Abstract: Consolidated, porous core layers that are lightweight while retaining the mechanical properties of heavier core layers are described. The consolidated, porous core layer can include a porous web formed from reinforcing materials held in place by a thermoplastic material. The consolidated, porous core layer can also include a lofting agent or other additives to provide for a desired thickness or properties.

Abstract: Methods of forming a lightweight reinforced thermoplastic core layer and articles including the core layer are described. In some examples, the methods use a combination of thermoplastic material, reinforcing fibers and bicomponent fibers to enhance retention of lofting agents in the core layer. The processes permit the use of less material while still providing sufficient lofting capacity in the final formed core layer.

Abstract: Composite articles that can resist discoloration or color changes are described. In some instances, the composite articles can include a compounded material that is substantially free of an antioxidant that changes from a first color to a second color upon exposure to an environment comprising an oxidizing agent. The composite articles can be flame retardant and may provide sound reduction as well.

Abstract: A thermoplastic composite article comprising a porous core layer and an open cell skin disposed on a first surface of the core layer is described. The composite article comprises a noise reduction coefficient of at least 0.5 as tested by ASTM C423-17 and a flame spread index of less than 25 and a smoke development index of less than 150 as tested by ASTM E84 dated 2009.

Abstract: Methods of forming a lightweight reinforced thermoplastic core layer and articles including the core layer are described. In some examples, the methods use a combination of thermoplastic material, reinforcing fibers and bicomponent fibers to enhance retention of lofting agents in the core layer. The processes permit the use of less material while still providing sufficient lofting capacity in the final formed core layer.

Abstract: A thermoplastic composite article comprising a porous core layer and an open cell skin disposed on a first surface of the core layer is described. The composite article comprises a noise reduction coefficient of at least 0.5 as tested by ASTM C423-17 and a flame spread index of less than 25 and a smoke development index of less than 150 as tested by ASTM E84 dated 2009.

Abstract: In-line systems and in-line methods of producing lightweight reinforcing thermoplastic composite panels are described. The in-line systems and in-line method can be used to produce composite panels with smoother surfaces and enhanced properties in an automated manner. The produced composite panels can include a decorative layer that can provide an overall smoother panel surface compared to a composite panel lacking a decorative layer.

Abstract: Methods and systems that can produce light weight reinforced thermoplastic articles are described. In some embodiments, a method includes heating and pressing a core layer and then cooling and pressing the core layer to maintain the thickness of the core layer during cooling. Automotive articles, building articles and recreational vehicle articles that can be produced using the methods and systems are also described.

Abstract: A thermoplastic composite article comprising a porous core layer and an open cell skin disposed on a first surface of the core layer is described. The composite article comprises a noise reduction coefficient of at least 0.5 as tested by ASTM C423-17 and a flame spread index of less than 25 and a smoke development index of less than 150 as tested by ASTM E84 dated 2009.

Abstract: Composite articles that can resist discoloration or color changes are described. In some instances, the composite articles can include a compounded material that is substantially free of an antioxidant that changes from a first color to a second color upon exposure to an environment comprising an oxidizing agent. The composite articles can be flame retardant and may provide sound reduction as well.

Abstract: Certain embodiments described herein are directed to articles that provide less sag. In some examples, the articles can include a fiber reinforced thermoplastic polymer core layer comprising reinforcing fibers and a thermoplastic polymer, and a frim disposed on the fiber reinforced polymer core layer. In certain examples, the frim comprises a film coupled to a scrim comprising an effective basis weight to prevent substantial sag of the article, e.g., during a forming operation.

Abstract: Lightweight reinforced thermoplastic articles with a core layer including bicomponent fibers in the core layer are described. In some examples, the core layer includes a thermoplastic material, reinforcing fibers, bicomponent fibers and a lofting agent. After molding of the composite article, an improvement in one or more of peak load values, stiffness values, flexural strength values and flexural modulus values can be achieved for a particular molding thickness.

Abstract: Methods of forming a lightweight reinforced thermoplastic core layer and articles including the core layer are described. In some examples, the methods use a combination of thermoplastic material, reinforcing fibers and bicomponent fibers to enhance retention of lofting agents in the core layer. The processes permit the use of less material while still providing sufficient lofting capacity in the final formed core layer.

Abstract: Methods of producing core layers with a variable basis weight across a width of the core layer and with a substantially uniform thickness across the width of the core layer are described. The core layers can be used in wall panels such as those present in recreational vehicle panels. Systems and various materials used to produce the core layers and articles are also described.

Abstract: A thermoplastic composite article comprising a porous core layer and an open cell skin disposed on a first surface of the core layer is described. The composite article comprises a noise reduction coefficient of at least 0.5 as tested by ASTM C423-17 and a flame spread index of less than 25 and a smoke development index of less than 150 as tested by ASTM E84 dated 2009.

Abstract: Certain embodiments described herein are directed to composite materials comprising untwisted fibers. In some embodiments, the article can include a core layer comprising a thermoplastic polymer and reinforcing fibers. In other embodiments, untwisted fibers can be disposed on the core layer. In certain examples, the article is effective to provide a Class A finish when painted.

Abstract: Prepregs, core layers and composite articles comprising one or more flame retardant materials are described. In some instances, a thermoplastic composite article comprises a porous core layer comprising a plurality of reinforcing fibers, a first thermoplastic material, and a second thermoplastic material from a compounded flame retardant material comprising the second thermoplastic material and a flame retardant material. In other instances, a thermoplastic composite article comprises a porous core layer comprising a plurality of reinforcing fibers, a first thermoplastic material, expandable graphite materials and a group II metal hydroxide or a group III metal hydroxide.

Abstract: Prepregs, composites and articles comprising expandable graphite materials dispersed in a thermoplastic layer are described. In some instances, articles that can be used in an as-produced state may provide a desired sound absorption coefficient or a desired flame spread index, e.g., less than or equal to 25 as tested by ASTM E84 dated 2009. Methods of producing the articles are also described.

Abstract: Certain embodiments described herein are directed to composite articles comprising a core layer and a film comprising a high viscosity thermoplastic layer and a tie layer. The articles can be used in automotive and/or aerospace applications to provide lightweight interior components such as a headliner, sidewall or other structural components. Cover layers and other layers can also be present on the articles to provide additional functionality or for aesthetic purposes.

Abstract: Prepregs, composites and articles comprising expandable graphite materials dispersed in a thermoplastic layer are described. In some instances, a thermoplastic composite article comprises a porous core layer comprising a plurality of reinforcing fibers and a thermoplastic material, and the porous core layer further comprises expandable graphite particles homogeneously dispersed in the porous core layer.