US 12,240,192 B2
Co-molding of non-crimped fabric and SMC
Rudolph A. Schrempf, Brampton (CA); Ranjit Pachha, Brampton (CA); Matthew Homen, North York (CA); and Ian M. Byberg, Williamstown (CA)
Assigned to Magna Exteriors Inc., Aurora (CA)
Filed by Magna Exteriors Inc., Concord (CA)
Filed on Jan. 13, 2021, as Appl. No. 17/147,803.
Claims priority of provisional application 62/960,568, filed on Jan. 13, 2020.
Prior Publication US 2021/0213692 A1, Jul. 15, 2021
Int. Cl. B29C 70/86 (2006.01); B29B 11/14 (2006.01); B29C 43/18 (2006.01); B29C 70/68 (2006.01); B29K 105/08 (2006.01); B29K 707/04 (2006.01); B29L 31/30 (2006.01); B62D 29/04 (2006.01)
CPC B29C 70/865 (2013.01) [B29B 11/14 (2013.01); B29C 43/18 (2013.01); B29C 70/683 (2013.01); B29K 2105/0863 (2013.01); B29K 2105/089 (2013.01); B29K 2707/04 (2013.01); B29L 2031/30 (2013.01); B62D 29/043 (2013.01)] 14 Claims
OG exemplary drawing
 
1. A method of manufacturing an automotive panel, comprising:
providing at least a first material;
providing at least one molding tool with a plurality of thorns in at least one predetermined area of said molding tool;
providing at least one second material including a predetermined non-crimped fabric;
providing at least one pre-forming tool;
coating an entire loading surface of said pre-forming tool in at least one layer of resin before loading said non-crimped fabric to said pre-forming tool;
pre-forming each of said at least one predetermined non-crimped fabric in said at least one pre-forming tool, respectively, forming at least one non-crimped fabric pre-preg;
drying the at least one non-crimped fabric pre-preg a predetermined amount to achieve operable predetermined stiffness to limit the movement and distortion of the at least one non-crimped fabric pre-preg during molding of the automotive panel;
loading said at least one non-crimped fabric pre-preg that is dried into said molding tool against said respective plurality of thorns; and
supplying a flow of said at least one first material to said molding tool and molding said automotive panel, wherein said plurality of thorns further prevents movement of said at least one non-crimped fabric pre-preg during said flow of said at least one first material.