US20170368767A1

US20170368767A1 - Composite molding techniques

Info

Publication number: US20170368767A1
Application number: US15/699,132
Authority: US
Inventors: Kelly Fitchett; Wendy Eldred
Original assignee: Jaguar Land Rover Ltd
Current assignee: Jaguar Land Rover Ltd
Priority date: 2012-03-16
Filing date: 2017-09-08
Publication date: 2017-12-28
Also published as: EP2825372A1; GB2502413B; WO2013135911A1; US20150064410A1; US9757907B2; JP2015513489A; GB201204690D0; GB2502413A; GB201304918D0; EP2825372B1

Abstract

A molded component and method of molding such a component having one or more features. At least one fibrous substrate is located in a mold. A matrix-forming material is also provided in the mold. Heat is applied to melt the matrix-forming material to form a matrix and to integrally mold the one or more features.

Description

The present invention relates to a composite component and a method of molding a composite component.

BACKGROUND OF THE INVENTION

It is known to use mold composite components comprising a fibrous substrate and a matrix. The fibrous substrate can comprise synthetic or natural fibers and the matrix can be a plastics material. These techniques are well developed for forming composite panels. Additional fixtures, such as brackets and support members, can be bonded to the composite panel. This bonding process can be performed by locating pre-formed fixtures in the mold when the composite panel is molded; or they can be bonded in place in a subsequent process. The bonding of fixtures to the composite component is undesirable since it typically adds an additional process step, either before or after the component has been molded.
The present invention, at least in certain embodiments, sets out to ameliorate or overcome the limitations associated with prior art molding techniques.

SUMMARY OF THE INVENTION

Aspects of the present invention relate to a composite component and a method of molding a composite component as defined in the appended claims.
In a further aspect, the present invention relates to a method of molding a component having at least one feature, the method comprising:

- locating at least one fibrous substrate in a mold; and
- providing a matrix-forming material in the mold;
- wherein the method further comprises applying heat to melt the matrix-forming material to form a matrix and to integrally mold said at least one feature.

