WO2018069225A1

WO2018069225A1 - Method of moulding a composite structure

Info

Publication number: WO2018069225A1
Application number: PCT/EP2017/075637
Authority: WO
Inventors: Alex LAKIC
Original assignee: Jaguar Land Rover Limited
Priority date: 2016-10-11
Filing date: 2017-10-09
Publication date: 2018-04-19
Also published as: GB2555089A; GB201617236D0

Abstract

Aspects of the present invention relate to composite moulding methods, systems, moulds, mouldings and moulding inserts. An embodiment of the invention provides a method of moulding a composite structure (6, 306, 406), comprising locating a holding means (3, 103, 203, 303, 403) about an interior surface (22) of a mould (2), the holding means comprising engaging means (32, 132, 232), and locating means (31, 131, 331, 431) for engaging a corresponding feature of the mould to inhibit relative movement the holding means with respect to the mould, wherein the engaging means extends perpendicular to said interior surface of the mould when the locating means is engaged with said corresponding feature placing a fibrous element (4) in relation to the mould (2) such that the engaging means (3, 103, 203, 303, 403) penetrates a surface of the fibrous element (4) facing the interior surface of the mould (2) and inhibits movement thereof, and forming in the mould (2) a composite structure (6, 306, 406) including the fibrous element (4), a polymeric matrix material (5) and the holding means (3, 103, 203, 303, 403). The holding means may, in some embodiments, provide a securement feature (31, 131, 331, 431) for a post-moulding operation.

Description

METHOD OF MOULDING A COMPOSITE STRUCTURE

TECHNICAL FIELD

The present disclosure relates to a method of moulding a composite structure. More specifically, although not exclusively, the present disclosure relates to the moulding of fibre reinforced composite structures using a fibrous element, such as a sheet or preform, incorporated within or fused with a polymeric or plastics matrix material. Aspects of the invention relate to a method of moulding a composite structure, a composite moulding, a composite moulding insert, a moulding system, and a vehicle.

BACKGROUND There are many known methods of forming fibre reinforced composite materials using either pre-impregnated or dry fibre sheets or preforms. This invention is particularly, although not exclusively, concerned with moulding processes involving the use of dry fibre sheets or preforms in which some or all of the matrix material is introduced during the moulding process. Examples of such processes include, for example, resin transfer moulding, vacuum assisted resin transfer moulding, reinforced or structural reaction injection moulding and vacuum moulding. It is also envisaged that the present invention may be used with other moulding techniques as would be apparent to the skilled person, such as wet compression moulding, thermoplastic mixed injection moulding of organic fibre sheets and the like. In the aforementioned moulding processes, the fibre sheet or preform is placed into a mould and subjected to complex forces, which can displace the sheet or preform during the moulding process. In order to mitigate this issue, the sheets are first cut to a shape that is larger than the intended finished component, moulded, cured and the moulded part is then cut to remove excess peripheral fibre and matrix material to obtain the desired finished component shape and size.

This post-moulding stage creates excess waste, cost and can lead to delamination and a tendency for cracks to propagate from the trimmed edge of the finished component. Cutting methods, such as laser, water jet or moving cutting edges, require substantial investment, process time and raw material and disposal costs. The fibre reinforced structure of the material complicates the cutting process, requiring excessive power, pressure and/or force to effect cutting. The agitation of fibres and matrix material at and adjacent to the edges being cut by heating, abrading or slicing creates weaknesses in the bond between the fibres, the matrix and between sheets (where applicable). These weaknesses can create potential crack initiation sites in the finished component. It is therefore an aim of the invention to mitigate the issues associated with prior art composite moulding methods, systems and moulds. It is a more general aim of the invention to provide an improved method, system and mould for moulding composite structures.

SUMMARY OF THE INVENTION

Aspects and embodiments of the invention provide a method of moulding a composite structure, a composite moulding, a composite moulding insert, a moulding system, and a vehicle. For the avoidance of doubt, any of the features described herein apply equally to any aspect of the invention.

According to an aspect of the invention there is provided a method of moulding a composite structure, the method comprising locating a holding means about a surface of a mould, the holding means comprising engaging means, and locating means for engaging a corresponding feature of the mould to inhibit relative movement the holding means with respect to the mould.

According to an aspect of the invention there is provided a method of moulding a composite structure, comprising locating a holding means about an interior surface of a mould, the holding means comprising engaging means, and locating means for engaging a corresponding feature of the mould to inhibit relative movement the holding means with respect to the mould, wherein the engaging means extends perpendicular to said interior surface of the mould when the locating means is engaged with said corresponding feature, placing a fibrous element in relation to the mould such that the engaging means penetrates a surface of the fibrous element facing the interior surface of the mould and inhibits movement thereof, and forming in the mould a composite structure including the fibrous element, a polymeric matrix material and the holding means.

