The purpose of the present invention is to further enhance the strength of a manufactured composite structure by further suppressing the occurrence of wrinkling. A method for manufacturing a composite structure, the method comprising: a lamination step for layering a plurality of fiber sheets and molding a plate-form laminate; a forming step for forming a recess formed by a curved surface in a prescribed portion of the laminate; a short-direction deformation step for deforming the laminate in the short direction thereof after the forming step to configure a long-direction cross-section of the laminate in a prescribed shape; and a long-direction deformation step for deforming the laminate in the long direction after the forming step, so that the recess formed in the forming step deforms, to configure a short-direction cross section in a prescribed shape.

The present invention relates to methods for forming a composite product having a patterned surface. A substrate including a porous structure (136), a sheet-form material (134) and a patterned sheet (131) are pressed together to form the composite product. In preferred examples, the patterned sheet is permeable to curable material in the sheet-form material.

The present invention relates to methods for forming a composite product having a patterned surface. A substrate including a porous structure (136), a sheet-form material (134) and a patterned sheet (131) are pressed together to form the composite product. In preferred examples, the patterned sheet is permeable to curable material in the sheet-form material.

Enclosure parts for portable information handling systems may be made by heat pressing material layers together. The material layers may include outer fiber-reinforced thermoplastic layers and a core thermoplastic layer comprising a plurality of thermoplastic film layers. The core thermoplastic layer may be die cut to create voids that reduce weight of the enclosure part. A finishing layer may be added, along with attachment features.

Enclosure parts for portable information handling systems may be made by heat pressing material layers together. The material layers may include outer fiber-reinforced thermoplastic layers and a core thermoplastic layer comprising a plurality of thermoplastic film layers. The core thermoplastic layer may be die cut to create voids that reduce weight of the enclosure part. A finishing layer may be added, along with attachment features.

A method is described for manufacturing a molded product having a recessed/protruding part from a molded substrate (A) including reinforcing fibers and a matrix resin by press molding, the method comprising: a step (I) of placing the molded substrate (A) between molds including an upper mold and a lower mold and deforming the molded substrate (A) in an in-plane direction by heating and pressing the molds; and a step (II) of deforming the molded substrate (A) in an out-of-plane direction by depressurizing the molds subsequent to the step (I), wherein a deformation rate ratio T represented by the following formula (1) is within a range of 0.1 to 1:
T=X/Z   (1)
where X and Z are as defined.

A method is described for manufacturing a molded product having a recessed/protruding part from a molded substrate (A) including reinforcing fibers and a matrix resin by press molding, the method comprising: a step (I) of placing the molded substrate (A) between molds including an upper mold and a lower mold and deforming the molded substrate (A) in an in-plane direction by heating and pressing the molds; and a step (II) of deforming the molded substrate (A) in an out-of-plane direction by depressurizing the molds subsequent to the step (I), wherein a deformation rate ratio T represented by the following formula (1) is within a range of 0.1 to 1:
T=X/Z   (1)
where X and Z are as defined.

An apparatus and method, according to an exemplary aspect of the present disclosure includes, among other things, a quarter panel comprised of a sheet molding compound and a fascia bracket. The fascia bracket includes a first flange integrated into the quarter panel, a second flange comprising a vehicle body mount interface, and a gripping feature configured to grip a portion of a fascia to be attached to the quarter panel.

An apparatus and method, according to an exemplary aspect of the present disclosure includes, among other things, a quarter panel comprised of a sheet molding compound and a fascia bracket. The fascia bracket includes a first flange integrated into the quarter panel, a second flange comprising a vehicle body mount interface, and a gripping feature configured to grip a portion of a fascia to be attached to the quarter panel.

A composite laminate structure includes one or more layers of prepreg and a thermoplastic polyurethane film layer on the surface of the one or more prepregs. A method of making a composite laminate structure including a thermoplastic polyurethane film is also provided.