The matrix-forming material melts and the molten material can flow within the mold. The molten material can penetrate each fibrous substrate to form the matrix. Moreover, the molten material can flow into apertures, recesses or detents formed in the mold to integrally mold said at least one feature. The at least one integrally molded feature is formed from the same source material as the matrix. The matrix and the at least one feature are thereby unified. It is not necessary for the fibrous substrate to extend into said apertures in the mold. Consequently, the at least one feature can be formed partially or substantially completely from the matrix-forming material.
The at least one feature can be defined on a surface of the component. The at least one feature can be a projection or protuberance. The at least one feature can be a bracket, a spigot, a flange, a rib or the like extending outwardly from a surface of the component. The method according to the present invention enables integral features to be formed in a single process cycle. The resulting composite component can comprise at least one feature molded integrally from the matrix-forming material.
The at least one fibrous substrate can comprise a single continuous fiber or a plurality of fibers.
The method can comprise locating a plurality of fibrous substrates in the mold. A second fibrous substrate can be located in the mold. The fibrous substrates can partially or completely overlap each other. The fibrous substrates can each comprise a plurality of fibers. The fibers in the fibrous substrates can be aligned with each other or can be angularly offset from each other. The matrix-forming material can be provided in the mold between the fibrous substrates. The material can thereby form a flowable core. When the matrix-forming material is melted, the molten material can flow outwardly through the fibrous substrates. The method can comprise forming alternate layers of fibrous substrate and matrix-forming material in the mold.
The matrix-forming material can be positioned adjacent the at least one fibrous substrate in the mold.
The at least one fibrous substrate can comprise one or more reinforcing fibers. The molten material can thereby penetrate between the fibers in the substrate to form the matrix. The fibers can be short or long fibers. The fibers could be synthetic, for example glass or carbon fibers. Alternatively, the fibers can be natural fibers, such as cotton, wool, flax, hemp, bamboo, jute, sisal, kenaf etc. A combination of different fibers, for example natural fibers and synthetic fibers, could be used to provide different material properties. The at least one fibrous substrate can comprise a continuous fiber, for example formed into a layer or wound onto a mandrel.
The matrix-forming material can be a plastics material. For example, the matrix-forming material can be a thermoset or thermoplastic material. The matrix-forming material can be a polymer, such as polyamide (nylon), polyvinylchloride (PVC), polystyrene, polyethylene, polypropylene and polyacrylonitrile. The matrix-forming material can also be a copolymer, such as acrylonitrile butadiene styrene (ABS). The matrix-forming material can be a resin or adhesive such as epoxy, melamine, or silicone.
The fibers in at least one fibrous substrate can be substantially aligned with each other. For example, the fibers could be substantially parallel to each other. The fibers can be formed into a thread or yarn. The at least one fibrous substrate can be formed by weaving said thread or yarn. The fibers could be spun into the thread or yarn. The fibers within the thread or yarn can be arranged substantially parallel to each other, for example using a wrap spun yarn.
The at least one fibrous substrate can comprise threads or yarns arranged substantially parallel to each other. The at least one fibrous substrate could be elongate, for example in the form of a strip. Several strips could be interlaced to form the at least one fibrous substrate.
The at least one fibrous substrate could consist of reinforcing fibers. Alternatively, the at least one fibrous substrate can further comprise matrix-forming fibers. The matrix-forming fibers can be made from the same material as the matrix-forming material introduced into the mold or a different (compatible) material. The matrix-forming fibers can also melt when heat is applied. When heated, the matrix-forming fibers and the matrix-forming material can coalesce.
The at least one fibrous substrate can be provided as a flexible sheet, for example made of woven material. Alternatively, the at least one fibrous substrate can be provided as a pre-consolidated sheet. Typically, pressure and heat can be applied to form the pre-consolidated fibrous sheet. A matrix can be provided for retaining the fibers in said pre-consolidated fibrous sheet. The matrix can be formed by matrix-forming fibers interwoven with the reinforcing fibers. The material forming the matrix can be re-melted upon application of heat, thereby allowing the matrix-forming material introduced into the mold to penetrate between the fibers in the at least one fibrous substrate.
The at least one fibrous substrate and the matrix-forming material can be introduced into the mold as separate, discrete layers. The matrix-forming material can be provided in the mold in a pliable or plastic form. For example, the matrix-forming material could have a semisolid composition (i.e. having a viscosity and rigidity intermediate between that of a liquid and a solid). The matrix-forming material could be pre-heated before it is introduced into the mold to provide the desired properties. Pre-heating the matrix-forming material can reduce its viscosity and rigidity and improve its flow characteristics when it is provided in the mold. Similarly, the at least one fibrous substrate could be pre-heated.
Alternatively, the matrix-forming material can be provided in the mold in a solid form. The matrix-forming material could be provided in a granular or powder form. Alternatively, the matrix-forming material can be provided in the form of at least one sheet or ply. The ply can be positioned in the mold adjacent to the fibrous substrate. The matrix-forming material can comprise a filler or bulking material, such as wood fibers. More than one ply can be provided in sections of the mold requiring additional material. The matrix-forming material could be formed into a shape for supporting the at least one fibrous substrate when it is located in the mold.
The mold can comprise first and second mold parts. The at least one fibrous substrate could be cut to size and then located in the mold. Alternatively, the at least one fibrous substrate can be cut to size in the mold. The first and second mold parts can have shearing edges for cutting the at least one fibrous substrate.
As outlined above, the molten matrix-forming material can integrally form at least one feature on the component. The at least one feature can be formed contemporaneously with the formation of the matrix in a single process cycle. Apertures and/or recesses can be formed in said first mold part and/or said second mold part to form one or more features in the component. At least one sprue can be in fluid communication with said one or more features. The sprue can allow molten matrix-forming material to exit the mold during the method. The method can comprise providing sufficient matrix-forming material in the mold to form the matrix and said at least one feature.
The method can comprise applying pressure to compress the material within the mold. The application of pressure can promote the flow of the molten matrix-forming material within said mold. For example, the application of pressure can force the molten matrix-forming material between the fibers and/or into recesses formed in the mold.
It will be appreciated that the method according to the present invention could be employed in a variety of molding techniques, including: vacuum molding or compression molding.
In a further aspect, the present invention relates to a method of molding a component, the method comprising:

- locating at least one fibrous substrate in a mold; and
- providing a matrix-forming material in the mold, the matrix-forming material being provided coincident with at least a portion of the at least one fibrous substrate;
- wherein the method further comprises applying heat to melt the matrix-forming material to form a matrix around the at least one fibrous substrate. The matrix can penetrate the at least one fibrous substrate surrounding the fiber(s) in the fibrous substrate.

