Compression-shaped foam core structure for composite vehicle component

Abstract

A non-planar composite component includes a core structure including a foam material having a first face and an opposing second face, the first face having a plurality of break lines thereon, the core structure having a non-planar contour. The composite component also includes a first veil adhered to the first face, a second veil adhered to the second face, a first layer of resin applied to the first veil, and a second layer of resin applied to the second veil.

Description

Docket No.: CSP0141WOCOMPRESSION-SHAPED FOAM 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 / 752,925 filed February 3, 2025, 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 which is compression-shaped to facilitate controlled, predictable shaping of the composite sandwich as it is molded into a non-planar vehicle component.BACKGROUND OF THE INVENTION

[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.Docket No.: CSP0141WO

[0004] A sandwich-structured composite is a special class of composite material that is fabricated 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, such as a foam material.

[0005] A problem with such foam core 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 difficulties that arise with molding or machining the shape of the foam core material of the sandwich structure. That is, molding and shaping foam cores into high-aspect ratio components can create defects in the foam core that 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. For example, molding of a foam core can create sink marks in the foam core, which are depressions on the surface of the foam due to uneven cooling and contraction. Another common defect in molded foam cores is weld lines, which occur when the molten material converges in the mold, resulting in a w eaker bond and potential surface defects. Furthermore, achieving the desired foam density and consistency across the core can be challenging due to factors like gas injection, temperature control, and mold design. Similarly, ensuring uniform thickness throughout the core is crucial for structural integrity and can be difficult to achieve with some foam molding methods. Finally, structural foam molding can involve longer cycle times compared to other injection molding processes, particularly due to the time required for the foam to expand and fill the mold.Docket No.: CSP0141WO

[0006] In order to form non-planar, high aspect ratio components, such as vehicle hoods, from a foam core composite sandwich material that are less prone to failure, additional machining of the sandwich structure, particularly the foam 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 of the core are aligned with contours in the mold. Also, this pre-machining prevents preassembly of additional layers onto the sandwich structure, thus requiring manufacturers to undertake additional steps. As such, existing solutions require long manufacturing times with many complicated steps and significant room for errors, resulting in low throughput and relatively high scrap rates.

[0007] Thus, there exists a need for a foam 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 defect prone foam molding of the core or additional highly toleranced machining steps in order to improve throughput and scrap rates.SUMMARY

[0008] A non-planar composite component includes a core structure including a foam material having a first face and an opposing second face, the first face having a plurality of break lines thereon, the core structure having a non-planar contour. The composite component also includes a first veil adhered to the first face, a second veil adhered to theDocket No.: CSP0141WO second face, a first layer of resin applied to the first veil, and a second layer of resin applied to the second veil.

[0009] A method of forming a non-planar composite component includes providing a foam material including a plurality7of pores and having a first face and an opposing second face. The method also includes forming a plurality7of break lines on the first face and forming the foam material to have a non-planar contour. Additionally, the method includes adhering a first veil to the first face and adhering a second veil to the second face. Further, the method includes applying a first layer of resin to the first veil and applying a second layer of resin to the second veil. Also, the method involves pressing the foam material, the first veil, the second veil, the first layer of resin, and the second layer of resin in a mold having a non-planar contour to form the non-planar composite component.

[0010] A second method of forming a non-planar composite component includes providing a foam material including a plurality7of pores and having a first face and an opposing second face and conditioning the foam material to facilitate localized deformation during compressing shaping. The method further includes compression shaping the foam material to have a non-planar contour, adhering a first veil to the first face, and adhering a second veil to the second veil. The method also involves applying a first layer of resin to the first veil and applying a second layer of resin to the second veil. The method also includes pressing the foam material, the first veil, the second veil, the first layer of resin, and the second layer of resin in a mold having a non-planar contour to form the non-planar composite component.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] 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 followingDocket No.: CSP0141WO detailed description taken in conjunction with the accompanying drawings in which:

[0012] FIG. 1 is a top view of a foam 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. 2 is a top perspective view of a foam core structure for a composite sandwich structure that has been compression-shaped into a non-planar foam core structure according to embodiments of the present invention;

[0014] FIGS. 3A-3D are cross sectional views of break lines according to embodiments of the present invention;

[0015] FIG. 4 is a partial cutaway perspective view of a composite sandwich panel assembly according to embodiments of the present invention;

[0016] FIG. 5 is a cross sectional view of a composite sandwich panel assembly according to embodiments of the present invention;

