Abstract: A process and system are provided for introducing a blend of chopped and dispersed fibers on an automated production line amenable for inclusion in molding compositions as a blended fiber mat for structural applications. The blend of fibers are simultaneously supplied to an automated cutting machine illustratively including a rotary blade chopper disposed above a vortex supporting chamber. The blend of chopped fibers and binder form a chopped mat. The chopped mat has a veil mat placed on either side, and is consolidated with the veil mat using heated rollers maintained at the softening temperature of thermoplastic binder, with consolidated mats being amenable to being stored in rolls or as flat sheets. A charge pattern is made using the consolidated mat, and the charge pattern can be compression molded in a mold maintained at a temperature lower than the melting point of the thermoplastic fibers.

Abstract: A molding composition is provided that includes a thermoset cross-linkable polymeric resin, a fibrous filler and a thickener system. The thickener system includes an amine and an isocyanate that are reactive to form a polyurea. The polyurea is operative to thicken the molding composition formulation prior to polymeric resin thermoset with superior properties relative to conventional thickener systems. A molded article produced from a cross-linked thermoset polymeric resin containing fibrous filler and a polyurea present from 1 to 5 total weight percent of the article either forms an interpenetrating network between the resin and the polyurea or the resin and polyurea crosslink upon resin thermoset to further strengthen the resulting article. An alkali earth oxide or hydroxide simultaneously thickens through interaction with carboxylate functionality of the cross-linkable resin to provide a superior viscosity build and humidity tolerance.

Abstract: A molding compound formulation is provided that includes a unsaturated polyester, a low profile additive, and high surface area conductive carbon black particulate. The carbon black is dispersed in at least one of the unsaturated polyester and the low profile additive to produce a cured panel having a surface resistivity value of between 1×105-108?, and a Diffracto analysis D number of less than 100 when cured against a mold platen having a Diffracto analysis D number of 25. A process for producing such a molding compound panel is also provided that includes mixing through rotary mechanical stirring the high surface area conductive carbon black particulate into one side of the molding compound formulation under conditions that satisfy: ln(viscosity)??0.82{ln(RPM)}+12.734??(I) where viscosity is in Centipoise and RPM denotes revolutions per minute.

Abstract: A vehicle bumper system having a mounting bracket disposed between a vehicle frame and a bumper having angulated walls. The angulated walls are disposed at selected cross-sectional elevations, to avoid parallelograming under impact and provide maximum energy absorption. The mounting bracket includes a first surface and a second surface. The first surface of mounting bracket is adapted to be secured to the vehicle frame. The second surface of the mounting bracket is adapted to be secured to the bumper. The walls of the mounting bracket absorb an impact to the bumper.