Method of forming a composite component

A method of forming a composite component including first and second side bolsters and a back member extending between the first and second side bolsters, the first side bolster including a first support portion and a reinforcing composite layer and the second side bolster including a second support portion and a reinforcing composite layer, and at least one cross member extending between one side of a base of the first and second support portions opposite contact surfaces of the base, each of the first and second support portions including a thermoplastic material initially separate from the reinforcing composite layer and the back member including the thermoplastic material and being integral with the thermoplastic material of the first and second support portions, the reinforcing composite layer comprising a polymeric material and a plurality of continuous fibers impregnated in the polymeric material, said method comprising:

• placing the reinforcing composite layer into a mold wherein the reinforcing composite layer is concave and has a base and a pair of sides spaced from each other and extending from the base with a cavity disposed therebetween with each of the base and pair of sides defining continuous contact surfaces facing the cavity;
• placing a cross member composite layer into the mold extending between one side of the first and second support portions opposite the contact surfaces of the base;
• heating the thermoplastic material to a molten state;
• disposing the thermoplastic material in the molten state in the cavity along at least a portion of the contact surfaces of at least the pair of sides of the reinforcing composite layer and defining ribs extending from the contact surfaces of the base and from one of the sides to the other of the sides;
• disposing the thermoplastic material in the molten state and forming the at least one cross member integrated with the cross member composite layer extending between one side of the first and second support portions opposite the contact surfaces of the base, wherein the at least one cross member includes the thermoplastic material and the at least one cross member composite layer and is integral with the one side of the base of the first and second support portions;
• promoting interaction between the thermoplastic material and the polymeric material to integrate the first support portion and the second support portion and the reinforcing composite layer by melting a portion of the polymeric material of the reinforcing composite layer while in contact with the thermoplastic material in the molten state and to integrate the thermoplastic material of the at least one cross member with the polymeric material of the base of the first support portion and the second support portion;
• and
• cooling the polymeric material and the thermoplastic material to define the base as an integrated combination of a portion of the thermoplastic material and the reinforcing composite layer, and to define each of the sides as an integrated combination of a portion of the thermoplastic material and the reinforcing composite layer with the base, the sides and the ribs being integrated with each other such that the reinforcing composite layer reinforces each of the first support portion and the second support portion to resist fracturing of the first support portion and the second support portion when subjected to a load as the first support portion and the second support portion extends between and simultaneously supports the reinforcing composite layer wherein the first and second side bolsters, the at least one cross member, and the back member are integral.

A method of forming a seat back for a vehicle, the seat back including first and second side bolsters and a back member extending between the first and second side bolsters, the first side bolster including a first support portion and a plurality of reinforcing composite layers and the second side bolster including a second support portion and a plurality of reinforcing composite layers, and at least one cross member extending between one side of a base of the first and second support portions opposite contact surfaces of the base, each of the first and second support portions including a thermoplastic material initially separate from the plurality of reinforcing composite layers and the back member including the thermoplastic material and being integral with the thermoplastic material of the first and second support portion, the plurality of reinforcing composite layers each comprising a polymeric material and a plurality of continuous fibers impregnated in the polymeric material with the first support portion and the second support portion each defining an axis along a length thereof, said method comprising:

• positioning at least one of the plurality of reinforcing composite layers with the continuous fibers extending in first direction along the axis;
• positioning at least another of the plurality of reinforcing composite layers with the continuous fibers extending angularly relative the first direction and the axis;
• combining the plurality of reinforcing composite layers into a single integral stack with the continuous fibers extending in at least two different directions;
• placing the integral stack of reinforcing composite layers into a mold wherein the stack of reinforcing composite layers is concave and has a base and a pair of sides spaced from each other and extending from the base with a cavity disposed therebetween with each of the base and pair of sides defining continuous contact surfaces facing the cavity;
• heating the thermoplastic material to a molten state;
• disposing the thermoplastic material in the molten state in the cavity along at least a portion of the contact surfaces of at least the pair of sides of the stack of reinforcing composite layers and defining ribs extending from the contact surfaces of the base and from one of the sides to the other of the sides;
• forming the at least one cross member extending between one side of the first and second support portions opposite the contact surfaces of the base, wherein the at least one cross member includes the thermoplastic material and is integral with the one side of the base of the first and second support portions;
• promoting interaction between the thermoplastic material and the polymeric material to integrate the support portion and the stack of reinforcing composite layers by melting a portion of the polymeric material of the stack of reinforcing composite layers while in contact with the thermoplastic material in the molten state and to integrate the thermoplastic material of the at least one cross member with the polymeric material of the base of the first support portion and the second support portion;
• and
• cooling the polymeric material and the thermoplastic material to define the base as an integrated combination of a portion of the thermoplastic material and the stack of reinforcing composite layers, and to define each of the sides as an integrated combination of a portion of the thermoplastic material and the stack of reinforcing composite layers with the base, the sides and the ribs being integrated with each other such that the stack of reinforcing composite layers reinforces each of the first support portion and the second support portion to resist fracturing of the first support portion and the second support portion when subjected to a load transverse to the direction of the continuous fibers as the first support portion and the second support portion extends between and simultaneously supports the stack of reinforcing composite layers wherein the first support portion and the second support portion supports the stack of the reinforcing composite layers to reduce or prevent flexing about the axis wherein the first and second side bolsters, the at least one cross member, and the back member are integral.