[0017] FIG. 6 is a partially exploded view of a composite component according to embodiments of the present invention;

[0018] FIGS. 7A-7D are cross-sectional views of edges used in the composite component of the present invention; and

[0019] FIG. 8 is a photograph showing a top perspective view of a non-planar composite component formed using a compression-shaped foam core structure according to embodiments of the present invention.DESCRIPTION OF THE INVENTION

[0020] The present invention has utility as a foam core material for a composite sandwich structure that is compression-shaped to have a high aspect ratio to facilitate controlled, predictable shaping of the composite sandwich as it is molded into a non-planarDocket No.: CSP0141WO vehicle component. The compression shaping of the foam core reduces defects in the foam core commonly caused by molding of the foam core into the high aspect ratio shape while also avoiding additional highly toleranced machining steps. Thus, the compression-shaped foam core reduces scrap rates while increasing through put of not only the foam core component but also the composite sandwich vehicle component as a whole.

[0021] 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.

[0022] The FIGURES show embodiments of an inventive 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, that avoids costs and defects typically associated with molding or machining the foam core to have a high aspect ratio shape. As shown in FIG. 1, embodiments of the core structure 10 include a foam 12 that defines a plurality of open area pores 14. The core structure 10 has a first face 16 and an opposing second face 18; see, for instance, FIG. 4. As shown in FIG. 1, some embodiments of the foam core structure 10 additionally include a plurality of break lines 20 formed in at least a portion of the foam 12 on at least one of a first face 16 or a second face 18 of the foam core structure 10.

[0023] According to embodiments, the foam 12 of the core structure 10 may be formed from polyurethane, polyethylene, ethylene vinyl acetate, polypropylene, polystyrene, polyvinyl chloride, aerogels, or other foams. Open-celled or closed-cell foam may be used. Closed-cell foam may advantageously be used to provide enhanced moisture resistance and edge sealing properties. According to embodiments, at least some pores 14 of the core structure 10 are inDocket No.: CSP0141WO fluid communication with at least one other pore 14. 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 compression or press molding process. As will be described in greater detail below, in some embodiments the edge region of the core structure 10 is crushed to form a sealed edge of the composite component 100; see FIGS. 7A-7D. In such situations, it is beneficial to provide fluid communication between 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.

[0024] According to embodiments, the foam 12 of the core structure 10 may be conditioned to facilitate localized deformation during compression shaping. This conditioning may be to open the pores 14 of the foam 12, to degas the foam 12, otherwise make it easier to compress shape the foam 12, or a combination thereof. According to embodiments the conditioning of the foam 12 may include applying to the foam 12, such as by spraying, a solvent such as a dilute spray of acetone or vacuum drawing the foam 12 to open the pores, degas the foam, and otherwise make it easier to compress.

[0025] Foam 12 may exhibit the behaviors of controlled, localized deformation. Such deformation may advantageously occur along break lines, such as break lines 20. Foam 12 may be selected and / or conditioned to advantageously maintain global dimensional integrity during compression shaping.

[0026] According to certain inventive embodiments, the core structure 10 and composite sandwich panel assembly 50 may provide 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 may be at least partially filled with a fill 19 illustratively including foam pellets, fireDocket No.: CSP0141WO retardant, or a phase change material. Phase change materials operative herein include waxes or inorganic salt hydrates. In a specific inventive embodiment, the flame retardant alumina trihydrate (ATH) may be used as a fill material.

[0027] According to embodiments, the break lines 20 that are formed in at least a portion of the foam 12 on the first face 16 or the second face 18 of the core structure 10 may be 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 foam 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 may be 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 may be formed by slashing, burning, laser etching, or cutting material of the foam 12 away from the core structure 10. According to embodiments, as shown in FIGS. 3A-3D, the break lines may 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.

[0028] According to embodiments, the core structure 10 includes a conduit 40 embedded in the foam 12. The conduit 40 may be used for ventilation or for electrical wires. According to embodiments, the conduit 40 comprises tubing or wires that are embedded into the foam 12 of 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, such as shown in FIG. 4. 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 shownDocket No.: CSP0141WO in FIG. 1. According to still other embodiments, the conduit 40 is a receptacle 41, as shown in FIGS. 1 and 4, that has only one open side. According to embodiments, the conduit 40 may be 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. 1) 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. 4). Accordingly, embodiments of the composite component 100 may be 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 may be 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 heating elements of the vehicle to function. According to embodiments, the core structure 10 includes a hard point 42 embedded in the foam 12. 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.

