Method for forming a sheet, fiber and resin composite

1. A method of forming a finished composite part comprising:

providing a mold, the mold defining a cavity with a shape-defining surface;

providing an in-mold paint sheet having a thickness of greater than about one millimeter, the in-mold paint sheet having a bonding side and a finish side;

installing the in-mold paint sheet in the cavity of the mold such that the finish side of the in-mold paint sheet is positioned adjacent to the shape-defining surface of the mold; introducing a mixture of a resin and a plurality of reinforcing fibers into the cavity of the mold such that the resin and fiber mixture contacts the bonding side of the in-mold paint sheet; said resin and fiber mixture being formed by impelling uncoated reinforcing fiber towards the mold cavity and causing a resin to substantially completely wet substantially all of said uncoated reinforcing fibers prior to the introduction of the fiber and resin mixture into the mold cavity;

enclosing the in-mold paint sheet and resin and fiber mixture in the mold; and

cooling the in mold paint sheet while at least some of the resin is curing; wherein the resin and fiber mixture is cured and bonded to the in-mold paint sheet to form a part having the finish side of the in-mold paint sheet as a finished Class A surface of the part.

2. The method of claim 1 , wherein the part is formed as a one-piece assembly of uneven thickness having a Class A surface, wherein at least one three dimensional reinforcing structure integral with the part such that the appearance of the Class A surface is undisturbed by the reinforcing structure.

3. The method of claim 1 , wherein the mold has a shear edge comprising:

an upper surface;

a lower surface spaced from the upper surface, defining an interior portion between the lower surface and the upper surface where the part is to be formed, and an exterior portion between the lower and upper surface configured to remain free of the paint sheet and the resin and fiber mixture during molding,

wherein an interior portion is configured to contain the paint sheet and the mixture of resin and fiber and an exterior portion of the mold shear edge is configured to operate with a spacing between the upper surface and the lower surface to allow evolved gasses to escape and allow the paint sheet to protrude from the mold.

4. The method of claim 1 , wherein the resin is a thermoset polyurethane resin, and the thermoset polyurethane resin expands as it cures.

5. The method of claim 1 , wherein the reinforcing fiber is a carbon fiber.

6. The method of claim 5 , wherein the carbon fibers are about 10-50 millimeters in length.

7. The method of claim 5 , wherein the carbon fibers are about 20-30 millimeters in length.

8. The method of claim 5 , wherein the carbon fibers are about 25 millimeters in length.

9. The method of claim 1 , wherein the paint sheet is maintained at a temperature of about 70° F. to 150° F.

10. The method of claim 1 , wherein the paint sheet is at least one and a half millimeters thick.

11. The method of claim 1 , wherein a reinforcing member is introduced into the mold and the reinforcing member is incorporated into the part to provide a one piece assembly of uneven thickness having a Class A surface, such that the appearance of the Class A surface is undisturbed by the reinforcing member, by the curing of the resin.

12. The method of claim 1 , wherein installing the paint sheet comprises pre-forming the paint sheet using a billow form/male form thermoforming process.

13. A method of forming a finished composite part comprising:

providing a mold, the mold defining a cavity with a shape-defining surface, the mold having a shear edge, the shear edge having an upper surface, having a lower surface spaced from the upper surface, defining an interior portion between the lower surface and the upper surface where the part is to be formed, and having an exterior portion between the lower and upper surface configured to remain free of the paint sheet and the resin and fiber mixture during molding, wherein an interior portion is configured to contain the paint sheet and the mixture of resin and fiber and an exterior portion of the mold shear edge is configured to operate with a spacing between the upper surface and the lower surface to allow evolved gasses to escape;

providing an in-mold paint sheet having a thickness of greater than about one millimeter, the in-mold paint sheet having a bonding side and a finish side;

installing the in-mold paint sheet in the cavity of the mold by preforming the paint sheet to the mold so that that the finish side of the in-mold paint sheet is conformed adjacent to the shape-defining surface of the mold;

introducing a mixture of a polyurethane thermoset resin and a plurality of carbon reinforcing fibers with a length of about 25 millimeters by impelling uncoated carbon reinforcing fiber towards the mold cavity so that the resin substantially completely wets substantially all of the reinforcing fibers prior to the introduction of the fiber and resin mixture into the cavity and so that the resin and fiber mixture contacts the bonding side of the in-mold paint sheet;

enclosing the in-mold paint sheet and resin and fiber mixture in the mold;

heating the resin and fiber mixture wherein the resin expands in the mold as it cures; and

cooling the paint sheet to a temperature of about 70° F. to 150° F., wherein the resin and fiber mixture is cured and bonded to the in-mold paint sheet in a one-shot process to form a one piece assembly having the finish side of the in-mold paint sheet as a finished Class A surface of the part.