Abstract: Certain configurations of composite panels are described that comprise at least one aesthetic edge. In some embodiments, the composite panel with the aesthetic edge comprises a sandwich panel coupled to a shell layer. The sandwich panel may comprise skin layers and a core layer.

Abstract: Composite articles comprising a porous prepreg or core layer and a powder coated layer thereon are described. In some instances, a thermoplastic composite article comprises a porous core layer comprising a web of reinforcing fibers held together by a thermoplastic material, and a powder coated layer disposed on the porous core layer, in which a particle size of the powder coated layer is selected to provide an interface between the powder coated layer and the porous core layer, wherein at least 50% by weight of the disposed powder coated layer is present above the interface.

Abstract: A thermoplastic composite article comprising a porous core layer comprising a plurality of reinforcing fibers, a lofting agent and a thermoplastic material is provided. In certain instances, the article further comprises a skin layer disposed on the core layer and an adhesive layer between the core layer and the skin layer. In some configurations, the adhesive layer comprises a thermoplastic polymer and an effective amount of a thermosetting material to provide a post-molding peel strength between the skin layer and the post lofted core layer of at least 0.5 N/cm (in either or both of the machine direction or cross direction) as tested by DIN 53357 A dated Oct. 1, 1982.

Abstract: Composite articles comprising a porous prepreg or core layer and a powder coated layer thereon are described. In some instances, a thermoplastic composite article comprises a porous core layer comprising a web of reinforcing fibers held together by a thermoplastic material, and a powder coated layer disposed on the porous core layer, in which a particle size of the powder coated layer is selected to provide an interface between the powder coated layer and the porous core layer, wherein at least 50% by weight of the disposed powder coated layer is present above the interface.

Abstract: Certain configurations are described herein of a thermoplastic sheet or article comprising a plurality of porous layers coupled to each other. In one configuration, the thermoplastic article may comprise a core layer, a first layer disposed on one surface of the core layer and a second layer disposed on another surface of the core layer. In some instances, each of the core layer, the first layer and the second layer may comprises a web of open celled structures formed by a plurality of reinforcing materials bonded together with a thermoplastic material and optionally may also include a lofting agent. The lofting capacity in different layers can be selected or tuned to provide desired properties.

Abstract: Underbody shield materials that can provide an underbody shield with high impact resistance are described. In some configurations, an underbody shield composition comprises a porous core layer comprising a plurality of reinforcing fibers, a lofting agent and a thermoplastic material. In some instances, the underbody shield composition may also comprise a film such that an underbody shield produced from the composition can withstand at least 50 individual impacts as tested using a SAE J400 protocol.

Abstract: A thermoplastic composite article comprising a porous core layer comprising a plurality of reinforcing fibers, a lofting agent and a thermoplastic material is provided. In certain instances, the article further comprises a skin layer disposed on the core layer and an adhesive layer between the core layer and the skin layer. In some configurations, the adhesive layer comprises a thermoplastic polymer and an effective amount of a thermosetting material to provide a post-molding peel strength between the skin layer and the post lofted core layer of at least 0.5 N/cm (in either or both of the machine direction or cross direction) as tested by DIN 53357 A dated Oct. 1, 1982.

Abstract: Composite articles comprising a porous prepreg or core layer and a powder coated layer thereon are described. In some instances, a thermoplastic composite article comprises a porous core layer comprising a web of reinforcing fibers held together by a thermoplastic material, and a powder coated layer disposed on the porous core layer, in which a particle size of the powder coated layer is selected to provide an interface between the powder coated layer and the porous core layer, wherein at least 50% by weight of the disposed powder coated layer is present above the interface.

Abstract: Certain configurations are described herein of a thermoplastic sheet or article comprising a plurality of porous layers coupled to each other. In one configuration, the thermoplastic article may comprise a core layer, a first layer disposed on one surface of the core layer and a second layer disposed on another surface of the core layer. In some instances, each of the core layer, the first layer and the second layer may comprises a web of open celled structures formed by a plurality of reinforcing materials bonded together with a thermoplastic material and optionally may also include a lofting agent. The lofting capacity in different layers can be selected or tuned to provide desired properties.

