Systems and methods for manufacturing structural materials

Patent metadata

Field	Value
Publication number	US-10022909-B2
Application number	US-201514592066-A
Country	US
Kind code	B2
Filing date	Jan 8, 2015
Priority date	Jan 8, 2015
Publication date	Jul 17, 2018
Grant date	Jul 17, 2018

Abstract

In accordance with these and other embodiments of the present disclosure, a method for forming a structural member may include providing a sheet of structural material and molding a chassis attachment frame comprising sheet molding compound to the structural material.

First claim

What is claimed is:

1. A method for forming a structural member, comprising:
providing:
a sheet of structural material between a top mold and a bottom mold, wherein a substantially rectangular perimeter of the sheet of structural material includes:
a first edge, comprising a first side of the substantially rectangular boundary; and
a second edge, comprising a second side of the substantially rectangular boundary, wherein the second side is substantially perpendicular to the first side;
a top release film between the top mold and the sheet of structural material;
a bottom release film between the bottom mold and the sheet of structural material; and
an in-mold decoration film between the bottom release film and a bottom surface of the sheet of structural material; and
compression molding the in-mold decoration film to the bottom surface of the sheet of structural material, wherein the in-mold decoration film extends to the first edge and includes a decoration film edge substantially parallel to the second edge of the sheet of structural material, wherein the decoration film edge defines a border of un-decorated structural material between the decoration film edge and the second edge.

2. The method of claim 1 , further comprising molding a chassis attachment frame comprising sheet molding compound to the sheet of structural material.

3. The method of claim 2 , further comprising forming attachment features to the chassis attachment frame after molding of the chassis attachment frame to the sheet of structural material.

4. The method of claim 3 , wherein forming the attachment features comprises forming the attachment features using computer numerical control.

5. The method of claim 1 , wherein the sheet of structural material comprises a fiber-reinforced polymer.

6. The method of claim 1 , wherein the sheet of structural material comprises a thermoset polymer.

7. The method of claim 1 , wherein the sheet of structural material comprises a layered composite structural material.

8. The method of claim 1 , wherein an upper side of the in-mold decoration film comprises an adhesive for bonding to the lower surface of the sheet of structural material.

9. The method of claim 1 , wherein the sheet of structural material includes a rounded second sidewall defining a convex curve terminating at the second edge.

10. The method of claim 9 , wherein the sheet of structural material includes a rounded first sidewall, substantially perpendicular to the rounded second sidewall, wherein the rounded first sidewall defines a convex curve terminating at the first edge.

11. The method of claim 9 , wherein the rounded second sidewall lies entirely within the border of un-decorated structural material between the decoration film edge and the second edge.

12. The method of claim 11 , wherein the sheet of structural material includes a rounded first sidewall, substantially perpendicular to the rounded second sidewall, wherein the rounded first sidewall defines a convex curve terminating at the first edge.

13. The method of claim 1 , wherein the sheet of structural material includes a rounded first sidewall defining a convex curve terminating at the first edge.

Assignees

• Dell Products Lp

Inventors

• Abbatiello Nicholas D
• Sim Chuan Beng
• Tian xin hua

Classifications

• B29L2009/00

  Layered products · CPC title

• B29C37/0025

  Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing (moulding on preformed layers as inserts B29C70/68; applying fluent material to surfaces in general B05) · CPC title

• B29C43/184

  shaped by the compression of the material during moulding · CPC title

• B29C2037/0042

  the coating being applied in solid sheet form, e.g. as meltable sheet · CPC title

• B29K2101/10

  Thermosetting resins · CPC title