The matrix-forming material can be provided in the mold in a form which is either solid or semisolid (i.e. having a viscosity and rigidity intermediate between that of a liquid and a solid). The matrix-forming material can, for example, be heated to reduce its viscosity and rigidity. The matrix-forming material can be pre-heated to improve its flow characteristics when it is provided in the mold.
This technique is suitable for forming components having at least one integral feature, such as a projection or protuberance. The features are formed from the matrix-forming material provided in the mold. The matrix-forming material forms a matrix around the fiber(s) in said the at least one substrate and also forms said at least one integral feature. The matrix and said at least one integral feature are molded concurrently. The matrix-forming material can be provided in the mold in a layer or ply. The layer or ply can be rigid or semi-rigid. The at least one fibrous substrate can be in a rigid or semi-rigid form.
In a still further aspect, the present invention relates to a molded component comprising:

- at least one fibrous substrate; and
- a matrix;
- wherein the component further comprises at least one integrally molded feature formed contemporaneously with the matrix from the same material. The at least one integrally molded feature is formed from the same source material as the matrix. The molded feature can be formed substantially completely from the material which forms the matrix. The matrix and the molded feature can have a unified, integral structure. The composite component can be formed using the method(s) described herein.

The at least one fibrous substrate can comprise one or more fibers. The molded feature can, for example, define a bracket, a spigot, a flange, a ridge or a rib. The molded feature can extend away from the at least one fibrous substrate. The molded feature can be formed at least substantially completely from said matrix material. During the molding process, the matrix material flows into a recess formed in the mold to form the molded feature. The formation of the molded feature occurs contemporaneously with the formation of the matrix. The fibers provided in the at least one fibrous substrate can be provided in a layer and arranged so as not to extend into the molded feature. The component can comprise a plurality of said integrally molded features.
The fibers can be natural fibers and/or synthetic fibers.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the present invention will now be described, by way of example only, with reference to the accompanying figures, in which:

FIG. 1 shows a front perspective view of a molded composite component formed using the method according to the present invention;

FIG. 2 shows a rear perspective view of the composite component shown in FIG. 1;

FIGS. 3 and 4 are images of the molded composite component shown in FIGS. 1 and 2;

FIGS. 5A and 5B show enlarged views of a yarn for forming the fibrous substrate used in the method according to the present invention;

FIG. 6 shows a schematic representation of the lay-up arrangement for molding the composite component;

FIG. 7 shows sample woven materials that can be used in accordance with the present invention;

FIG. 8 shows a schematic representation of the lay-up arrangement for molding the composite component;

FIG. 9 shows a schematic representation of the lay-up arrangement for molding the composite component;

FIG. 10 shows a schematic representation of the lay-up arrangement for molding the composite component; and

FIG. 11 shows a schematic representation of the lay-up arrangement for molding the composite component.

