Thermoplastic injection molded element with integral thermoplastic positioning system for reinforced composite structures

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 an 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 top surface of said composite is attached to an ITPS which comprises a first set of longitudinal structures joined in a perpendicular configuration by crossbar structures disposed inwardly of respective ends of the longitudinal structures, and wherein the bottom surface of said composite is attached to an ITPS which comprises a second set of longitudinal structures joined in a perpendicular configuration by crossbar structures disposed inwardly of respective ends of the longitudinal structures, and wherein the first set of longitudinal structures is above said second set of longitudinal structures;

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, and wherein the plurality of apertures are perpendicular to said longitudinal structures;

the ITPS comprises a plurality of penetration elements that extend through the apertures in the composite and a plurality of spires extending distally to a 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.

2. The element of claim 1 wherein the composite is multi-layered.

3. The element of claim 1 further comprising an aperture through the element, wherein the composite and ITPS are precisely positioned about the aperture to provide structural support about the aperture to minimize concerns regarding weak spots about the aperture.

4. An element comprising:

a composite comprising an array of reinforcing fibers disposed in a thermoplastic material;

an ITPS configured to position the composite within the element during formation; and an encapsulating thermoplastic forming an exterior geometry of the element, the ITPS comprising a first set of longitudinal structures and a second set of longitudinal structures each joined in a perpendicular configuration by crossbar structures disposed inwardly of respective ends of the longitudinal structures and wherein the first set of longitudinal structures is above said second set of longitudinal structures;

the composite comprises a plurality of apertures therethrough; and

the ITPS comprises a plurality of penetration elements that extend through the apertures in the composite and a plurality of spires extending distally to a final geometric limit of the element.

5. The element of claim 4 wherein the composite comprises an outer surface and the ITPS is located on and affixed to at least a portion of the outer surface of the composite to form a composite-ITPS assembly.

6. The element of claim 5 wherein the encapsulating thermoplastic is located about and affixed to the composite-ITPS assembly.

7. The element of claim 4 wherein the ITPS and the encapsulating thermoplastic each comprise a thermoplastic material, and the composite, ITPS, and encapsulating thermoplastic each comprise the same thermoplastic material.

8. The element of claim 7 wherein the thermoplastic material comprises one of the following: polycarbonate, polyphenylene sulfide, polyetherimide, and combinations thereof.

9. The element of claim 6 wherein the composite, ITPS, and encapsulating thermoplastic are affixed via chemical fusing.

10. The element of claim 5 wherein the composite-ITPS assembly provides the minimum required structural support for the element.

11. The element of claim 4 wherein the ITPS comprises a plurality of spires, and the spires each comprise a distal end, wherein the distal ends of the plurality of spires extend to the final geometric limit of the element.

12. The element of claim 11 wherein the plurality of spires each narrow as they extend distally.

13. The element of claim 4 wherein the ITPS comprises a plurality of spires projecting distally to the final geometric limit of the element; and wherein the plurality of spires of the ITPS are aligned with the plurality of apertures in the composite.

14. The element of claim 6 wherein the composite-ITPS assembly is formed by injection molding, and the encapsulating thermoplastic is formed about the composite-ITPS assembly using injection molding.

15. The element of claim 4 wherein the composite is multi-layered.

16. The element of claim 15 wherein the multi-layered composite further comprises a spacer located between a portion of the two layers of composite.

17. The element of claim 16 wherein the ITPS comprises a plurality of spires projecting distally to the final geometric limit of the element; and wherein the spacer comprises a plurality of projections aligned with corresponding spires on an assembly of the composite and the ITPS, the spacer comprises a thermoplastic material, and the thermoplastic material of the spacer is the same as that of the composite.