Patents Assigned to Azdel, Inc.
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Patent number: 11866557Abstract: 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.Type: GrantFiled: July 18, 2020Date of Patent: January 9, 2024Assignee: Hanwha Azdel, Inc.Inventors: Peng Cheng, Hongyu Chen, Liqing Wei, Ruomiao Wang
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Patent number: 11858221Abstract: Certain configurations of multilayer assemblies are described. In certain embodiments, the multilayer assembly can include a core layer, a skin layer and one or more depressions in a surface of the multilayer assembly. In other configurations, the multilayer assembly can include a core layer, a skin layer, one or more depressions in a surface of the multilayer assembly and one or more additional layers.Type: GrantFiled: October 8, 2021Date of Patent: January 2, 2024Assignee: Hanwha Azdel, Inc.Inventor: Peter Thomas Evers, Jr.
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Patent number: 11813824Abstract: 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.Type: GrantFiled: November 14, 2021Date of Patent: November 14, 2023Assignee: Hanwha Azdel, Inc.Inventor: Ruomiao Wang
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Patent number: 11780215Abstract: Prepregs, composites and articles are described that comprise a porous core layer and a surface layer comprising bi-component fibers which can enhance formability of the article without breakthrough. The enhanced formability can permit forming or drawing of the article to increased depths without breakthrough. Interior and exterior automotive components including the articles are described.Type: GrantFiled: December 11, 2017Date of Patent: October 10, 2023Assignee: Hanwha Azdel, Inc.Inventors: Hong Xu, Peter T Evers, Jr., Mark O Mason, Ziniu Yu
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Patent number: 11708036Abstract: A thermoplastic composite article comprising a porous core layer and a textured film disposed on a first surface of the porous core layer is described. The composite article can be configured as a recreational vehicle building substrate such as a ceiling or interior wall panel.Type: GrantFiled: September 20, 2021Date of Patent: July 25, 2023Assignee: Hanwha Azdel, Inc.Inventors: Liqing Wei, Mark O. Mason
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Patent number: 11649574Abstract: A moldable composite sheet having improved thermal and mechanical property characteristics. In one aspect, the composite sheet may be a porous fiber-reinforced thermoplastic resin comprising discontinuous mineral reinforcing fibers, and one or more skin layer materials. Generally, the composite sheet may have a void content or porosity from about 5% to about 95% by volume of the sheet, an areal weight between about 400 g/m2 to about 4000 g/m2 (gsm), a mineral fiber content from about 20% to about 80% by weight, and a thermoplastic resin content from about 20% to about 80% by weight of the composite sheet. The composite sheet can be molded via low pressure processes, such as thermoforming, match metal molding on stops, vacuum forming and pressure forming, to produce durable automotive interior trim parts and construction articles having improved thermal and mechanical properties in addition to other beneficial characteristics.Type: GrantFiled: February 10, 2020Date of Patent: May 16, 2023Assignee: Hanwha Azdel, Inc.Inventors: Brian Timothy Good, Jesse Guy Hipwell, Coray Harper, Thomas A Ebeling
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Patent number: 11634550Abstract: 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.Type: GrantFiled: January 31, 2020Date of Patent: April 25, 2023Assignee: Hanwha Azdel, Inc.Inventor: Ruomiao Wang
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Patent number: 11628646Abstract: 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.Type: GrantFiled: April 6, 2020Date of Patent: April 18, 2023Assignee: Hanwha Azdel, Inc.Inventors: Mark J Mason, Peter T Evers, Jr., Anthony J Messina
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Patent number: 11364858Abstract: Methods of producing core layers with a variable basis weight across a width of the core layer are described. The core layers can be used in vehicle headliners to permit proper side air bag deployment in the vehicles during crashes. Systems and various materials used to produce the core layers are also described.Type: GrantFiled: September 3, 2019Date of Patent: June 21, 2022Assignee: Hanwha Azdel, Inc.Inventors: Peng Cheng, Mark O. Mason, Andrew Anderson, Mark Fero, Shriram Joshi, Jonathan Rosin, Anthony Messina
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Patent number: 11173689Abstract: 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.Type: GrantFiled: January 4, 2019Date of Patent: November 16, 2021Assignee: Hanwha Azdel, Inc.Inventor: Ruomiao Wang
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Patent number: 11124134Abstract: A thermoplastic composite article comprising a porous core layer and a textured film disposed on a first surface of the porous core layer is described. The composite article can be configured as a recreational vehicle building substrate such as a ceiling or interior wall panel.Type: GrantFiled: June 6, 2019Date of Patent: September 21, 2021Assignee: Hanwha Azdel, Inc.Inventors: Liqing Wei, Mark O. Mason
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Patent number: 11090899Abstract: 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.Type: GrantFiled: May 25, 2017Date of Patent: August 17, 2021Assignee: Hanwha Azdel, Inc.Inventors: Yune Seo Park, Shriram Joshi, Hong Xu, Mark O Mason, Anthony J Messina