According to another aspect of the invention, there is provided a method of moulding a composite structure, the method comprising: locating a holding means about an interior surface of a mould, the holding means comprising engaging means, and locating means for engaging a corresponding feature of the mould to inhibit relative movement the holding means with respect to the mould, wherein the engaging means extends perpendicular to said interior surface of the mould when the locating means is engaged with said corresponding feature; then placing a fibrous element in relation to the mould; then forcing the fibrous element down onto the interior surface such that the engaging means penetrates a surface of the fibrous element facing the interior surface of the mould and inhibits movement thereof; and then forming in the mould a composite structure including the fibrous element, a polymeric matrix material and the holding means.

Advantageously the holding means prevents movement of the fibrous material, such as when the matrix material is introduced, sometimes forcibly i.e. under pressure, into the mould.

A method described above, wherein:

said holding means comprises an insert;

said engaging means comprises one or more engaging features; and

locating means comprises a locating structure.

The method may comprise removing the composite structure from the mould. The method may comprise supporting the composite structure by the locating means. Advantageously the locating means allows convenient support for the composite structure when removed from the mould. The locating means may be used to support one or more composite structures for assembly or finishing to form a product. In some embodiments a plurality of composite structures may be supported in relation to one-another, for example to allow fixing of the composite structures in the supported relation. The supporting of the composite structure may comprise engaging a supporting means with the locating means. The supporting means may be provided as part of a jig or other structure about which one or more composite structures are supported, such as during assembly of a product or vehicle. The locating means may extend in a generally opposed direction to the engaging means.

Optionally the locating means protrudes from a surface of the composite structure. Advantageously the protrusion allows easy gripping or holding of the locating means to support the composite structure. The composite structure may be an integral composite structure in which the holding means is at least partially bonded within the matrix material. Advantageously the holding means is formed securely with the composite structure. The penetrating the fibrous element with the engaging means may comprise urging one or more engaging means to extend at least partly into the fibrous element. Advantageously the penetration of the fibrous materiel ensures secure engagement of the holding means with the fibrous material. The placing the fibrous element may comprise closing the mould such that the engaging means penetrates the fibrous element. Advantageously a separate step of penetrating the fibrous material is not required.

The locating the holding means may comprise mounting one or more inserts into a cavity of the mould. Advantageously the inserts may be located about the cavity of the mould prior to the fibrous materiel.

Optionally the method comprises inserting a male locating means at least partially into a female corresponding feature of the mould.

The method may comprise mounting a plurality of holding means at predetermined locations about the mould. Advantageously the holding means may be distributed about the mould. The locations may be selected such that the locating means provide securement features for post-moulding operations of the composite part.

The forming in the mould the composite structure may comprise introducing into the mould the matrix material to form the composite structure. The penetration of the fibrous material by the engaging means may resist a force of the matrix material being introduced. Advantageously the matrix material is securely held by the penetration.

The forming in the mould the composite structure may comprise forming one or more lines of weakness which delineate one or more removable regions or portions in the composite structure. According to another aspect of the invention there is provided a composite moulding, comprising a composite structure including a fibrous element, a polymeric matrix material and one or more holding means each having one or more engaging means extending perpendicular to a surface of the composite structure and at least partially embedded in the fibrous element from a first side of the fibrous element and moulded into the composite structure, and a mounting means at the first side of the fibrous material for supporting the composite moulding there-from.

A composite moulding as described above, wherein the one or more holding means are one or more inserts, the engaging means are one or more engaging features extending perpendicular to a surface of the composite structure and the mounting means is at least one mounting feature.

The composite moulding may comprise a plurality of engaging features at least partially embedded in the fibrous element. Advantageously the engaging features securely engage with the fibrous material.

Each engaging feature may comprise a male projection penetrating the fibrous element from the first side.

The mounting feature may be used to support the composite moulding during one or more post-moulding operations. The mounting feature may comprise one of a male feature and a female feature. Advantageously, the use of a holding means makes it possible to locate accurately and secure the fibrous element during the moulding process, thereby ensuring that the fibrous element is incorporated in the desired area or areas of the finished component. The aforementioned method also enables the fibrous element to be cut once only, prior to moulding, so that the fibres did not overhang the intended finished part periphery. Where the holding means forms part of the composite structure, demoulding of the finished part may also be simplified.

