Method for molding tailored composites

Abstract

In at least one embodiment, a molding method for producing a molded article is provided. The method may include introducing polymer and fiber separately into an extruder in a first ratio to produce a first extruded material having a first fiber content and in a second ratio to produce a second extruded material having a second fiber content different from the first fiber content. The method may further include filling a first region of a mold with the first extruded material and a second region of the mold with the second extruded material. The extruded material may be formed as blanks for use in compression molding or may be introduced into an injection chamber for use in injection molding. The method may be used to form molded articles having a plurality of regions having different fiber contents.

What is claimed is: 
     
         1 . A molded article comprising:
 a single, fiber-reinforced polymer having a first continuous bulk region with a first fiber content and a second continuous bulk region with a second fiber content different from the first fiber content.   
     
     
         2 . The molded article of  claim 1 , wherein the first and second fiber contents are from 10 to 70 wt %. 
     
     
         3 . The molded article of  claim 1 , wherein the first and second regions contact each other. 
     
     
         4 . The molded article of  claim 1 , further comprising a transition region located between the first and second regions and having a fiber content that is intermediate the first and second fiber contents. 
     
     
         5 . The molded article of  claim 1 , further comprising a third continuous bulk region with a third fiber content that is different from the first and second fiber contents. 
     
     
         6 . The molded article of  claim 1 , wherein the first region and the second region include different fiber types.