to the non-planar contours of the mold.

[0046] According to embodiments, such as shown in FIG. 9, the resin layers 52, 54 impregnate the veils 44 (shown as 52’ and 54’). According to embodiments, the resin of the resin layers 52, 54 is engineered to have an initial viscosity on contact with the faces 16, 18, respectively, and the walls 12 of the core structure 10 so as partially fill the pores 14 of the core structure 10. It is appreciated that the viscosity upon application is a function of factors that include application temperature, pore dimensions at the face, and intrinsic resin viscosity. The viscosity of the resin layers 52, 54 coupled with the presence of the veil 44 ensures that the resin does not excessively run into the pores 14 defined in the core structure 10 before molding. Accordingly, the area for adhesion between resin layers 52, 54 and an core structure10 is at least 5% more than surface area of the walls 12attheface 16, 18. This increased surface area of adhesion reduces delamination of the components of the inventive composite sandwich 50 and reduces bond line read through.

[0047] According to embodiments, the thickness of the core structure 10, the veils 44, and the resin layers 52, 54 may vary based on design parameters and intended use of a finished component 100 formed from a composite sandwich panel assembly 50 of the present disclosure. According to embodiments, the resin layers 52, 54 each independently have a thickness of 0.5 to 3.5 mm. The ratio of the resin layer 52, 54 average thickness to the core structure 10 average thickness is 0.01-1 : 1. In a particular inventive embodiment, the resin layers 52, 64 have an average thickness of 1.5 to 5 mm and the core structure 10 has an average pore diameter of 6 to 25 mm.

[0048] Notably, the press molding operation for forming a non-planar composite component 100 using an inventive core structure 10 brings the first resin layer 52 and the second resin layer 54 together around the perimeter of the core structure 10 such that the first resin layer 52 terminates against the backside of the second resin layer 54 to seal all edges 33A-33D of the non-planar composite component 100 thereby encapsulating the core structure 10 and inhibiting moisture, as shown in FIGS. 11A-11D. In some situations, depending on the intended use and location of a part formed of the composite sandwich panel assembly 50, preventing moisture from entering the interior of the composite component 100 is important given that freeze thaw cycles of moisture within the part cause expansion and potentially failure of the component 100. Additionally, in embodiments in which the core structure 10 is formed of a hydrophilic material such as paper, moisture within the composite sandwich panel assembly 50 would destroy the open are core 10 and cause the part to fail. According to embodiments, the press molding operation for forming a non-planar composite component 100using an inventive core structure 10 simultaneously trims all edges of the non-planar composite component 100.

[0049] FIGS. 11A-11D show various embodiments of ways in which the resin layers 52, 54 are joined together to form a sealed edge 33A-33D, respectively according to the present disclosure. In some inventive embodiments an elastomeric gasket 34 is disposed between the resin layers 52, 54 at the edge 33C to make the edge 33C more water resistant. It is appreciated that a gasket is readily included in the other edge joinder 33A, 33B, and 33D. The gasket 34 enhances maintenance of the edge seal over a wider range of use conditions.

[0050] As will be understood by one having ordinary skill in the art, to form an edge seal between the resin layers 52, 54, at least one of the resin layers 52, 54 requires enough material to wrap around the edge of the core structure 10. According to certain inventive embodiments, at least one of the resin layers 52, 54 is provided in dimensions greater than the dimensions of the final composite part 100 such that the material is able to wrap around the edge core structure 10. According to certain inventive embodiments, the at least one of the resin layers 52, 54 on the veil 44 of a glass mat material is pushed into the other resin layer 52, 54 reinforced with the glass mat veil 44 with a shear edge, which joins the two resin layers 52, 54 together at the edges 33A-33D.

[0051] According to certain inventive embodiments, excess material is cut from the composite component once the edge seal is formed. As shown in FIG. 11 A, excess material of the first resin layer 52 has been trimmed from the composite component 100 by a knife or router that presses against the divot 35A that is formed by second resin layer 54. In FIG. 1 IB, the edge 33B formed by removing excess material for tool engagement against a shoulder 35B. In FIG. 11C, the edge 33C formed by removing excess material for tool engagement against a shoulder 35C. Also, as shown in FIG. 1 ID, excess material of one or both the resin layers 52,54 are trimmed with tool pressure against shoulder 35D. It is also noted that the edge region of the core structure 10 often crushes during a press molding to form the edge seal. The crushing of the pores 14 of the core structure 10 near the edge that is crushed in order to form a seal also contribute to moisture absorption inside the open area core. That is, the crushed region of the open are core 10 aids in suppressing moisture absorption of the core structure 10.

