THERMOPLASTIC INJECTION MOLDED ELEMENT WITH INTEGRAL THERMOPLASTIC POSITIONING SYSTEM FOR REINFORCED COMPOSITE STRUCTURES

摘要

Disclosed embodiments may relate generally to manufactured elements having composite reinforcement, and more specifically to elements comprising a composite precisely positioned within the element for support. Embodiments of such elements typically may be formed using injection molding. Embodiments may further comprise an integral thermoplastic positioning system for positioning the composite, and encapsulating thermoplastic forming the exterior geometry of the element.

主权项

1. A thermoplastic injection molded element comprising:
a composite comprising an array of parallel carbon fibers disposed in a thermoplastic material; an ITPS configured to position the composite within the element during formation; and an encapsulating thermoplastic forming the exterior geometry of the element; wherein: the composite comprises an outer surface, the outer surface of the composite comprises a top surface and a bottom surface, and the ITPS is located on and affixed to at least a portion of the top and bottom surfaces of the composite to form a composite-ITPS assembly; the composite-ITPS assembly provides minimum required structural support for the element; the encapsulating thermoplastic is located about and affixed to the composite-ITPS assembly; the ITPS and the encapsulating thermoplastic each comprise thermoplastic material, and the composite, ITPS, and encapsulating thermoplastic each comprise the same thermoplastic material; the thermoplastic material comprises one of the following: polycarbonate, polyphenylene sulfide, polyetherimide, and combinations thereof; the composite comprises a plurality of apertures therethrough; the ITPS comprises a plurality of penetration elements that extend through the apertures in the composite and a plurality of spires extending distally to the final geometric limit of the element; the composite-ITPS assembly is formed by injection molding; the encapsulating thermoplastic is formed about the composite-ITPS assembly using injection molding; and the composite, ITPS, and encapsulating thermoplastic are affixed via chemical fusing during injection molding.