Abstract: The instant disclosure relates to a laminated composite and methods of making the same. The laminated composite includes a plurality of stacked prepregs having an interface formed between each pair of adjacent prepregs. Each prepreg includes a matrix material and reinforcing fibers dispersed therein. At least one fibrous veil is laminated to at least a portion of at least one of the interfaces, the at least one fibrous veil having graphite nano-platelets attached to at least one surface thereof.

Abstract: The instant disclosure relates to a laminated composite and methods of making the same. The laminated composite includes a plurality of stacked prepregs having an interface formed between each pair of adjacent prepregs. Each prepreg includes a matrix material and reinforcing fibers dispersed therein. The laminated composite also includes at least one fibrous veil laminated to at least a portion of at least one of the interfaces, the at least one fibrous veil having nanofibers attached to at least one surface thereof. Also disclosed herein are a fibrous veil and a method of making the nanofiber-doped fibrous veil.

Abstract: A method for reducing cure shrinkage of a thermoset resin includes forming a plurality of surface modified nanofibers. The surface modified nanofibers are formed by soaking nanofibers in an oxidizing acidic solvent. An oxidizing agent is added to the soaking nanofibers, thereby generating heat sufficient for at least one of in-situ oxidation and in-situ exfoliation of a subsurface of each of the nanofibers. Excess oxidizing agent and acidic solvent are removed from the nanofibers, which are then dried. The dried nanofibers have reduced surface hydrophobicity. The surface modified nanofibers are substantially uniformly dispersed into the thermoset resin. The surface modified nanofibers are adapted to reduce cure shrinkage of the thermoset resin during subsequent curing processes.

Abstract: A method for reducing cure shrinkage of a thermoset resin includes forming a plurality of surface modified nanofibers. The surface modified nanofibers are formed by soaking nanofibers in an oxidizing acidic solvent. An oxidizing agent is added to the soaking nanofibers, thereby generating heat sufficient for at least one of in-situ oxidation and in-situ exfoliation of a subsurface of each of the nanofibers. Excess oxidizing agent and acidic solvent are removed from the nanofibers, which are then dried. The dried nanofibers have reduced surface hydrophobicity. The surface modified nanofibers are substantially uniformly dispersed into the thermoset resin. The surface modified nanofibers are adapted to reduce cure shrinkage of the thermoset resin during subsequent curing processes.

Abstract: One exemplary embodiment may include a coating composition including an additive to prevent or hinder at least one of the coating or an underlying substrate from destabilization upon exposure to electromagnetic radiation.

Abstract: Mold tooling formed of suitable iron-nickel alloys and provided with a hard electroless nickel coating on the mold cavity surface are useful for high volume production of carbon fiber reinforced, polymer matrix, composites. The iron and nickel alloy provides thermal expansion properties for the molding of dimensionally accurate parts. The nickel alloy coating provides a durable surface, without adversely affecting the expansion properties of the mold, and remains adherent to the base metal during the repeated thermal cycling encountered in high volume production of substantially identical molded carbon composite parts.

Abstract: One embodiment of the invention provides a method for compression molding cosmetic panels with visible carbon fiber weaves using clear or lightly filled resins. The method uses a modified, two-step compression molding process to reflow the surface of a partially cured preform of carbon fiber weave and epoxy resin.

Abstract: One embodiment of the invention provides a method including molding composite panels that are UV resistant, substantially free of fiber readout, and have visible fibers from epoxy compositions comprising resins having aromatic rings.

Abstract: A process comprising: placing a preform stack in a cavity of a molding tool; the preform stack comprising a fiber mat, and at least a first veil underlying the fiber mat, and a first resin impregnating at least the fiber mat, and wherein at least a portion of the first resin is cured; injecting a second resin into the cavity of the molding tool and over at least the fiber mat; applying heat and pressure to the preform stack and second resin to cure any uncured portion of the first resin and to cure the second resin to form a composite having a resin layer over the fiber mat as the cosmetic surface.

Abstract: A method for reducing cure shrinkage of a thermoset resin includes forming a plurality of surface modified nanofibers. The surface modified nanofibers are formed by soaking nanofibers in an oxidizing acidic solvent. An oxidizing agent is added to the soaking nanofibers, thereby generating heat sufficient for at least one of in-situ oxidation and in-situ exfoliation of a subsurface of each of the nanofibers. Excess oxidizing agent and acidic solvent are removed from the nanofibers, which are then dried. The dried nanofibers have reduced surface hydrophobicity. The surface modified nanofibers are substantially uniformly dispersed into the thermoset resin. The surface modified nanofibers are adapted to reduce cure shrinkage of the thermoset resin during subsequent curing processes.

Abstract: A molded fiber panel is disclosed having a fibrous material with a core and an outer surface, a relatively low density filler material disposed at the core, and a relatively high density filler material disposed at the outer surface. The outer surface has an as-molded surface roughness average of equal to or less than about 2 micro-meters.

Abstract: A metallized epoxy die formed by depositing boron nitride and iron oxide particle layers on the pattern used to form the die and spraying molten metal onto the particle layers followed by casting the epoxy against the exposed surface of the sprayed metal.

Abstract: A machinable, high strength epoxy tool which is the polymeric reaction product of a mixture containing 5 to 12 weight percent of a bisphenol A epoxy, 3 to 8 weight percent of at least one polyoxypropylene amine catalyst, 60 to 85 weight percent of a mixture of no less than three different sized particulate fillers, the major portion of which is iron powder, 5 to 15 weight percent of short (<250 .mu.m) glass fibers, and 0.02 to 1 weight percent of a surface active agent.

Abstract: A tough, durable, high temperature epoxy tooling composition for making cast-to-size forming tools. The composition comprises a bisphenol-A epoxy, a trifunctional aromatic epoxy, an anhydride catalyst, and an imidazole catalyst. The composition may optionally contain a filler system comprising filler particles having different diameters that are interstitially-matched.

Abstract: A high strength, room temperature curable epoxy tooling compositions containing interstitially-matched filler systems for making cast-to-size forming tools for metal sheet stamping. The composition can be fully cured by at least one aliphatic amine catalyst in twelve hours producing a rigid article having a tensile strength of at least 40 MPa and a compressive strength of at least 100 MPa.

Abstract: A tough, durable, high temperature epoxy tooling composition for making cast-to-size forming tools. The composition comprises a bisphenol-A epoxy, a trifunctional aromatic epoxy, an anhydride catalyst, and an imidazole catalyst. The composition may optionally contain a filler system comprising filler particles having different diameters that are interstitially-matched.

Abstract: A method of forming perforations in polymer film includes the steps of forming a conductive film pattern on the film preferably in a bow tie shape using a material with a moderate resistivity and applying a microwave field across the film for a few seconds whereupon sufficient electrical energy is dissipated in the conductive spot to perforate the polymer. This method is operative even when the polymer film is laminated between layers of other dielectric material prior to the microwave processing.

Abstract: A method of rapidly curing a thermoset polymer by blending and dispersing a quantity of electrically conductive fibers into the polymer and subjecting it to microwave radiation.

Abstract: Dicumyl peroxide-dimaleimide cured EPDM elastomers can be molded to molded nylon articles so that the EPDM strongly adheres to the nylon. This practice is particularly useful in molding EPDM gaskets to nylon heat exchanger tanks.