In embodiments, the placing of the holding means in or on the mould comprises mounting the holding means to the mould or on or in or within a cavity thereof. The holding means may be placed adjacent to or in contact with a moulding surface or cavity wall of the mould. Mounting the holding means may comprise engaging one or more mounting features or mounts of the holding means with one or more cooperating mounting features or mounts of the mould, for example the moulding surface or cavity wall. In embodiments, mounting the holding means comprises inserting a male feature at least partially into a cooperating female feature. The male feature may comprise a projection or pin or stem. The female feature may comprise a recess or depression or aperture or hole, e.g. a blind hole. In embodiments, the male feature is comprised in or on or associated with the holding means and the female feature is comprised in or on or associated with the mould. In an alternative embodiment, the male feature is comprised in or on or associated with the mould and the female feature is comprised in or on or associated with the holding means.

In embodiments, the fibrous element is placed in or on the mould such that one or more engaging features of the holding means engage, key, extend or are urged to extend at least partly in or into the fibrous element, for example into gaps between fibres thereof. The method may comprise urging the one or more engaging features to extend at least partly into or through the fibrous element. Additionally or alternatively, the method may comprise closing the mould such that one or more engaging features engages the fibrous element or extends therein or further therein. The engaging features of the holding means may, but need not, be on an opposite side or surface thereof to the mounting feature or features, for example such that one or more engaging features are exposed when the holding means is placed into or mounted to the mould. Optionally, the placing of the fibrous element in or on the mould is carried out manually, e.g. by an operator, or automatically or by using a device or apparatus, which may be automated, such as a robot.

Optionally, the placing of the holding means comprises placing one or more, for example two or more, e.g. three or four or more, such as multiple or a plurality of, holding elements. The holding elements may comprise one or more holders, inserts, location means, locators, gripping means or grippers. The placing of the holding elements may comprise placing each holding element at a different location or position, for example a plurality of predetermined locations or positions. In embodiments, the one or more locations is or are adapted or predetermined or selected to provide one or more jig or fixture features, for example locating and/or gripping features. The jig or fixture features may comprise any one or more of projections, pins, stems, recesses, depressions, apertures or holes, e.g. for post-moulding operations. It is also envisaged that such male and/or female features may be used for attaching the moulding to other vehicle components, e.g. as securement features. For example, at least one of the holding elements may comprise a fixing or securement feature. The fixing or securement feature may comprise any one or more of a groove, undersized neck, rim, flange or other feature therein or thereon. According to a further aspect of the invention there is provided a composite moulding, comprising: a composite structure including a fibrous element, a polymeric matrix material and one or more inserts each having one or more engaging features extending perpendicular to a surface of the composite structure and at least partially embedded in the fibrous element from a first side of the fibrous element and moulded into the composite structure, and a mounting feature at the first side of the fibrous material for supporting the composite moulding there-from.

According to a further aspect of the invention there is provided a composite moulding insert comprising a body with a mounting feature on one side of the body for cooperation with corresponding mounting feature about an interior surface of a mould, and a plurality of engaging features on a second side of the body for penetrating into a fibrous element to inhibit movement of the fibrous element in relation to the insert.

According to another aspect of the invention there is provided a method of moulding a composite structure, the method comprising providing an insert having a mount on a first side thereof and one or more projections on a second side thereof, mounting the insert onto a moulding surface of a mould by engaging the insert with a mount in or on the moulding surface such that the one or more projections extend away from the moulding surface, placing a fibrous material on or over the moulding surface or in the mould such that the one or more projections of the insert engage the fibrous material and inhibit movement thereof, and forming in the mould a composite structure including the fibrous material, a polymeric matrix material and the insert.

For the avoidance of doubt the method according to either of the aforementioned aspects may comprise any one or more features described in respect of the other or that would be apparent to the skilled person from the above disclosure.

In embodiments, the method may comprise providing a plurality of inserts each having a mount on a first side thereof and one or more projections on a second side thereof. The method may comprise mounting the plurality of inserts at a plurality of predetermined locations on the moulding surface such that the one or more projections extend away from the moulding surface. The predetermined locations may be selected such that the insert mounts are configured or adapted to provide jig or fixture location and/or grip features for post-moulding operations.

In embodiments, forming comprises forming the composite structure such that the holding means is at least partially integral with or otherwise connected to the fibrous element or to the a matrix material or composite structure. The holding means may be moulded in, overmoulded, embedded, adhered, bonded, fused to or in or within the fibrous element or matrix material or composite structure. The method or forming may comprise introducing a matrix material, for example in or on the mould, such as within a cavity thereof. The matrix material may comprise a flowable or molten or semi-liquid or liquid matrix material. The introduction of the matrix material may comprise surrounding, impregnating or immersing the fibrous element, e.g. with or in the matrix material. Additionally or alternatively, introducing the matrix material may occur before or during or after, the placing of the fibrous element in or on the mould and/or the placing of the holding means in or on the mould.