DETAILED DESCRIPTION

Detailed descriptions of specific embodiments of a method of molding a component according to the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. Indeed, it will be understood that the method of molding a component described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.
A method of molding, in particular compression molding, a composite component 1 in accordance with the present invention will now be described. FIGS. 1 and 2 show perspective views of the component 1; and images showing portions of the molded component 1 are shown in FIGS. 3 and 4.
As shown in FIGS. 1 and 2, the component 1 is semi-structural member for mounting on an interior of a motor vehicle door. The component 1 comprises a panel section 3 having a plurality of integrally molded features (denoted generally herein by the reference numeral 5). The component 1 is formed from a fibrous substrate 7 held in a solid matrix 9. As shown in FIGS. 3 and 4, the features 5 are integrally molded from the material which forms the matrix 9 in a single, contemporaneous process step. Detents and recesses can be formed in the panel section 3. In the present embodiment, the features 5 include (four) mounting brackets 11, (two) flanges 13, and (two) locating spigots 15. The features 5 could also include reinforcing ribs, ridges, bushes and the like.
The substrate 3 in the molded component 1 comprises two layers of fabric 17 each woven from a yarn 19. The yarn 19 is formed from a plurality of natural fibers 21 (such as flax) interspersed with thermoplastic, e.g. polypropylene polyester or polyamide, matrix-forming fibers 23, as shown in the cross-sectional view in FIG. 5A. To preserve the longitudinal strength of the natural fibers 21, the yarn 19 is wrap spun by supporting a central aggregate of natural fibers 21 and thermoplastic (e.g. polypropylene) fibers 23 inside a helically-wound outer fiber 25, as shown in FIG. 5B. The yarn 19 is woven to form each layer of fabric 17 in conventional manner and different weaving patterns can be employed to provide different mechanical properties in the substrate 3.
The thermoplastic fibers 23 are provided in the yarn 19 to enable the layer of fabric 17 to be consolidated into a fibrous sheet 27 (i.e. a sheet containing fibers). In particular, heating the layer of woven fabric 17 causes the polypropylene fibers 23 to melt and bond the natural fibers 21 together thus forming a matrix. The application of pressure allows the layer of fabric 17 to be formed into the fibrous sheet 27. The distribution and alignment of natural fibers 21 in the fibrous sheet 27 is substantially uniform. Moreover, the fibrous sheet 27 is resilient and can be readily handled.
The features 5, and all or part of the matrix 9, are formed from a feature-forming material comprising polypropylene and optionally a filler material, such as wood fiber or pulp. This material can, for example, be that which is supplied under the trade name Arbofill by TECNARO GmbH of Burgweg 5, D 74360 Ilsfeld-Auenstein, Germany. To facilitate handling, the feature-forming material in the present embodiment is supplied as a continuous feature-forming sheet 29. However, the sheet may be discontinuous as described below.
The molding process according to the present invention will now be described with reference to FIG. 6. The component 1 is formed in a compression mold comprising first and second cooperating mold parts 33, 31 each having profiled surfaces to define the component 1. Recesses (denoted generally by the reference numeral 35) are formed in the surfaces of the first and/or second mold parts 33, 31 to define the features 5.
First and second fibrous sheets 27 a, 27 b and a feature-forming sheet 29 are positioned between the first and second mold parts 33, 31. The feature-forming sheet 29 is provided between the first and second fibrous sheets 27 a, 27 b to form a core. The first and second fibrous sheets 27 a, 27 b and the feature-forming sheet 29 can optionally be pre-heated before they are introduced into the mold.
The first and second mold parts 33, 31 are brought together to compress the first and second fibrous sheets 27 a, 27 b and the feature-forming sheet 29, as illustrated by the arrows A in FIG. 6. The first and second mold parts 33, 31 have shearing edges which trim the fibrous sheets 27 a, 27 b and the sheet 29 to the required size when the mold is closed. The edge(s) of the fibrous sheets 27 a, 27 b could be held between the first and second mold parts 33, 31 to maintain the fibrous sheets 27 a, 27 b in position within the mold. The first and second fibrous sheets 27 a, 27 b conform to the profile of the first and second mold parts 33, 31, for example to form detents and ridges in the component 1. The mold is heated to reduce the viscosity of the matrix-forming material in the feature-forming material sufficiently to enable it to penetrate between the natural fibers 21 in the woven fabric 17 and flow into the recesses 35 in the first and/or second mold parts 33, 31. In the present embodiment the mold is heated to 180-200° C. to melt the polypropylene, but different temperature ranges may be suitable for different materials. By applying pressure to the first and second mold parts 33, 31, the flow of the molten polypropylene within the mold is promoted.
The molten polypropylene impregnates the woven fabric 17 and flows into the recesses 35 formed in the surfaces of the first and second mold parts 33, 31. The polypropylene of the feature-forming material thereby forms the features 5 in a single process step. The filler material contained in the feature-forming sheet 29 can pass between the fibers in the woven fabric 17 and thereby travel through the first and second fibrous sheets 27 a, 27 b into the recesses 35. The flow of molten polypropylene within the mold thereby forms the features 5 integrally with the rest of the component 1 in a single process step. It is noted that the feature-forming material may be provided to aid formation of the matrix encapsulating the fibers of the fibrous substrate. Equally, some of the thermoplastic fibers in the fibrous substrate may move, during molding, into the recesses and thus, in-part, form the features.
The first and second mold parts 33, 31 are cooled and the molded component 1 is removed. As shown in FIGS. 3 and 4, the mounting brackets 11 and the locating spigots 15 are formed integrally with the rest of the component 1. In the present embodiment, the features 5 are molded at least substantially completely from polypropylene with a relatively small degree of penetration of the natural fibers 21. To provide further reinforcement for the features 5, additional natural fibers 21 could be provided proximal some or all of the recesses 35 in the first and second mold parts 33, 31.
If necessary, the component 1 can be trimmed to remove excess material after it has been removed from the mold. For example, the component 1 can be trimmed to remove one or more sprues (not shown) provided in the first and/or second mold parts 33, 31 to enable excess polypropylene to be removed during the molding process. In another example, the component may be trimmed to remove flashes (not shown).
The present embodiment has been described with reference to pre-consolidated fibrous sheets 27 a, 27 b, but it will be appreciated that it is not essential that the woven fabric 17 is pre-consolidated. Rather, the woven fabric 17 could be introduced directly into the mold as a flexible material. This approach may, for example, be appropriate for mold parts having a larger draw. Similarly, it is not essential that the matrix-forming material is introduced into the mold in the form of a pre-consolidated fibrous sheet 27. For example, the matrix-forming material could be provided in a granular or powder form.
