Structural foam molding method using continuous fiber composites, and parts formed therefrom

1. A method for forming a fiber-composite part, comprising:

determining, based on expected load conditions and part requirements, a desired fiber-alignment and positioning of fibers within the fiber-composite part;

forming an assemblage comprising a plurality of fiber-bundle-based preforms, wherein the plurality of fiber-bundle-based preforms are arranged to achieve the desired fiber-alignment and positioning of fibers when the assemblage is placed in a mold cavity;

placing the assemblage of the plurality of fiber-bundle-based preforms in the mold cavity;

forming a melt flow, wherein the melt flow includes:

a) melted first resin and loose fiber, or

b) melted first resin without fiber;

forming a mixture by adding a foaming agent to the melt flow; and

delivering the mixture of melt flow and foaming agent to the mold cavity, wherein pressure is lower in the mold cavity than under conditions in which the foaming agent is added to the melt flow, thereby causing the foaming agent to foam in the melt flow.

2. The method of claim 1 , wherein the assemblage is a preform charge.

3. The method of claim 1 , wherein forming the melt flow comprises adding the first resin, or fiber and the first resin to an auger screw that heats the first resin until the first resin melts.

4. The method of claim 1 , wherein delivering the mixture to the mold cavity comprises delivering the melt flow and foaming agent to a region defined within the assemblage of the plurality of fiber-bundle-based preforms.

5. The method of claim 2 , wherein placing the assemblage comprises registering the preform charge with a feature of the mold cavity.

6. The method of claim 1 , comprising flowing a portion of the assemblage to an internal location in the mold cavity via the melt flow, such that alignment and positioning of some fibers in the fiber-composite part is dictated, at least in part, by fluid dynamics of the melt flow.

7. The method of claim 1 , wherein placing the assemblage comprises positioning a portion of the assemblage proximal to a surface region of the mold cavity.

8. The method of claim 7 , wherein the assemblage has a shape that conforms to contours of walls of the mold cavity.

9. The method of claim 1 , wherein the melt flow includes the melted first resin and the loose fiber.

10. The method of claim 1 , wherein the plurality of fiber-bundle-based preforms in the assemblage comprise second resin, and wherein delivering the mixture of melt flow and foaming agent to the mold cavity comprises melting a portion of the second resin in at least some of the plurality of fiber-bundle-based preforms.

11. The method of claim 10 , comprising physically intermingling a portion of the first resin from the melt flow and the portion of the second resin to form a coherent polymer matrix in the fiber-composite part.

12. The method of claim 10 , comprising forming four regions in the fiber-composite part, including:

(i) aligned and continuous fiber region formed from the assemblage of plurality of fiber-bundle-based preforms;

(ii) porous structural foam region formed as the foaming agent foams in the melt flow;

(iii) skin layer formed proximal to the porous structural foam region; and

(iv) interfacial co-melting regions comprising the first resin and the second resin, wherein the interfacial co-melting regions are formed between (a) the aligned and continuous fiber region and the porous structural foam region, and (b) the skin layer and the aligned and continuous fiber region.

13. The method of claim 1 , wherein placing an assemblage of the plurality of fiber-bundle-based preforms comprises structuring the assemblage so that some, but not all of a plurality of fibers in the fiber-bundle-based preforms remain at a location at which the plurality of fiber-bundle-based preforms were placed in the mold cavity, the fibers not remaining at the location flowing with the melt flow.

14. The method of claim 13 , wherein structuring the assemblage comprises forming cuts partially through some of the plurality of fiber-bundle-based preforms in the assemblage at one or more specific locations.

15. The method of claim 14 , wherein the plurality of fiber-bundle-based preforms having the cuts are situated in the mold cavity proximal to features in which fibers released from the plurality of fiber-bundle-based preforms are intended to flow.

16. A method for forming a fiber-composite part, comprising:

placing an assemblage of fiber-bundle-based preforms in a mold cavity, each fiber-bundle-based preform comprising a plurality of co-aligned fibers impregnated with a first thermoplastic resin;

forming a melt flow, wherein the melt flow includes:

a) melted second thermoplastic resin and loose fiber having a length that is less than about 25 millimeters, or

b) melted second thermoplastic resin without fiber;

forming a mixture by adding a foaming agent to the melt flow;

delivering the mixture of melt flow and foaming agent to the mold cavity, wherein pressure is lower in the mold cavity than under the conditions in which the foaming agent is added to the melt flow, thereby causing the foaming agent to foam in the melt flow;

melting at least some of the first thermoplastic resin, wherein a portion of the melted first thermoplastic resin and a portion of the melted second thermoplastic resin intermingle to form a coherent polymer matrix, linking compositionally disparate regions of the fiber-composite part to one another.

17. The method of claim 16 , wherein the melt flow includes the melted second thermoplastic resin and the loose fiber.