Method for molding composite component

A method for molding a composite component, comprising steps of:

• (a) providing a forming mold and a preformed substrate, the forming mold including a lower mold and an upper mold matched with each other, the lower mold having an inner sidewall surface and an inner lower surface connected to the inner sidewall surface, the inner sidewall surface and the inner lower surface cooperatively defining an accommodating space for accommodating the preformed substrate, the inner sidewall surface having a shaping portion adjacent to the inner lower surface and recessed inwardly into the lower mold, the upper mold having a sprue spatially communicating with the accommodating space, the preformed substrate being a curved sheet and having a sidewall portion and a bottom portion, the sidewall portion having a height not smaller than a height of the inner sidewall surface and being parallel to the inner sidewall surface, the bottom portion being connected to the sidewall portion and parallel to the inner lower surface of the lower mold;
• (b) disposing the preformed substrate into the accommodating space, and clamping the upper mold against the lower mold such that an abutment surface of the upper mold faces toward but not in contact with an abutment surface of the lower mold, thereby forming a gap therebetween, that a mold cavity is formed between the preformed substrate and the upper mold, and that a shaping space is formed between the sidewall portion of the preformed substrate and the shaping portion of the inner sidewall surface of the lower mold;
• (c) injecting a polymer material into the mold cavity from the sprue under an injecting pressure, while pushing the preformed substrate by the polymer material which is formed by the injecting pressure, so that the sidewall portion of the preformed substrate is pressed into the shaping space, thereby forming a first deformed portion;
• and
• (d) further clamping the upper mold against the lower mold using a molding pressure such that the abutment surface of the upper mold and the abutment surface of the lower mold are brought into a tight contact with each other, while pushing the polymer material and the first deformed portion into the shaping space using the molding pressure to deform the first deformed portion into a second deformation portion, thereby obtaining a semi-finished product having a shaped substrate formed from the preformed substrate and a polymer structure formed from the polymer material and covering a surface of the shaped substrate.