Optionally, the method or forming may comprise solidifying or otherwise altering the matrix material. Solidifying may comprise cooling, melding, curing or setting, for example crystalisation and/or chemical polymerization of the matrix material. Additionally or alternatively, forming may comprise moulding in, overmoulding, embedding, connecting, adhering, bonding or fusing at least part of the holding means, e.g. at least a portion of one or more of the engaging features thereof, with at least a portion of the composite structure, e.g. at least a portion of the matrix material and/or fibrous element.

In embodiments, the method comprises moulding one or more removable or frangible or breakable regions or portions. The method may comprise moulding one or more lines of weakness, e.g. frangible lines, which lines of weakness may delineate or define one or more such regions or portions. The method may additionally or alternatively comprise removing or ejecting the composite structure, for example a component or part comprising the composite structure, from the mould. Removal or ejection may, for example, be carried out after forming and/or solidifying.

According to another aspect of the present invention, there is provided a composite moulding, which may but need not be formed by the aforementioned method. The moulding may comprise a fibrous element, a matrix material, e.g. a polymeric or plastics matrix material, and a holding means, which may be at least partially integral with or otherwise connected to the fibrous element or to the a matrix material or composite structure.

The fibrous element may comprise a fibrous material or fibres or fabric that may be immersed in and/or surrounded by and/or impregnated with the matrix material. The composite moulding may comprise a vehicle body panel or vehicle bumper.

In embodiments, the holding means comprises one or more mounting features or mounts, which may comprise male and/or female features. The one or more mounting features or mounts may comprise a projection, pin, stem, recess, depression, aperture or hole, e.g. a blind hole.

Additionally or alternatively, the holding means may comprise one or more engaging features, e.g. for engaging or keying or extending at least partially in or into the fibrous element, for example into gaps in the yarn and/or between adjacent fibres thereof. The one or more engaging features may be nanoscopic or microscopic or macroscopic. The one or more engaging features may comprise, or be provided by, a profiled or textured surface or one or more, for example two or more, e.g. a plurality of, projections or elements. The one or more engaging features may comprise a pin, post, spike or hook element, such as natural spikes or nanotube hooks, any of which elements may comprise one or more barbs. In embodiments, the one or more engaging features comprise one or more straight or tapered projections, which may be elongate and/or conical. The one or more engaging features may comprise one or more recesses, depressions or channels, which may comprise fibre engaging features such as lips and the like.

Optionally, the holding means may comprise one or more, e.g. two or three or four or more, such as multiple or a plurality of, holding elements. At least one of the holding elements may comprise a holder, insert, location means, locator, gripping means or gripper, one or more or each of which may comprise a body. The body may comprise a plate, base or substrate. The body may be substantially disc shaped and/or round or elliptical in plan. Alternatively, the body may be square, rectangular, e.g. with rounded or sharp corners, or any other suitable shape in plan. The one or more mounting features or mounts may be comprised in or on or located in or on a first side of the body. The one or more engaging features may be comprised in or on or located in or on a second side of the body. The second side may be opposite, or on an opposite side of the body, to the first side. The first and/or second side of the body may comprise a surface, for example a major surface, on or in which the feature or features may be comprised or located. The holding elements may each be at a different location or position. In embodiments, the one or more locations may be adapted, predetermined or selected to provide one or more jig or fixture features, for example location and/or gripping features, e.g. for post-moulding operations. At least one of the jig or fixture features may comprise a projection, pin, stem, recess, depression, aperture or hole, for example a blind hole. The jig or fixture features may be exposed and/or extend from or into the moulding, e.g. for post-moulding operations.

In embodiments, the holding means may comprise or be formed of a polymer material, which may be glass or carbon fibre filled. The polymer material may comprise polypropylene, which may be flame treated, or a polyamide or thermoplastic polyamide, such as nylon or any other suitable polymer material, or any suitable combination thereof. Additionally or alternatively, the holding means may comprise or be formed of a metal or metallic material, which may be surface passivated. The metal or metallic material may comprise aluminium, zinc, magnesium or steel, e.g. surface passivated steel or unpassivated stainless steel, or any suitable combination thereof.

In embodiments, the matrix material comprises a plastics or polymer matrix material, which may comprise a thermoplastic, thermoset or shape memory polymer resin or material, or any suitable combination thereof. Optionally, the matrix material may comprise any suitable combination of one or more of polyesters, vinyl esters, epoxies, phenolics, polyurethanes, polyimides, furans, styrene, and/or bismaleimide materials. Additionally or alternatively, the matrix material may comprise one or more additive materials, e.g. as required and as would be apparent to the skilled person.