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Patent number: 10981606Abstract: 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.Type: GrantFiled: May 10, 2016Date of Patent: April 20, 2021Assignee: Hanwha Azdel, Inc.Inventors: Yankai Yang, Anthony J Messina, Mark O. Mason
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Patent number: 10557224Abstract: A moldable composite sheet having improved thermal and mechanical property characteristics. In one aspect, the composite sheet may be a porous fiber-reinforced thermoplastic resin comprising discontinuous mineral reinforcing fibers, and one or more skin layer materials. Generally, the composite sheet may have a void content or porosity from about 5% to about 95% by volume of the sheet, an areal weight between about 400 g/m2 to about 4000 g/m2 (gsm), a mineral fiber content from about 20% to about 80% by weight, and a thermoplastic resin content from about 20% to about 80% by weight of the composite sheet. The composite sheet can be molded via low pressure processes, such as thermoforming, match metal molding on stops, vacuum forming and pressure forming, to produce durable automotive interior trim parts and construction articles having improved thermal and mechanical properties in addition to other beneficial characteristics.Type: GrantFiled: June 2, 2016Date of Patent: February 11, 2020Assignee: Hanwha Azdel, Inc.Inventors: Brian Timothy Good, Jesse Guy Hipwell, Coray Harper, Thomas A Ebeling
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Patent number: 10384418Abstract: 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.Type: GrantFiled: November 27, 2013Date of Patent: August 20, 2019Assignee: Hanwha Azdel, Inc.Inventors: Ruomiao Wang, Jesse Hipwell, Mark Mason, Thomas A Ebeling, Erich Vorenkamp, Stephen Senkow
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Patent number: 10364368Abstract: Certain embodiments described herein are directed to composite materials comprising one or more high melt flow index resins. In some examples, the composites can be used to provide automotive parts such as, for example, vehicle interior parts and vehicle exterior parts. In some configurations, the composite comprises a fiber reinforced polymer core comprising reinforcing fibers and a resin comprising a high melt flow index of greater than 325 g/10 min. as measured by ASTM D1238, condition L.Type: GrantFiled: December 29, 2014Date of Patent: July 30, 2019Assignee: Hanwha Azdel, Inc.Inventors: Kumar Kunal, Coray Harper, Mark O Mason, Thomas A Ebeling
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Patent number: 10059079Abstract: Certain embodiments described herein are directed to composite materials effective for use in deep draw processes. In some examples, the composites can be used to provide vehicle panels such as, for example, vehicle underbody panels. In some configurations, the composite comprises a fiber reinforced polymer core and a skin material disposed on at least some portion of the fiber reinforced polymer core, in which the skin material comprises a basis weight of at least 65 g/m2 and an elongation at break of at least 20%.Type: GrantFiled: July 7, 2012Date of Patent: August 28, 2018Assignee: Hanwha Azdel, Inc.Inventors: Kumar Kunal, Thomas Arnold Ebeling, Jesse Guy Hipwell, Erich James Vorenkamp
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Patent number: 8920915Abstract: Certain embodiments described herein are directed to composite materials comprising one or more high melt flow index resins. In some examples, the composites can be used to provide automotive parts such as, for example, vehicle interior parts and vehicle exterior parts. In some configurations, the composite comprises a fiber reinforced polymer core comprising reinforcing fibers and a resin comprising a high melt flow index of greater than 325 g/10 min. as measured by ASTM D1238, condition L.Type: GrantFiled: July 15, 2013Date of Patent: December 30, 2014Assignee: Hanwha Azdel, Inc.Inventors: Kumar Kunal, Mark O. Mason, Coray Harper, Thomas A Ebeling
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Patent number: 8568853Abstract: A fiber reinforced thermoplastic composite having an improved combination of flexural, impact, and heat distortion characteristics. The composite comprises a fiber reinforced thermoplastic core containing fibers bonded together with a first thermoplastic resin in which the core has a first surface and a second surface and at least one first skin applied to the first surface. The first skin comprises one or more bi-directional continuous fiber tapes having a plurality of continuous fibers bonded together with one or more thermoplastic resins. The fibers in each first skin are arranged in a first and a second direction, with the fibers in each direction being unidirectionally oriented within the skin. Bi-directional orientation of the continuous fiber tapes is present in at least one of the tapes, or is achieved through the use of two or more tapes having unidirectional continuous fibers.Type: GrantFiled: December 14, 2007Date of Patent: October 29, 2013Assignee: Hanwha Azdel, Inc.Inventors: Venkat Raghavendran, Gary Francis Smith
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Patent number: RE44893Abstract: A composite sheet material in one embodiment includes a porous core layer. The porous core layer includes a thermoplastic polymer, about 20 weight percent to about 80 weight percent of reinforcing fibers based on a total weight of the porous core layer, and an effective amount of a flame retardant agent.Type: GrantFiled: March 22, 2012Date of Patent: May 13, 2014Assignee: Hanwha Azdel, Inc.Inventors: Venkat Krishna Raghavendran, Thomas Arnold Ebeling