To provide a smoother finish on the component 1, a surface film could be provided in the first and/or second mold parts 33, 31. The surface film could, for example, be provided on a surface of the component 1 which will be exposed in use (referred to as an A-surface).
As mentioned above, the yarn 19 can be woven in different patterns to form the fabric 17. By way of example, three different samples of fabric 17 a, 17 b, 17 c having different weaving patterns are shown in FIG. 7 alongside a pre-consolidated fibrous sheet 27. The different weave patterns arrange the natural fibers 21 in different orientations which can provide different mechanical properties in the molded component 1.
Furthermore, the angular orientation of the first and second fibrous sheets 27 a, 27 b within the mold can be offset to alter the mechanical properties of the molded component 1. The pre-consolidated fibrous sheet 27 could be formed from more than one layer of fabric 17. The layers of fabric 17 could be aligned or angularly offset from each other. Different types of fibers could be used in different layers of fabric 17 or different fibrous sheets 27.
Rather than use a woven fabric 17, an elongate tape consisting of aligned natural fibers 21 and/or synthetic fibers 23 could be used. The tape can be woven and optionally pre-consolidated in the same as the fabric 17.
It will be appreciated that various changes and modifications can be made to the embodiment described herein without departing from the scope of the present invention.
The invention has been described with reference to a woven fabric 17 having a uniform distribution of natural fibers 21. However, a non-uniform distribution of natural fibers 21 could be employed. The fabric 17 could be woven with a non-uniform distribution to provide localized reinforcement. Indeed, three dimensional weaving could be employed to provide enhanced material properties.
The matrix-forming material can be provided in a variety of forms, for example powder, granules and sheet(s). Furthermore, a non-uniform distribution of matrix-forming material can be provided in the mold. For example, additional matrix-forming material can be provided proximal recesses 35 in the mold to form the features 5.
The present invention has been described with reference to compression molding techniques. Compression molding techniques may be in the form of using the first mold part 33 and a second mold part 31. In view of the above description, the second mold part 31 may apply pressure (via arrows A) to the components to be molded against the first mold part 33. The second mold part 31 may therefore be replaced by a bag whereby a vacuum compression method is used to compress the bag onto the components 27 a, 27 b, 29 and into the first mold part 31. It is noted that the present invention could be employed in other molding processes, for example blow molding or vacuum forming.
Although the present invention has been described with particular reference to natural fibers, it will be appreciated that it could be implemented using synthetic fibers, such as glass fibers, carbon fibers or aramid fibers. Indeed in another embodiment of the present invention, the fibrous substrates 27 a, 27 b are formed using carbon fiber, and in particular recycled carbon fibers. Recycled carbon fibers may be retrieved from offcuts of other known carbon fiber molding processes and the resulting components. The recycled fibers are combed to achieve substantially aligned long fibers, which are combined with thermoplastic (matrix-forming) fibers (for example, polypropylene, polyester or polyamide) into a fabric or tape as mentioned above. The long carbon fibers are substantially aligned and optionally woven into a substantially perpendicular weave, thus giving the resulting component excellent strength properties in its planar configuration, i.e. across the component.
In this example, the feature-forming material 29 also optionally comprises synthetic fibers. In one embodiment the feature-forming material comprises short carbon fibers that are preferably recycled carbon fibers. The short nature of the fibers in the feature-forming material permits egress of the short fibers through the long fibers of the fibrous substrate and into the recesses of the mold part so as to form the features. This has the advantage of providing strength to the feature.
Components formed using synthetic materials may be suited to external applications, i.e. those applications which are subject to moisture and gas and should be impermeable to one or both. For example, the method may be used to form exhaust ducts, aerofoils, car panels, etc.
As shown in FIG. 8, in a further embodiment of the present invention, the feature forming material 29 a may be provided only over the region of the mold part where there is a recess 35 and indeed, a feature is to be formed. This is possible because the matrix-forming fibers in the fibrous substrates fuse during molding to form a matrix. Therefore, this embodiment further reduces the weight of the component produced by the method because only the feature is formed from the feature-forming material. With reference to FIG. 9, it is noted that the second mold part 31, as described above, may be provided with at least one recess 35. In this example, a section of feature forming material 29 a is positioned over the recess 35. As the mold closes, e.g. as the second mold part 31 is moved toward the first mold part 33, the feature forming material 29 a flows into the recess 35. Preferably, the volume of feature forming material 29 a provided is substantially equivalent to the volume of the recess and indeed, the feature to be formed.
With reference to FIGS. 10 and 11, in another embodiment of the method according to the present invention, the method of molding takes the form of the first mold part 33′ being a cylindrical mold whereby the molding components 27 a′, 27 b′ and 29 a′, are placed inside or outside the cylinder (see 33′ FIGS. 10 and 33′ FIG. 11, respectively). In the embodiment where the components are placed inside the cylinder (FIG. 10), a second mold part 31′ in the form of a mandrel is drawn through the cylinder to provide a force in the A direction to promote formation of the matrix and flow of the feature-forming material 29 a′ into recesses 35′ positioned on the inside surface of the first mold part 33′ so as to form features. It should be noted that the mandrel is schematically shown to have a smaller diameter than the first mold part. The diameter may be smaller for a leading edge of the mandrel (with respect to its drawn direction) but to exert force, the mandrel diameter is substantially equal to the internal diameter of the first mold part less the thickness of the molding components 27 a′, 27 b′. In the embodiment where the molding components are placed outside of the cylinder (FIG. 11), a second mold part 31′ in the form of a cylindrical bag or the like is placed around/over the molding components 27 a′, 29 a′ and 27 b′, and the first mold part 33′. Inflation of the bag or withdrawal of air between the bag and the molding components applies pressure in the A direction to the molding components to promote formation of the matrix and flow of the feature-forming material 29 a′ into recesses 35 positioned on the outside surface of the first mold part 33′ so as to form features. As with the foregoing embodiments, it should be noted that the feature forming material 29 a′ in FIGS. 10 and 11 may be provided in the form of a continuous sheet around the mold. Components produced by these methods may be used, for example, in exhaust ducts or the like, where tubular structures are required and integrally molded features provide for those tubular structures to be strong and lightweight.