In embodiments, the fibrous element comprises a fibre sheet, preform, fabric or fabric sheet. The fibrous element may comprise fibres, which may be long or short fibres. The fibres may be woven or knitted or braided or stitched. The fibres may be organised or of random alignment with one-another. The fibres may be weakly aggregated. The fibres may be synthetic, e.g. synthetic polymer, mineral or natural fibres. Optionally, the fibres may comprise any suitable combination of one or more of carbon, aramid, polymer, glass, graphite, acrylic, boron and/or any other suitable material. Where the fibres comprise glass fibres, they may comprise one or more of E-glass, ECR-glass, S-glass, R-glass and Te- glass, silica, quartz, D-glass and/or any other suitable material. The fibrous element may comprise fibreglass or woven rovings, sheet moulding compounds or chopped strand mats. Where the fibres comprise carbon fibres, they may comprise standard or intermediate or high modulus fibres and/or may comprise polyacrylonitrile or any other suitable material. For the avoidance of doubt the composite moulding may comprise any one or more features described above or that would be apparent to the skilled person from the above disclosure. According to another aspect of the present invention, there is provided a composite moulding insert, e.g. for use as a holding means in the method or composite moulding described above, the insert comprising a mounting feature or mount on a first side thereof, e.g. for cooperation with a mounting feature or mount in a mould, and a plurality of engaging features on a second side thereof, e.g. for engaging, in use, a fibrous element to inhibit movement thereof within a mould in which the insert is mounted.

For the avoidance of doubt the insert may comprise any one or more features of the holding means described above. According to another aspect of the present invention, there is provided a mould, e.g. for use in the method described above. The mould may comprise a cavity and may include a mounting feature or mount within or on or adjacent the cavity. The mounting feature or mount may be configured or adapted to cooperate with a mounting feature or mount of a holding means, for example an insert as described above, e.g. for holding, in use, a fibrous element within or on the cavity to inhibit movement thereof.

The mould may comprise first and second mould parts, each of which may comprise a moulding surface. The mould may comprise one or more further mould parts, at least one of which may comprise a moulding surface. In embodiments, one or more of the mould parts comprises a core. The cavity may be defined in part by each mould part. In embodiments, the mould comprises first and second mould halves, for example wherein the cavity is defined therebetween.

The cavity may be defined by or between respective moulding surfaces of each of the mould parts or halves. At least one of the moulding surfaces may comprise one or more features, such as one or more projections or depressions, which may define or delineate a desired finished component or one or more removable or frangible or breakable regions or portions.

The one or more features may define or delineate or be configured to form one or more edges that may delineate or define a desired finished component. The one or more features may define or delineate or be configured to form one or more lines of weakness, e.g. frangible lines, that may delineate or define a desired finished component or removable or frangible or breakable regions or portions. For the avoidance of doubt the mould may comprise any one or more features relevant to the invention, for example from the above disclosure, which would be apparent to the skilled person.

According to yet another aspect of the invention, there is provided a moulding system comprising a mould as described above and any one or more of a holding means or insert as described above, a fibrous element as described above, a matrix material as described above, a device or apparatus or robot for placing the fibrous element into the mould and any other features that would be apparent to the skilled person, such as a moulding apparatus or machine that may include a mould clamp and/or injection unit.

A yet further aspect of the invention provides a vehicle incorporating a composite moulding, e.g. as described above.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1 shows a schematic representation of part of a moulding system according to an embodiment of the invention illustrating the placement of an insert into the cavity of a mould;

Figure 2 is a schematic representation similar to that of Figure 1 illustrating the placement of a fabric sheet into the mould cavity; Figure 3 is a schematic representation similar to those of Figures 1 and 2 illustrating the closing of the mould over the insert and fabric sheet;

Figure 4 is a schematic representation similar to those of Figures 1 to 3 illustrating the insert and fabric sheet captivated within the mould cavity with the mould in a closed condition;

Figure 5 is a schematic representation similar to that of Figure 4 with the mould cavity filled with matrix material; Figure 6 shows a schematic representation of part of a composite moulding according to an embodiment of the invention following ejection from the mould of Figure 5;

Figure 7 shows a schematic representation of a composite moulding insert according to another embodiment of the invention;

Figure 8 shows a schematic representation of a composite moulding insert according to yet another embodiment of the invention;

Figure 9 shows images of further engaging feature embodiments;

Figure 10 shows an image of yet another engaging feature embodiment;

Figure 1 1 shows a schematic representation of a composite moulding insert according to a further embodiment of the invention; and

Figure 12 shows a vehicle according to an embodiment of the invention.

DETAILED DESCRIPTION A composite moulding system 1 in accordance with an embodiment of the present invention is described herein with reference to accompanying Figures 1 to 5.

With reference to Figures 1 to 5, the composite moulding system 1 includes a mould 2 within which is mounted a holding means in the form, in some embodiments, of an insert 3 and a fibrous element 4 that is held in place by the insert 3 for inhibiting movement of the fibrous element 4 with respect to the mould 2, such as during a moulding process. The insert 3 may also be used, in some embodiments, for supporting a composite structure there-from after removal from the mould 2, such as in a post-moulding operation, as will be explained.

