Injection molded composite blank and guide
First Claim
1. An article of manufacture comprising at least one thermoplastic injection molded guide melt bonded to a structural blank, whereinthe at least one thermoplastic injection molded guide comprises a guide thermoplastic matrix, wherein the at least one thermoplastic injection molded guide includes a first thermoplastic injection molded guide having a guide shape comprising a guide shape width, a guide shape length and a guide shape height with a guide shape top side corresponding to a first side of a guide shape horizontal plane, a guide shape bottom side corresponding to a second side of the guide shape horizontal plane opposite the first side of the guide shape horizontal plane with the guide shape horizontal plane corresponding to a guide shape length and a guide shape width;
- the structural blank having a structural blank length, a structural blank width, and a structural blank height wherein the structural blank height is less than the structural blank width and the structural blank width is less than or equal to the structural blank length, and the structural blank comprisesat least one ply containing a plurality of oriented continuous fibers in a structural blank thermoplastic or thermoset matrix wherein the plurality of oriented continuous fibers are selected from the group consisting of unidirectional oriented fibers and woven oriented fibers, and the at least one ply lies in a structural blank horizontal plane defined by the structural blank length and the structural blank width,a structural blank top side corresponding to one side of the structural blank horizontal plane,a structural blank bottom side opposite of the structural blank top side,a structural blank perimeter, andat least one structural blank hole passing from the structural blank top side to the structural blank bottom side; and
the first thermoplastic injection molded guide is molded to at least a portion of the structural blank top side, around the structural blank height, and to at least a portion of the structural blank bottom side wherein the guide thermoplastic matrix does not contact an internal edge of the at least one structural blank hole passing through the structural blank plane or a surface of the structural blank top side and the structural blank bottom side immediately adjacent a periphery of the at least one structural blank hole, andthe at least one thermoplastic injection molded guide further comprises a plurality of randomly dispersed fibers in the guide thermoplastic matrix.
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Accused Products
Abstract
This specification discloses an article of manufacture. The article of manufacture has at least one structural blank and at least one guide. The structural blank has a plurality of oriented fiber plies in a thermoplastic matrix. The guide has a plurality of random dispersed fibers in a thermoplastic matrix. The guide is affixed to the structural blank by injection molding and over molding the guide onto the structural blank. The article of manufacture can take a number of forms for use in industries such as aircraft, automobiles, motorcycles, bicycles, trains or watercraft.
5 Citations
14 Claims
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1. An article of manufacture comprising at least one thermoplastic injection molded guide melt bonded to a structural blank, wherein
the at least one thermoplastic injection molded guide comprises a guide thermoplastic matrix, wherein the at least one thermoplastic injection molded guide includes a first thermoplastic injection molded guide having a guide shape comprising a guide shape width, a guide shape length and a guide shape height with a guide shape top side corresponding to a first side of a guide shape horizontal plane, a guide shape bottom side corresponding to a second side of the guide shape horizontal plane opposite the first side of the guide shape horizontal plane with the guide shape horizontal plane corresponding to a guide shape length and a guide shape width; -
the structural blank having a structural blank length, a structural blank width, and a structural blank height wherein the structural blank height is less than the structural blank width and the structural blank width is less than or equal to the structural blank length, and the structural blank comprises at least one ply containing a plurality of oriented continuous fibers in a structural blank thermoplastic or thermoset matrix wherein the plurality of oriented continuous fibers are selected from the group consisting of unidirectional oriented fibers and woven oriented fibers, and the at least one ply lies in a structural blank horizontal plane defined by the structural blank length and the structural blank width, a structural blank top side corresponding to one side of the structural blank horizontal plane, a structural blank bottom side opposite of the structural blank top side, a structural blank perimeter, and at least one structural blank hole passing from the structural blank top side to the structural blank bottom side; and the first thermoplastic injection molded guide is molded to at least a portion of the structural blank top side, around the structural blank height, and to at least a portion of the structural blank bottom side wherein the guide thermoplastic matrix does not contact an internal edge of the at least one structural blank hole passing through the structural blank plane or a surface of the structural blank top side and the structural blank bottom side immediately adjacent a periphery of the at least one structural blank hole, and the at least one thermoplastic injection molded guide further comprises a plurality of randomly dispersed fibers in the guide thermoplastic matrix. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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Specification