US 11,951,696 B2
Method for compression molding cosmetic composite parts
Bert D. Mannhalter, Kensington, CA (US); J. Scott Perkins, Oakland, CA (US); Allison R. Light, Orinda, CA (US); Ian Graham, Oakland, CA (US); Joe Wong, Livermore, CA (US); and Riley Reese, Oakland, CA (US)
Assigned to Arris Composites Inc., Berkeley, CA (US)
Filed by Arris Composites Inc., Berkeley, CA (US)
Filed on Jan. 10, 2022, as Appl. No. 17/572,445.
Claims priority of provisional application 63/135,390, filed on Jan. 8, 2021.
Prior Publication US 2022/0219409 A1, Jul. 14, 2022
Int. Cl. B29C 70/34 (2006.01); B29B 11/06 (2006.01); B29B 11/10 (2006.01); B33Y 80/00 (2015.01)
CPC B29C 70/345 (2013.01) [B29B 11/06 (2013.01); B29B 11/10 (2013.01); B33Y 80/00 (2014.12)] 14 Claims
OG exemplary drawing
 
1. A method for forming, via compression molding in a single molding operation, a fiber-composite part having at least one cosmetic surface, wherein the cosmetic surface is formed without post processing, the method comprising:
forming an assemblage of feed constituents, wherein the assemblage includes:
a. a plurality of fiber-bundle-based preforms, each preform comprising a plurality of fibers infused with a first resin, and
b. a resin-only constituent consisting essentially of a second resin; and
compression molding and thereby consolidating, in a mold cavity, the plurality of fiber-bundle-based preforms and the resin-only constituent, wherein the resin-only constituent is positioned in the assemblage so that the resin-only constituent abuts a surface of the mold cavity that forms the cosmetic surface of the fiber-composite part, and wherein consolidating comprises:
a. a first consolidation, including:
(i) increasing a temperature of the fiber-bundle-based preforms to reach melt-flow of the first resin, while maintaining a temperature of the resin-only constituent below a temperature required to achieve melt flow of the second resin; and
(ii) increasing pressure in the mold cavity sufficient for greater than 50 percent consolidation of the fiber-bundle-based preforms but 25 percent or less consolidation of the resin-only constituent; and
b. a second consolidation, including:
(i) increasing a temperature of the resin-only constituent to reach melt-flow of the second resin; and
(ii) increasing pressure in the mold cavity sufficient to complete consolidation of the resin-only constituent and the fiber-bundle-based preforms.