Abstract: Underbody shield materials that can provide an underbody shield with high impact resistance are described. In some configurations, an underbody shield composition comprises a porous core layer comprising a plurality of reinforcing fibers, a lofting agent and a thermoplastic material. In some instances, the underbody shield composition may also comprise a film such that an underbody shield produced from the composition can withstand at least 50 individual impacts as tested using a SAE J400 protocol.

Abstract: A thermoplastic composite article comprising a porous core layer comprising a plurality of reinforcing fibers, a lofting agent and a thermoplastic material is provided. In certain instances, the article further comprises a skin layer disposed on the core layer and an adhesive layer between the core layer and the skin layer. In some configurations, the adhesive layer comprises a thermoplastic polymer and an effective amount of a thermosetting material to provide a post-molding peel strength between the skin layer and the post lofted core layer of at least 0.5 N/cm (in either or both of the machine direction or cross direction) as tested by DIN 53357 A dated Oct. 1, 1982.

Abstract: Vehicle cockpit assemblies and methods of installing same within vehicles are provided. A vehicle cockpit assembly includes a dash insulator that is configured to be attached to a vehicle firewall, an instrument panel attached to the dash insulator, and a floor covering also attached to the dash insulator. A plurality of apertures are formed through the dash insulator, each of which is configured to overlie a respective opening in a vehicle firewall when attached thereto. Each aperture is configured to sealably receive an item extending therethrough such that substantially no gaps exist between the item and the substrate. Polyurethane may be added to one or more selected portions of the dash insulator to reflect and/or absorb sound.

Abstract: Vehicle cockpit assemblies and methods of installing same within vehicles are provided. A vehicle cockpit assembly includes a dash insulator that is configured to be attached to a vehicle firewall, an instrument panel attached to the dash insulator, and a floor covering also attached to the dash insulator. A plurality of apertures are formed through the dash insulator, each of which is configured to overlie a respective opening in a vehicle firewall when attached thereto. Each aperture is configured to sealably receive an item extending therethrough such that substantially no gaps exist between the item and the substrate. Polyurethane may be added to one or more selected portions of the dash insulator to reflect and/or absorb sound.

Abstract: Vehicle cockpit assemblies and methods of installing same within vehicles are provided. A vehicle cockpit assembly includes a dash insulator that is configured to be attached to a vehicle firewall, an instrument panel attached to the dash insulator, and a floor covering also attached to the dash insulator. A plurality of apertures are formed through the dash insulator, each of which is configured to overlie a respective opening in a vehicle firewall when attached thereto. Each aperture is configured to sealably receive an item extending therethrough such that substantially no gaps exist between the item and the substrate. Polyurethane may be added to one or more selected portions of the dash insulator to reflect and/or absorb sound.

Abstract: Vehicle cockpit assemblies and methods of installing same within vehicles are provided. A vehicle cockpit assembly includes a dash insulator that is configured to be attached to a vehicle firewall, an instrument panel attached to the dash insulator, and a floor covering also attached to the dash insulator. A plurality of apertures are formed through the dash insulator, each of which is configured to overlie a respective opening in a vehicle firewall when attached thereto. Each aperture is configured to sealably receive an item extending therethrough such that substantially no gaps exist between the item and the substrate. Polyurethane may be added to one or more selected portions of the dash insulator to reflect and/or absorb sound.

Abstract: Vehicle cockpit assemblies and methods of installing same within vehicles are provided. A vehicle cockpit assembly includes a dash insulator that is configured to be attached to a vehicle firewall, an instrument panel attached to the dash insulator, and a floor covering also attached to the dash insulator. A plurality of apertures are formed through the dash insulator, each of which is configured to overlie a respective opening in a vehicle firewall when attached thereto. Each aperture is configured to sealably receive an item extending therethrough such that substantially no gaps exist between the item and the substrate. Polyurethane may be added to one or more selected portions of the dash insulator to reflect and/or absorb sound.