The mould 2 includes first and second mould halves 20, 21 which are movable relative to one another by the clamping unit (not shown) of a resin transfer moulding machine (not shown). Each mould half 20, 21 includes respective moulding surfaces 22, 23, which together define a mould cavity 24. The moulding surfaces 22, 23 represent interior surfaces of the mould 2. The lowermost mould half 20 includes on its moulding surface 22 a plurality of insert mounting features in the form of mounting recesses or holes 25 in this embodiment, only one of which is shown in the Figures. The locations of these holes 25 correspond to jig fixture locations on a jig (not shown) used for post-moulding operations. Each mounting recess 25 is in the form of a cylindrical blind hole with a lead-in taper 25a. The lowermost moulding surface 22 in this embodiment is recessed into the lowermost mould half 20 and includes a shallow projecting wall 26 extending about, but spaced inwardly from, its periphery to delineate a desired finished component.

The uppermost mould half 21 includes on its moulding surface 23 a plurality of tapered depressions 27 at locations corresponding to the mounting holes 25 of the lower mould half 20 such that when the mould 2 is closed, the holes 25 and depressions 27 are on opposite sides of the cavity 24. The lowermost mould half 20 is fixed in this embodiment, while the uppermost mould half 21 is movable by the clamping unit (not shown) between open and closed positions or conditions.

The inserts 3, only one of which is shown in the Figures, each include a body 30 with a locating means 31 which, in this embodiment, is a mounting feature in the form of a pin 31 on a first side of the body 30 and engaging means which may be a plurality of engaging features in the form of spikes 32 on a second side thereof in this embodiment. The locating means 31 is provided for engaging a corresponding feature 25 of the mould 2 to inhibit relative movement the insert 3 with respect to the mould 2. When the locating means 31 is engaged with said corresponding feature, such as the hole 25, the engaging means 32, such as the spikes 32, extend perpendicular to the interior surface of the mould 2. In other words, the spikes 32 are directed toward an interior of the mould 2. The insert 3 is a unitary structure and is formed of a nylon material in this embodiment. The body 30 is in the form of a flat disc that is circular in plan and tapers from a larger base surface 33 to a smaller top surface 34. The pin 31 is cylindrical and extends downwardly from the centre of the base surface 33. In this way the locating means, such as the pin 31 , extends in an opposed direction from the engaging means such as the spikes 32. The pin 31 and spikes may be arranged at opposing sides of the body 30. The pin 31 is sized and dimensioned for close fitting with the mounting hole 25 of the mould 2 to ensure that matrix resin is unable to infiltrate the mounting hole 25 during the moulding process. The spikes 32 are conical and extend upwardly from and are distributed evenly across the top surface 34 of the body 30. In this embodiment, each spike 32 has a sharp apex for penetrating into the fibrous element 4, which is a dry woven carbon fibre sheet 40 in this embodiment. As illustrated by Figures 1 to 5, the system described above is used to mould a composite structure by first opening the mould 2 by moving the uppermost mould half 21 to an open position or condition to expose the moulding surface 22 of the lowermost mould half 20. As illustrated by Figure 1 , the plurality of inserts 3 are then placed in the cavity 24 by inserting the mounting pin 31 of each insert 3 into a respective one of the mounting holes 25, which may be done automatically using a robotic arm (not shown). The placing of the inserts 3 into the cavity 24 is such that the base surface 33 of each insert 3 is flush and in contact with the portion of the moulding surface 22 surrounding the mounting hole 25 with the spikes 32 exposed and extending into the cavity 24. As illustrated by Figure 2, the carbon fibre sheet 40 is then positioned in the cavity 24 such that its periphery is inside the projecting wall 26 and forced down onto the moulding surface 22 such that the spikes 32 penetrate into the sheet 40. The mould 2 is then closed by moving the uppermost mould half 21 to a closed position or condition as illustrated by Figure 3. With the mould 2 in a closed condition as shown in Figure 4, a flowable matrix resin 5, which is an epoxy resin in this embodiment, is introduced into the mould cavity 24 under pressure in order to surround or immerse or impregnate the fabric sheet 40 and surround the spikes 32, the top surface 34 and the tapered sides of the insert 3. As the matrix resin 5 is introduced into the mould cavity 24, the engagement between the spikes 32 of the inserts 3 and the fabric sheet 40 inhibit movement of the sheet 40. The matrix resin 5 is then allowed to cure, embedding both the fabric sheet 40 and the inserts 3 within the composite structure 6 and forming lines of weakness 60 corresponding to the projecting wall 26. The mould 2 is then opened to expose the composite structure 6. The composite structure 6 may then be removed from the mould 2. The composite structure may be removed by holding or gripping the locating means, such as pin 31 .

