Abstract: A battery containment construct is provided that includes a unitary tray having a bottom and a set of walls including a first side wall, a second side wall, a first end wall, and a second end wall. The set of walls extending from the bottom of the tray and defining a cavity within the tray. A cover removably attached to the plurality of walls of said tray opposite the bottom of said tray. Energy absorption components attached to the bottom of the tray external to at least one of the set of walls in some versions to enhance impact resistance. The construct has high strength, is light weight and well suited for containing and protecting energy cells or batteries that adjusted to impact resistance, fire resistance, and fluid penetration prevention.

Abstract: A vehicle component includes a body, a first beam, and a second beam. The body has a first fixture region and a second fixture region. The first beam is formed of a first composite material and has a first beam shape. The first beam is attached to the body and extends between the first fixture region and the second fixture region of the body. The second beam is formed of a second composite material and has a second beam shape that is simple compared to the first beam shape. The second beam is attached to the body and extends between the first fixture region and the second fixture region of the body.

Abstract: A vehicle removable roof system including a roof support structure removably attachable to a vehicle, the roof support structure including a plurality of vertically oriented supports and at least one horizontally oriented support. The at least one removable panel configured to engage with the roof support structure. The vehicle removable roof system formed of a light weight sandwich composite structure that affords a high gloss surface without resort to additional processing after production with improved moisture resistance and edges suitable for sealing the removable roof assembly to other vehicle components.

Abstract: A process for resin transfer molding (RTM) with staggered injection of a resin is provided that injects resin into a plurality of injection ports of a mold. The temperature and pressure applied to the mold are controlled during injection to limit promote rapid filling of the mold cavity. The injection ports are activated for injecting the resin in any order of individually, in groups, or pairings. Fibers are readily added to the mold separately or within the resin. Cycle times of from 1 to 5 minutes are provided for the process.

Abstract: A composite sandwich panel assembly including an open area core, a high gloss surface sheet, and a structural skin. The open are core defines a plurality of pores and has a first face and an opposing second face. The high gloss surface sheet is adhered to the first face of the open area core by a first adhesive layer. The high gloss surface sheet has a high gloss surface. The structural skin is adhered to the second face of the open area core by a second adhesive layer. A process for forming the composite sandwich panel assembly includes positioning the high gloss surface sheet, joining the first face of the open area core to the high gloss surface sheet with a first adhesive layer intermediate therebetween, and joining the structural skin to the second face of the open area core with a second adhesive layer intermediate therebetween.

Abstract: A polyurea additive is provided that strengthens a given base sheet molding composition (SMC) An isocyanate containing species and an amine containing species are introduced into an uncured polymeric resin of a sheet molding compound (SMC) under conditions suitable for the formation of a polyurea polymer network. Upon cure of the SMC base resin, an interpenetrating network is formed that is stronger than the base SMC absent the polyurea. As a result, an article is formed from the SMC that is stronger at the same dimensions than a conventional article or thinned to achieve the same properties to obtain a lightweight article compared to that formed from conventional SMC. The properties of the article are also attractive relative to aluminum for the formation of vehicle body and exterior panels.

Abstract: A process for debundling a carbon fiber tow into dispersed chopped carbon fibers suitable for usage in molding composition formulations is provided. A carbon fiber tow is fed into a die having fluid flow openings, through which a fluid impinges upon the side of the tow to expand the tow cross sectional area. The expanded cross sectional area tow extends from the die into the path of a conventional fiber chopping apparatus to form chopped carbon fibers, or through contacting tines of a mechanical debundler. Through adjustment of the relative position of fluid flow openings relative to a die bore through which fiber tow passes, the nature of the fluid impinging on the tow, the shape of the bore, in combinations thereof, an improved chopped carbon fiber dispersion is achieved. The chopped carbon fiber obtained is then available to be dispersed in molding composition formulations prior to formulation cure.

Abstract: A dual layer cured composite article is provided that has an outer part having an outer part thickness composed of a first resin matrix having between 50 and 70 total weight percent of the outer part being an outer part mixed fiber filler, the outer part mixed fiber filler having an outer part primary fiber:carbon fiber ratio of 0.05-20:1. An inner part complementary to the outer part is provided and has an inner part thickness composed of a second resin matrix having between 40 and 60 total weight percent of the inner part of an inner mixed fiber filler, the inner mixed fiber filler having an inner part primary fiber:carbon fiber ratio of less than said outer part primary fiber:carbon fiber ratio. A joinder between the outer part and the inner part is provided. A process for producing such an article is also provided.

Abstract: A vehicular body structural arrangement includes a polymeric deck panel. The deck panel includes corrugations, a crosswise crossbeam footprint and, along a partial length of the crossbeam footprint, two features for securing a crossbeam thereto. The corrugations include an adjacent ridge and valley. The features include a first feature having a first direction along the deck panel, and a second feature having a second direction toward the deck panel. The first feature includes a unitarily-formed web projecting normally to the deck panel past the ridge, and a rivet nut installed to the web against a backing facing the first direction. The second feature includes a unitarily-formed stanchion behind the web projecting normally to the deck panel from inside the valley, and a threaded insert seated in the stanchion facing the second direction.

Abstract: A vehicle component is provided that includes a first cured layer of a molding composition having a predominant fiber filler chopped glass fibers, a second cured layer of molding composition having a predominant fiber filler chopped carbon fibers, and an elastomeric bonding agent with elongation properties configured to accommodate the differential coefficients of linear thermal expansion between the first cured layer and the second cured layer. The second cured layer is substantially devoid of glass fiber. The bonding agent is an elastomeric adhesive, which is operative from ?40 to 205° C. The first cured layer forms an outer skin layer surface of a vehicle and the second cured layer forms an interior layer, where the outer skin layer surface has a class-A finish.

