A method for manufacturing a thrust reverser blocker door may comprise thermoforming a sandwich panel comprising a facesheet, a backsheet, and a honeycomb core. The method may further comprising overmolding a mounting structure onto the backsheet. The first thermoplastic material may comprise a continuous fiber reinforced thermoplastic composite material. The second thermoplastic material may comprise a discontinuous fiber reinforced thermoplastic composite material.

A mold insert assembly includes a base section having a base side removably attachable to a base plate of a mold and a first interface surface having a notched portion thereon. A first section includes a first interface side with a first interconnecting tab sized to engage the notched portion of the base section when the first interface side abuts the first interface surface, the first section further including an adjoining side having an interconnecting notch. A second section includes a second interface side having a second interconnecting tab, where the second interconnecting tab is sized to engage the interconnecting notch of the first section when the second interface side abuts the adjoining side, and where the base section, the first section, and the second section when assembled form a contoured insert configured to create a contoured cavity in a part formed within the mold.

A mandrel for a molding process that includes a first portion that has a first portion outer surface, a first portion inner surface, a first portion first end, and a first portion second end. A thickness of the first portion first end is greater than the first portion second end. A second portion has a second portion outer surface, a second portion inner surface, a second portion first end, and a second portion second end. A thickness of the second portion first end is smaller than the second portion second end. The first portion inner surface engages the second portion inner surface to form a mandrel that has a constant cross-section.

A trim component for a vehicle interior is disclosed. The trim component may comprise a fiber panel comprising a compression-formed component and a structure comprising a resin. The compression-formed component may provide a structural substrate. The structure may comprise a molded resin feature for the structural substrate formed in at least one hole of the fiber panel. The structure may reinforce the structural substrate. The structure may also comprise a border. The fiber panel may comprise structural fibers and a resin. The structural fibers may comprise at least one of natural fibers; synthetic fibers; glass fibers; carbon fibers; polymeric fibers. The resin may comprise at least one of thermoplastic resin; polypropylene; acrylonitrile butadiene styrene; polycarbonate; thermoset resin; epoxy; polyimide; polyester; vinylester. The component may comprise at least one of a center console; a floor console; a door panel; an instrument panel; a headliner; an overhead console; a sun visor.

A trim component for a vehicle interior is disclosed. The trim component may comprise a fiber panel comprising a compression-formed component and a structure comprising a resin. The compression-formed component may provide a structural substrate. The structure may comprise a border (e.g. edge, dimensionally accurate border, etc.); the structure may comprise a molded feature (e.g. rib, ridge, edge, ancillary component, etc.) configured to reinforce and/or support the fiber panel. The fiber panel may comprise a resin to bond the fibers; the structure comprising a resin (e.g. injection-molded plastic/material) may be bonded to the fiber panel. The trim component may comprise a cover for the structural substrate provided by the compression-formed component.

Prior to curing a composite workpiece assembly, an expandable element can be inserted into a cavity of the workpiece assembly. The expandable element is configured to expand when a predetermined change is produced in an attribute of the element. The attribute can be a temperature of the element. The element is expanded by producing the predetermined change, and the workpiece assembly is cured while the expanded element is in the cavity, so that the expanded element applies positive pressure to inner surfaces of the cavity during curing. The expanded element can be removed from the cavity after curing. The expanded element can comprise a plurality of expandable pellets.

The present invention applies to a molding method for a fiber-reinforced plastic structure having an internal cavity. Firstly, grain groups, which mainly consist of a plurality of high-rigidity grains, are accommodated in bags, and a plurality of cores are formed. A reinforcing fiber substrate, is placed between the plurality of adjacent cores so as to be interposed therebetween. For example, a plurality of molding base materials are prepared by surrounding each core with a prepreg, and the plurality of molding base materials are combined and placed inside a molding die, and the molding base materials are compression molded. When compression molding, a part of the outer surface of the cores is locally pressurized, and the internal pressure of the cores is increased, changing the shape thereof, thus eliminating voids that are present between the cores and the prepreg and/or the prepreg and the molding surface of the die.

Systems and methods are provided for securing laminates to mandrels. One embodiment is a method for facilitating layup of preforms, the method including selecting a mandrel that includes at least one receptacle, disposing a first vacuum bag atop the mandrel that covers the receptacle, selecting a Ply Location Template (PLT) that includes a securement element, aligning a portion of the securement element with the receptacle, pressing the portion of the securement element downward into the first vacuum bag and driving the portion of the securement element into the receptacle, and abutting a preform against the PLT.

The present invention applies to a molding method for a fiber-reinforced plastic structure having an internal cavity Firstly, grain groups, which mainly consist of a plurality of high-rigidity grains, are accommodated in bags, and a plurality of cores are formed. A reinforcing fiber substrate, is placed between the plurality of adjacent cores so as to be interposed therebetween. For example, a plurality of molding base materials are prepared by surrounding each core with a prepreg, and the plurality of molding base materials are combined and placed inside a molding die, and the molding base materials are compression molded. When compression molding, a part of the outer surface of the cores is locally pressurized, and the internal pressure of the cores is increased, changing the shape thereof, thus eliminating voids that are present between the cores and the prepreg and/or the prepreg and the molding surface of the die.

A component for a vehicle interior is disclosed. The component may comprise a structural substrate comprising a fiber panel with at least one hole and a resin-formed structure; and a cover coupled to the fiber panel or the resin-formed structure. The fiber panel may be formed into a compression-formed component; the resin-formed structure may comprise a molded feature formed in the hole of the fiber panel. The resin-formed structure may reinforce the structural substrate. The fiber panel and the resin-formed structure may provide a substantially continuous structure. The resin-formed structure may extend along a surface of the fiber panel to form the resin-formed structure to the fiber panel. The cover may be applied to the fiber panel during compression molding. The component may comprise a trim panel, instrument panel, door panel, or other interior trim part. A method of manufacturing a vehicle trim component is also disclosed.