[0052] According to embodiments, the method for forming a non-planar composite component 100 additionally includes applying a Class-A high gloss surface 56 of chopped glass rovings or an SMC layer to at least a portion of at least one of the first layer of resin 52 and the second layer of resin 54 prior to pressing in the mold. Application of such a Class-A high gloss surface 56 of glass rovings or SMC layer enable the provision of a Class-A high gloss surface on a surface of the composite component 100. As used herein, the term “high gloss surface” refers to a surface having minimal perceptible surface defects when visually inspected for about three seconds from about 24-28 inches from the viewer and normal to the part surface + / - 90 degrees in a well-lit area. That is, the term “high gloss surface” refers to a surface capable of being painted and accepted as a “Class A” autobody part. This is commonly measured by ASTM D523. In the automotive industry, a Class A surface is a surface a consumer can see without functioning the vehicle (e.g., opening the hood or decklid), while a Class A surface finish generally refers to painted outer panels and specifically to the distinctness of image (DOI) and gloss level on the part. It is appreciated that a surface layer may be subjected to sanding, trimming, and priming prior to receiving a paint coating that imparts high gloss, yet must retain dimensionality and adhesion uniformity to primer and paint so as to achieve a high gloss finish. According to some embodiments, circuitry 66 printed on or attached to a backside of the Class-A high gloss surface 56, as shown in FIG. 9. Such printedcircuits 66 can be printed on any substrate of the non-planar composite component 100 which is non-conductive or that has a non-conductive coating applied thereto. According to embodiments, the circuitry 66 is configured to provide lights and / or defrosting elements for removing ice or snow present on the vehicle component 100.

[0053] Patent documents and publications mentioned in the specification are indicative of the levels of those skilled in the art to which the invention pertains. These documents and publications are incorporated herein by reference to the same extent as if each individual document or publication was specifically and individually incorporated herein by reference.

[0054] The foregoing description is illustrative of particular embodiments of the invention but is not meant to be a limitation upon the practice thereof. The following claims, including all equivalents thereof, are intended to define the scope of the invention.

Claims

CLAIMS1. A core structure for a composite sandwich panel assembly, the core structure comprising:a plurality of walls defining a plurality of open area pores, the plurality of walls joined together to form an array of the plurality of open area pores, the array of the plurality of open area pores having a first face and an opposing second face; anda plurality of break lines formed in at least a portion of the plurality of walls on at least a first face of the core structure.

2. The core structure of claim 1 wherein the plurality of walls are formed of at least one of: cellulosics, thermoplastic, thermoset, metal, or foam.

3. The core structure of claim 1 wherein the open area pores have a shape of hexagonal, circular, rhomboidal, triangular, parallelogram quadrilateral, or regular quadrilateral.

4. The core structure of claim 1 wherein the plurality of break lines are formed in at least a portion of the plurality of walls on the second face of the core structure.

5. The core structure of claim 1 wherein the plurality of break lines are formed by cutting or scoring.

6. The core structure of claim 1 wherein the plurality of break lines are formed by leaving gaps between the plurality of walls when forming the array of the plurality of open area pores.

7. The core structure of claim 1 further comprising a conduit embedded in the array of the plurality of open area pores.

8. The core structure of claim 7 wherein the conduit is one of a hollow tube, a channel, or a receptacle.

9. The core structure of claim 7 wherein the conduit is configured to receive electrical wiring, heating elements, or circuitry therein.

10. The core structure of claim 1 further comprising a hard point embedded in at least one of the plurality of open area pores.

11. The core structure of claim 1 further comprising a first veil adhered to the first face of the array of the plurality of open area pores.

12. The core structure of claim 11 wherein the first veil comprises a sheet of non-oriented glass fibers.

13. The core structure of claim 11 further comprising a second veil adhered to the second face of the array of the plurality of open area pores.

14. The core structure of claim 13 wherein the second veil comprises a sheet of nonoriented glass fibers.

15. A composite sandwich panel assembly comprising:the core structure of claim 1;a first veil applied to the first face of the core structure; anda second veil applied to the second face of the core structure.

16. The composite sandwich panel assembly of claim 15 wherein at least one of the first veil and the second veil comprises a sheet of non-oriented glass fibers.

17. The composite sandwich panel assembly of claim 15 wherein the first veil is adhered to the first face of the core structure and the second veil is adhered to the second face of the core structure.

18. The composite sandwich panel assembly of claim 17 wherein the first veil and the second veil are adhered to the first face and the second face, respectively, by a plurality of tack points.

19. A method of forming a non-planar composite component using the composite sandwich panel assembly of claim 15, the method comprising:applying a first layer of resin to the first veil on the first face of the core structure; applying a second layer of resin to the second veil on the second face of the core structure; andpressing the composite sandwich panel assembly, first layer of resin, and second layer of resin in a mold having a non-planar contour to form the non-planar composite component.

20. The method of claim 19 wherein at least one of the first layer of resin and the second layer of resin are a polyurethane resin.

21. The method of claim 19 wherein applying the first layer of resin and the second layer of resin comprises spraying a liquid resin.

22. The method of claim 19 further comprising applying a Class-A high gloss surface to at least a portion of at least one of the first layer of resin and the second layer of resin prior to pressing.

23. The method of claim 22 wherein the Class-A high gloss surface is formed of chopped glass rovings or an SMC layer.

24. The method of claim 22 wherein the Class-A high gloss surface has circuitry printed on or attached to a backside thereof.

25. The method of claim 19 wherein pressing the composite sandwich panel assembly, first layer of resin, and second layer of resin in the mold seals all edges of the non-planar composite component thereby encapsulating the core structure and inhibiting moisture intrusion into the core structure.

26. The method of claim 19 wherein pressing the composite sandwich panel assembly, first layer of resin, and second layer of resin in the mold simultaneously trims all edges of the non-planar composite component.

27. The method of claim 19 wherein the non-planar composite component is a vehicle component.

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