[0029] According to embodiments, the foam 12 of the core structure 10 of the present invention is shaped using compression into a desired shape that corresponds ultimately to the shape of a vehicle composite component that may have a high aspect ratio, i.e., a component that has 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. 6. According to embodiments, the compression shaping of the foam 12 of core structure 10 may be accomplished in a compression mold that is separate from a mold that ultimately forms theDocket No.: CSP0141WO composite vehicle component 100. It is noted that while separate compression shaping of the foam 12 of core structure 10 may be a post formation machining step, this machining step is fast and does not require precise, highly toleranced machining.

[0030] According to embodiments, a veil 44 is provided on at least one of the first face 16 or the second face 18 of the foam 12 of the core structure 10, thereby forming a composite sandwich panel assembly 50, as shown in FIGS. 4 and 5. According to embodiments, the veils 44 may each independently be 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, nonwoven 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.

[0031] According to embodiments, the veils are independently woven or nonwoven yet having sufficient porosity to allow a liquid resin layer 52, 54, described below, to penetrate therethrough (penetrated layers shown as 52’ and 54’ in FIG. 5). 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 veils 44 are believed to function to mitigate surface tension differences relative to various layers of the composite sandwich panel assembly 50 and resulting composite component 100 that may arise such as in 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 ofDocket No.: CSP0141WO 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. Veils 44 may have a mesh size of 10 to 1000, that is, the mesh layer has 10 to 1000 openings per square inch.

[0032] Once the composite sandwich panel assembly 50 is formed with the core structure 10 and at least one veil 44 on a face 16, 18 thereof, the composite sandwich panel assembly 50 may 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. 6. According to embodiments, forming such a non-planar composite component 100 may include 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 may be 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 may be placed in a compression mold or a vacuum mold having a non-planar contour and pressed or vacuum formed in the mold to form the non-planar composite component. According to embodiments, the compression molding and / or vacuum molding steps bring the edges of the resin layers 52. 54 together along at least one edge of the composite component 100 to form a seal along the edge. According to embodiments, at least one of the resin layers 52, 54 isDocket No.: CSP0141WO preformed such that it has edges extending generally perpendicularly from the plane of the sheet material, this edge providing sufficient material such that the edges of the resin layers 52, 54 can be joined together. According to embodiments, the resin layers 52, 54 are each independently a polyurethane resin. According to embodiments, the resin layers 52, 54 may be sprayed or rolled on in liquid form.

[0033] FIG. 8 is a photograph showing a top perspective view of a non-planar composite component 100 formed using an inventive compression-shaped foam core structure 10. Notably the non-planar composite component of FIG. 8 is defect free.

[0034] According to embodiments, such as shown in FIG. 5, 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 foam 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 veils 44 helps provide 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 core structure 10 may be at least 5% more than surface area of the foam 12 at the face 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.

[0035] 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 may 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 10Docket No.: CSP0141WO average thickness may be 0.01-1:1. In a particular inventive embodiment, the resin layers 52, 54 may have an average thickness of 1.5 to 5 mm and the core 10 has an average thickness of 6 to 25 mm.

[0036] Notably, the press molding operation for forming a non-planar composite component 100 using an inventive core structure 10 may bring 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 intrusion, as shown in FIGS. 7A-7D. 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, moisture within the composite sandwich panel assembly 50 may destroy the core structure 10 and cause the part to fail. According to embodiments, the press molding operation for forming a non-planar composite component 100 using an inventive core structure 10 simultaneously trims all edges of the non-planar composite component 100.

[0037] FIGS. 7A-7D 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 edges 33A, 33B, and 33D. The gasket 34 enhances maintenance of the edge seal over a wider range of use conditions.

[0038] As will be understood by one having ordinary skill in the art. to form an edge sealDocket No.: CSP0141WO between the resin layers 52, 54, at least one of the resin layers 52, 54 may be facilitated by providing 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 of core structure 10. According to certain inventive embodiments, the at least one of the resin layers 52, 54 on a veil 44 may be pushed into the other resin layer 52, 54 reinforced with the veil 44 with a shear edge, which joins the two resin layers 52, 54 together at the edges 33A-33D.