As shown more clearly in Figure 6, the composite structure 6 is a unitary structure incorporating the fibre sheet 40, the matrix material 5 and the inserts 3. The locating means, such as the pins 31 , may be used to support the formed composite structure. The inserts 3 are included at predetermined locations that correspond to locations of supporting means for supporting one or more composite structures thereon, such as jig fixture locations on a jig (not shown) used for post-moulding operations, which include a finishing operation in this embodiment. More specifically, the composite structure 6 is ejected from the mould cavity 24 onto a robotic end of arm tool (not shown) and transferred to a jig (not shown) with fixtures that locate and grip the pins 31 of the inserts 3 and secure the composite structure 6 in a predetermined orientation. One or more composite structures 6 may be supported in this way to allow for assembly of a product or vehicle from the composite structures 6.

A peripheral region 61 of the composite structure 6 as delineated by the lines of weakness 60 is highlighted by cross-hatching in Figures 5 and 6. In order to produce the finished product, the peripheral region 61 of the composite structure 6 is removed by severing it along the lines of weakness 60. This can be carried out with the composite structure 6 mounted to the jig (not shown) as explained above, thereby to produce a finished component with minimal stages and very little waste. Alternatively, the severing of the peripheral region may be carried out manually by an operator.

Following the demoulding of the composite structure 6, and optionally in parallel with the post-moulding operations, a further set of inserts 3 may be placed in the mould with the process starting once again.

Turning now to Figure 7, there is shown an insert 103 according to another embodiment. The insert 103 according to this embodiment differs from the insert 3 described above in that the mounting pin 31 is replaced with mounting holes 131 each configured to receive a respective pin extending from the moulding surface of a mould (not shown). The spikes 132 according to this embodiment are also in the form of outwardly skewed pyramids for improved gripping. Reference is now made to Figure 8, which shows an insert 203 according to yet another embodiment. The insert 203 according to this embodiment differs from the first embodiment of insert 3 in that the spikes 32 are replaced with hook elements 232 in this embodiment. It will be appreciated by the skilled person that the hook elements 232 of the insert 203 according to this embodiment are configured to engage the fibres of the fabric sheet 40 in a similar manner to so-called hook and loop fasteners. It is also envisaged that the engaging features may be in the form of natural barbed spikes or of nanotube hooks in place of the spikes 32, 132 of the inserts 3, 103 according to the two preceding embodiments.

Figure 9 shows an insert 303 and cooperating mould mounting feature 325 according to another embodiment, which is similar to previous embodiments, wherein like references depict like features that will not be described further herein. The insert 303 according to this embodiment differs from the insert 3 of Figures 1 to 6 in that the pin 31 is replaced with a recess or blind hole 331 with a lead-in taper 331 a. Similarly, the mould surface 320 in this embodiment includes a corresponding mounting pin 325 that the insert 303 is mounted onto such that the mounting pin 325 is received within the blind hole 331 . A moulded composite structure 306 according to an embodiment of the invention incorporating the insert 303 of Figure 9 is shown in Figure 10, wherein the blind hole 331 of the insert 303 provides one of a plurality of jig fixture gripping features used for post-moulding operations.

Figure 1 1 shows a moulded composite structure 406 incorporating an insert 403 according to yet another embodiment similar to previous embodiments, wherein like references depict like features that will not be described further herein. The insert 403 according to this embodiment differs from the insert 3 of Figures 1 to 6 in that the pin 431 of the insert 403 of this embodiment includes a head 431 a at its free end joined to the remainder of the pin 431 by an undersized neck portion 431 b. Whilst the pin 431 in this embodiment may be used as one of a plurality of jig fixture gripping features used for post-moulding operations, this design also enables the additional function of a means of mounting and engaging the composite structure 406 to a vehicle (not shown) or vehicle component 436. More specifically and as illustrated in Figure 1 1 , the neck portion 431 b is received within and is engaged by a circumferential lip 435a of a snap fitment 435 incorporated on a vehicle component 436. Thus, the insert 403 serves three functions, namely i) a retaining means for the carbon fibre sheet 40 during moulding, ii) a jig fixture gripping feature for post mould operations and iii) a fixing feature for securing the composite structure 406 to the vehicle (not shown) or vehicle component 436.

Figure 12 shows a vehicle 10 incorporating body panels 1 1 , 12 formed as moulded composite structures 6, 106, 206, 306 or 406 as described above. Whilst the two body panels 1 1 , 12 indicated are a door outer 1 1 and rear wing and door outer 12, it will be appreciated that embodiments of the invention are not limited in this respect and that any body panels may be used.

