Methods for compression molding multi-layered and multi-functional thermoplastic composite structures

A method for manufacturing a multi-layered and multi-functional thermoplastic composite structure, comprising:

• supplying a plurality of reinforcing layers including reinforcing fibers and thermoplastic resin to an intermittent press;
• supplying at least one functional layer to the intermittent press adjacent to the plurality of reinforcing layers,
• wherein the at least one functional layer is selected from a group consisting of an electromagnetic shielding layer and a thermal runaway protection layer, and
• wherein the at least one functional layer includes a first functional layer arranged on one side of the plurality of reinforcing layers, and a second functional layer arranged on an opposite side of the plurality of reinforcing layers;
• heating and pressing the plurality of reinforcing layers and the at least one functional layer to form a composite laminate;
• arranging the composite laminate in a compression molding tool;
• arranging discontinuous fiber reinforced material in the compression molding tool;
• and
• consolidating the discontinuous fiber reinforced material and the composite laminate to form the multi-layered and multi-functional thermoplastic composite structure,
• wherein the discontinuous fiber reinforced material flows into a stiffening feature of a mold cavity.