[0039] According to certain inventive embodiments, excess material is cut from the composite component 100 once the edge seal is formed. As shown in FIG. 7A, 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. 7B, the edge 33B formed by removing excess material for tool engagement against a shoulder 35B. In FIG. 7C, the edge 33C formed by removing excess material for tool engagement against a shoulder 35C. Also, as shown in FIG. 7D, 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 open area core 10 often crushes during a press molding to form the edge seal. The crushing of the pores 14 of the core 10 near the edge that is crushed in order to form a seal also contributes to suppressing moisture absorption inside the core. That is, the crushed region of the core structure 10 aids in suppressing moisture absorption of the core 10.

[0040] 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 a sheet molding compound (“SMG’) 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 theDocket No.: CSP0141WO 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 may be 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 may be printed on or attached to a backside of the Class-A high gloss surface 56, as shown in FIGS. 4 and 5. Such printed circuitry 66 may be applied 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.

[0041] 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.

[0042] 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

Docket No.: CSP0141WO CLAIMS1. A non-planar composite component comprising:a core structure including a foam material having a first face and an opposing second face, the first face having a plurality of break lines thereon, the core structure having a non-planar contour;a first veil adhered to the first face;a second veil adhered to the second face;a first layer of resin applied to the first veil; anda second layer of resin applied to the second veil.

2. The component of Claim 1, wherein the foam material includes a plurality of pores in fluid communication with one another.

3. The component of Claim 1, further including a conduit embedded in the foam material.

4. The component of Claim 3, wherein the conduit is one of a hollow tube, a channel, and a receptacle.

5. The component of Claim 4, wherein the conduit is configured to receive electrical w iring, a heating element, or electrical wiring therein.

6. The component of Claim 1, further comprising a hard point embedded in the foam material.Docket No.: CSP0141WO 7. The component of Claim 1, wherein the first veil comprises a sheet of nonoriented glass fibers.

8. The component of Claim 7, wherein the first veil has 10 to 1000 openings per square inch.

9. A method of forming a non-planar composite component, the method comprising:providing a foam material including a plurality of pores and having a first face and an opposing second face;forming a plurality of break lines on the first face;forming the foam material to have a non-planar contour;adhering a first veil to the first face;adhering a second veil to the second face;applying a first layer of resin to the first veil;applying a second layer of resin to the second veil; andpressing the foam material, the first veil, the second veil, the first layer of resin, and the second layer of resin in a mold having a non-planar contour to form the non-planar composite component.

10. The method of Claim 9, wherein at least one of the first layer of resin and the second layer of resin is a polyurethane resin.

11. The method of Claim 9, wherein applying at least one of the first layer of resin and the second layer of resin comprises spraying a liquid resin.Docket No.: CSP0141WO12. The method of Claim 9, 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 the foam material, the first veil, the second veil, the first layer of resin, and the second layer of resin in a mold having a non-planar contour to form the non-planar composite component.

13. The method of Claim 12, wherein the Class-A high gloss surface is formed of chopped glass rovings or a sheet molding compound (“SMC”) layer.

14. The method of Claim 12 wherein the Class-A high gloss layer has circuitry printed on or attached to a backside thereof.

15. The method of Claim 9, wherein pressing the foam material, the first veil, and second veil, the first layer of resin, and the second layer of resin in a mold having a non-planar contour to form the non-planar composite component seals all edges of the non-planar component, thereby encapsulating the core structure and inhibiting moisture.

16. The method of Claim 15, wherein pressing the foam material, the first veil, and second veil, the first layer of resin, and the second layer of resin in a mold having a non-planar contour to form the non-planar composite component simultaneously trims all edges of the non-planar composite component.

17. The method of Claim 9 wherein the non-planar composite component is a vehicle component.Docket No.: CSP0141WO18. A method of forming a non-planar composite component, the method comprising:providing a foam material including a pl urality of pores and having a first face and an opposing second face;conditioning the foam material to facilitate localized deformation during compression shaping;compression shaping the foam material to have a non-planar contour; adhering a first veil to the first face;adhering a second veil to the second veil;applying a first layer of resin to the first veil;applying a second layer of resin to the second veil; andpressing the foam material, the first veil, the second veil, the first layer of resin, and the second layer of resin in a mold having a non-planar contour to form the non-planar composite component.

19. The method of Claim 18, wherein conditioning the foam material includes applying a solvent thereto.

20. The method of Claim 18, wherein conditioning the foam material includes applying a vacuum draw thereto.

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