Composite component

摘要

A composite component such as a seat back for a vehicle comprises a support portion and at least one reinforcing composite layer. The support portion comprises a thermoplastic material and the reinforcing composite layer comprises a polymeric material impregnating a plurality of fibers. The polymeric material of the reinforcing composite layer is integrated with the thermoplastic of the support portion. A method of forming the composite component includes placing the composite layer into a mold, heating the thermoplastic material to a molten state, and disposing the thermoplastic material in the molten state into contact with the composite layer. The method further includes promoting interaction between the thermoplastic material and the polymeric material to integrate the support portion and the reinforcing composite layer. The thermoplastic material supports the reinforcing composite layer and the reinforcing composite layer reinforces the thermoplastic material to prevent failure when subjected to a load.

主权项

1. A seat back for a vehicle, said seat back comprising:
a pair of side bolsters and a back member extending between said side bolsters; each of said side bolsters including a support portion and a reinforcing composite layer; said support portion of each of said side bolsters including a thermoplastic material initially separate from said reinforcing composite layer; said back member including said thermoplastic material and being integral with said thermoplastic material of said support portion; said reinforcing composite layer of each of said side bolsters including a polymeric material and a plurality of continuous fibers impregnated in said polymeric material; wherein each reinforcing composite layer of each of said side bolsters is concave with a base and a pair of sides spaced from each other and extending from said base defining a cavity disposed therebetween with each of said base and said pair of sides defining continuous contact surfaces facing said cavity; at least one cross member extending between one side of said base of said support portion of each of said side bolsters opposite said contact surfaces of said base; said at least one cross member including said thermoplastic material and being integral with the one side of said base of said support portion of each of said side bolsters; wherein said thermoplastic material of said support portion is disposed in said cavity along at least a portion of said contact surfaces of at least said base and said pair of sides of said reinforcing composite layer and defining a set of ribs extending from said contact surfaces of said base and said sides and interaction between said thermoplastic material and said polymeric material integrates by melting a portion of said polymeric material with said thermoplastic material in a molten state; wherein said support portion extends between and is integrated with said polymeric material of said pair of sides and said base and said ribs of said reinforcing composite layer of each of said side bolsters; wherein said thermoplastic material of said at least one cross member extends between and is integrated with said polymeric material of said base of said support portion of each of said side bolsters; wherein said polymeric material and said thermoplastic material are cooled to define said base of each of said side bolsters as integrated combinations of said thermoplastic material and said reinforcing composite layer, respectively, and to at least partially define each of said sides as an integrated combination of said thermoplastic material and said reinforcing composite layer, respectively, with said base and said sides being integrated with each other such that said reinforcing composite layer reinforces said support portion to resist fracturing of said support portion when subjected to a load as said support portion extends between and simultaneously supports said reinforcing composite layer; and wherein said side bolsters, said at least one cross member, and said back member are integral.