Abstract: A composite part made from a sheet molding compound is disclosed as having improved characteristics over traditional sheet molding compound composite parts. The fibrous material is introduced as a veil layer adjacent a paste layer, the veil flows well during the molding process. The improved flow and surface characteristics of a composite part are attributed to the elongation of the veil during molding and to the improved filling capabilities.

Abstract: The present invention is directed towards an apparatus for guiding continuous materials. In one embodiment of the invention, the apparatus comprises first and second conveyors, each comprising a continuous conveyor belt carried by a set of pulleys including a drive pulley and an idler pulley. The conveyor belts have opposing inner surfaces that are oriented to travel substantially parallel to one another to sandwich continuous materials therebetween. The ratio of the diameters of the idler pulleys to the drive pulleys is greater than about 8:1. In another embodiment of the invention, a chopper is provided. The chopper comprises a cutting roll and a cot member defining a nip region therebetween. The cutting roll has an axis of rotation that is aligned substantially parallel to an axis of rotation of a cot member. The small turning radii permit the conveyor belts to extend within the nip region.

Abstract: A composite part made from a sheet molding compound is disclosed as having improved characteristics over traditional sheet molding compound composite parts. The composite part may be made from a unique sheet molding compound material having a resin impregnated filamentized fiber layer and a resin impregnated fiber layer prior to compaction. The resin impregnated filamentized fiber layer side prevents the movement of partially filamentized or unfilamentized fibers to the visible surface of the composite part when the part is molded. The resin impregnated filamentized fiber layer may be contain a conductive filamentized fiber such that the surface of a sheet molding compound may be conductive and be capable of being electrostatically sprayed.

Abstract: A two-part sizing system for making colorless, densified fiber pellets of a reinforcing fiber material. The densified product may be advantageously produced by first applying a precursor size composition to reinforcing fiber strands, chopping the reinforcing fiber strands into chopped strand segments, applying a binder size, and densifying the chopped strand segments to form densified fiber pellets. The binder size is formulated using a copolymer of maleic anhydride which generates a product free from discoloration. In the process of making the pellets, the sized chopped strands are densified by tumbling in a rotating chamber for a period of time sufficient to increase their density but insufficient to degrade the fibers to a point where composite articles formed from such pellets have lower tensile or impact strengths than comparable composite articles formed from unpelletized strand segments.

Abstract: A one-step direct method of making a high molecular weight functionalized polyolefin aqueous emulsion is provided. In this one-step direct method, a functionalized polyolefin having a molecular weight of at least 10,000, a fatty acid, a base, a surfactant, and water are heated in a pressure reaction vessel to a temperature above the emulsification temperature of the polyolefin with agitation for a period of time sufficient to form an aqueous emulsion. This high molecular weight functionalized polyolefin aqueous emulsion can be added to a sizing composition and applied directly onto glass fibers in the glass fiber manufacturing process.

Abstract: A reinforcement liner and methods of manufacturing the liner are disclosed. The liner includes a fabric (100) material having first and second fibers (112, 122). The second fibers comprise chopped fibers in substantially parallel alignment for being positioned substantially about the circumference of a pipe, so the fabric can be elongated in a direction parallel to the second fibers. The liner may includes a stitching material (130) that is used to couple the first and second fibers together. The stitching material is preferably an elastic yarn.

Abstract: A process is provided for filling a muffler shell with fibrous material. It comprises the step of providing a muffler shell comprising one or more muffler shell outer parts which define an internal cavity and an internal structure adapted to extend at least part way through the shell internal cavity and having one or more openings adapted to communicate with the shell internal cavity. The process further comprises the step of providing a bag filled with fibrous material. The bag has a first side with one or more first perforations defining a first side total open area and a second side with either no perforations or one or more second perforations defining a second side total open area. The first open area is greater than the second open area.

Abstract: A process is provided for filling a muffler shell with fibrous material. The process involves providing a muffler shell comprising first and second muffler shell outer parts which define an internal cavity when coupled together and an internal structure adapted to extend at least part way through the shell internal cavity and having one or more openings communicating with the shell internal cavity.

Abstract: A process is provided for filling a muffler with fibrous material as well as a muffler filled with fibrous material. The process includes a first step of providing a muffler comprising a closed outer shell having an inner cavity and a perforated pipe. The perforated pipe has a first end portion with at least one fill opening. A second step comprises feeding fibrous material into the outer shell inner cavity through the at least one fill opening in the perforated pipe to form a fibrous product in the outer shell.

Abstract: An in-line mixing apparatus for the substantially continuous production of size to be supplied to a glass fiber forming process. The in-line mixing apparatus comprises a plurality of stages wherein the first stage is a static mixing device in which sizing components are carefully metered into a flow of water or other carrier fluid, and blended together. A second stage, hydrolyzer, connected to the first stage, provides a chamber in which the blended water and size materials are allowed to chemically react as they move therethrough. A second static mixing device may be connected to the output of the hydrolyzer if additional components need to be added, or if additional mixing of the materials blended in the first stage and reacted in the second stage is necessary. The output of the in-line mixing device may be piped directly to the size applicators of the respective fiber producing operations.

Abstract: In a method of forming discrete length fibers, a first engagement member is moved in orbit relative to a second engagement member. A continuous fiber is positioned between the first and second engagement members. The fiber is engaged between the first and second engagement members to cut it into discrete length fibers.