Claims

1. A molded component comprising:

at least one fibrous substrate; and

a matrix;

wherein the component further comprises at least one integrally molded feature formed contemporaneously with the matrix from the same material.

2. A molded component as claimed in claim 1, wherein said molded feature is formed at least substantially completely from the same material as the matrix.

3. A vehicle comprising the molded component of claim 1.

4. A molded component comprising:

at least one fibrous substrate that includes a substrate matrix-forming material and a plurality of fibers; and

a feature-forming material that includes a feature matrix-forming material;

wherein the substrate matrix-forming material and the feature matrix-forming material together form a matrix having at least one feature that is integrally molded while forming the matrix by applying pressure to combine the substrate matrix-forming material and the feature matrix-forming material together in a mold.

5. A vehicle comprising the molded component of claim 4.

6. A molded component formed by a method comprising the steps of:

locating a first fibrous substrate in a mold, the mold including two recesses and the first fibrous substrate comprising a substrate matrix-forming material and a plurality of fibers;

providing a feature-forming material in the mold, the feature forming material comprising a feature matrix-forming material;

locating, in the mold, a second fibrous substrate at least partially overlapping the first fibrous substrate, wherein the feature-forming material is provided between the first and second fibrous substrates to form a core; and

applying pressure to combine the first and second fibrous substrates substrate and feature matrix-forming material to form a matrix and to integrally mold the at least one feature,

wherein the mold comprises a first mold part comprising at least one of said recesses, whereby at least the feature matrix-forming material flows through one of the first and second fibrous substrates before flowing into the at least one recess during the application of pressure, and

further wherein the feature matrix-forming material is provided as two or more discrete portions of material, each of said two or more discrete portions being positioned in the mold adjacent to a respective one of the recesses, and

the feature-forming material forming the core between the first and second fibrous substrates further comprising a plurality of short fibers, wherein the short fibers are shorter than the plurality of fibers in the first fibrous substrate.

7. A vehicle comprising the molded component of claim 6.