It will be appreciated that various changes and modifications can be made to the embodiments described herein without departing from the scope of the present application.

For example, the fibrous element 4 need not be a fabric sheet 40 and need not comprise carbon fibres. Indeed, both the fibrous element 4 and the matrix material 5 may comprise any suitable construction or material, for example any one or more of those listed above in the summary of invention. Similarly, the insert 3 may be formed of a different material, for example a different polymer material or a metal material as explained above in the summary of invention. The skilled person would also appreciate that the insert 3 may also be replaced with any suitable holding means. The process need not comprise a resin transfer moulding process and need not involve the introduction of matrix material 5 per se.

It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.

Claims

1 . A method of moulding a composite structure, the method comprising: locating a holding means about an interior surface of a mould, the holding means comprising engaging means, and locating means for engaging a corresponding feature of the mould to inhibit relative movement the holding means with respect to the mould, wherein the engaging means extends perpendicular to said interior surface of the mould when the locating means is engaged with said corresponding feature; then placing a fibrous element in relation to the mould; then forcing the fibrous element down onto the interior surface such that the engaging means penetrates a surface of the fibrous element facing the interior surface of the mould and inhibits movement thereof; and then forming in the mould a composite structure including the fibrous element, a polymeric matrix material and the holding means.

2. The method of claim 1 , comprising: removing the composite structure from the mould; and supporting the composite structure by the locating means;

3. The method of claim 2, wherein supporting the composite structure comprises engaging a supporting means with the locating means.

4. The method of claim 1 , 2 or 3, wherein the locating means extends in a generally opposed direction to the engaging means.

5. The method of any preceding claim, wherein the locating means protrudes from a surface of the composite structure.

6. The method according to any preceding claim, wherein the composite structure is an integral composite structure in which the holding means is at least partially bonded within the matrix material.

7. The method according to any preceding claim, wherein the penetrating the fibrous element with the engaging means comprises urging one or more engaging means to extend at least partly into the fibrous element.

8. The method according to any preceding claim, wherein the placing the fibrous element comprises closing the mould such that the engaging means penetrates the fibrous element.

9. The method according to any preceding claim, wherein the locating the holding means comprises mounting one or more inserts into a cavity of the mould.

10. The method according to claim 9, wherein locating the holding means comprises inserting a male locating means at least partially into a female corresponding feature of the mould.

1 1 . The method according to any preceding claim, comprising mounting a plurality of holding means at predetermined locations about the mould selected such that the locating means provide securement features for post-moulding operations of the composite part.

12. The method according to any preceding claim, wherein forming in the mould the composite structure comprises introducing into the mould the matrix material to form the composite structure, wherein the penetration of the fibrous material by the engaging material resists a force of the matrix material being introduced.

13. The method according to any preceding claim, wherein forming in the mould the composite structure comprises forming one or more lines of weakness which delineate one or more removable regions or portions in the composite structure.

14. A composite moulding, comprising: a composite structure including a fibrous element, a polymeric matrix material and one or more holding means each having one or more engaging means extending perpendicular to a surface of the composite structure and at least partially embedded in the fibrous element from a first side of the fibrous element and moulded into the composite structure, and a mounting means at the first side of the fibrous material for supporting the composite moulding there-from.

15. The composite moulding according to claim 14, wherein the or each holding means comprises a plurality of engaging means at least partially embedded in the fibrous element.

16. The composite moulding according to claim 14 or 15, wherein each engaging means comprises a male projection penetrating the fibrous element from the first side.

17. The composite moulding according to any one of claims 14 to 16, wherein the mounting means is arranged for supporting the composite moulding during post- moulding operations.

18. The composite moulding according to claim 16 or 17, wherein the mounting means comprises one of a male feature and a female feature.

19. A composite moulding insert comprising a body with a mounting feature on one side of the body for cooperation with corresponding mounting feature about an interior surface of a mould, and a plurality of engaging features on a second side of the body for penetrating into a fibrous element to inhibit movement of the fibrous element in relation to the insert.

20. A composite moulding insert according to claim 19, wherein each engaging feature; optionally each engaging feature comprises one of a pin, post, spike or hook element.

21 . A moulding system comprising at least one insert according to claim 19 to 20 and a mould with a cavity having at least one mounting feature for cooperation with the at least one insert.

22. A vehicle comprising a composite moulding according to any one of claims 14 to 18.

23. A method of moulding a composite structure substantially as described herein and/or as illustrated in the accompanying drawings.

24. A composite moulding substantially as described herein and/or as illustrated in the accompanying drawings.

25. A composite moulding insert substantially as described herein and/or as illustrated in the accompanying drawings.

26. A vehicle substantially as described herein and/or as illustrated in the accompanying drawings.