Abstract: A process is provided for molding a resin matrix around a distribution of well distributed epoxy coated glass fibers to produce an article. The article is mass produced by the molding process based on a one or more layer structure, with an outer panel having a high degree of surface smoothness common to automotive body panels and a comparatively high tensile strength joinder thereto. The epoxy coated glass fibers are present in a single panel of an article or all such panels of a multiple layer article. The epoxy coated glass fibers can be present in an articles in a form of: chopped glass fibers that are intermixed and vary in orientation, a woven roving containing predominately epoxy glass fibers with carbon fibers dispersed there through, or non-woven fiber mats.

Abstract: An energy-absorbing assembly includes a housing and a plurality of discrete energy-absorbing elements. The housing includes a first wall and a second wall. The first wall and the second wall are spaced apart from one another to at least partially define an interior compartment. Each element of the plurality of energy-absorbing elements includes a polymer and a plurality of reinforcing fibers. The plurality of energy-absorbing elements is at least partially disposed within the interior compartment and fixed to the housing. Each energy-absorbing element of the plurality of energy-absorbing elements includes an elongated hollow structure extending between a first end and a second end. Each elongated hollow structure defines a longitudinal axis extending nonparallel to at least one of the first wall and the second wall. In various alternative aspects, each energy-absorbing element may include a transverse wall.

Abstract: A system for debundling fiber tow into chopped fibers is provided that has one or more reels of fiber tow, a cutting element configured to receive the fiber tow to form chopped fiber, and a tube with introduced gas flow configured to receive the chopped fiber. A moving belt is positioned under the tube to collect the chopped fiber. A dispenser is positioned along the moving belt for applying a binder or additive. A treatment chamber receives the treated chopped fiber. A process for debundling fiber tow into chopped fibers is provided that supplies one or more reels of fiber tow to a cutting system, drops the chopped fiber into a tube with introduced gas flow to debundle the chopped fiber with a vortex, collects the chopped fiber exiting the tube onto a moving belt, chemically treats the chopped fiber, and provides the chemically treated chopped to a treatment chamber.

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 process is provided to reclaim carbon fiber from a cured vinyl ester, crosslinked unsaturated polyester, or epoxy thermoset matrix. The composite pieces are added to a polyol solvent composition under to conditions to free more than 95% by weight of the carbon fiber from the composite. The freed carbon fibers are washed and dried to reclaim carbon fiber reusable to reinforce a polymer to form a new FRC article. Solvents are chosen that are low cost and low toxicity. Processing is further facilitated by techniques such as solvent pre-swell of the particles, microwave heating, and sonication to promote thermoset matrix digestion to free reinforcing carbon fibers.

Abstract: A headliner for use in a vehicle having a roof, the headliner including a sheet and a plurality of first snap portions adapted to couple with a plurality of corresponding second snap portions fixed to the vehicle roof to mount the sheet to an interior side the vehicle roof through the interaction of the plurality of first snap portions and the corresponding second snap portions. A method for installing a headliner on a vehicle roof structure includes providing a headliner comprising a sheet having an upper surface, a lower surface, and a plurality of first snap portions fixed to the sheet, and joining the plurality of first snap portions to a plurality of second snap portions fixed to the roof structure, the plurality of second snap portions adapted to couple with the plurality of first snap portions to mount the sheet to the interior side the vehicle roof structure.

Abstract: A molding composition formulation is provided that includes polypropylene, glass fiber, and a cellulosic powder used as a filler. The filler may be at least one of coconut shell powder, walnut shell powder, or rice hull. The molding composition formulation may further include natural cellulosic fiber illustratively including at least one of coconut fibers, bamboo fibers, sugar cane fibers, or banana skin fibers. The molding composition may be compression moldable long fiber thermoplastic (LFTD). The molding composition formulation may be used in thermoforming. In a specific embodiment of the molding composition, the formulation proportion of the polypropylene is 50 to 60 percent of the formulation; and the polypropylene substitute is 5 to 15 percent of the formulation, and in an alternative embodiment, the formulation proportion of the polypropylene is 40 to 80 percent, the cellulosic powder is 1 to 25 percent, and the glass fiber is 1 to 50 percent.

Abstract: A monomer is provided for a thermoset molding compound. The monomer is also polymerized with conventional monomers to form thermoplastic polymers. Graphene oxide is used to chelate metal ions to form a graphene oxide chelate that is coupled to a monomer retaining an aliphatic unsaturation capable of free radical polymerization reaction. Inclusion of a metal ion chelated to the graphene oxide affords control over the conductivity of the resultant article. In some embodiments, the monomer is found polymerized into a resulting article proximal to the article surface.

Abstract: A system for debundling fiber tow into chopped fibers is provided that has one or more reels of fiber tow, a cutting element configured to receive the fiber tow to form chopped fiber, and a tube with introduced gas flow configured to receive the chopped fiber. A moving belt is positioned under the tube to collect the chopped fiber. A dispenser is positioned along the moving belt for applying a binder or additive. A treatment chamber receives the treated chopped fiber. A process for debundling fiber tow into chopped fibers is provided that supplies one or more reels of fiber tow to a cutting system, drops the chopped fiber into a tube with introduced gas flow to debundle the chopped fiber with a vortex, collects the chopped fiber exiting the tube onto a moving belt, chemically treats the chopped fiber, and provides the chemically treated chopped to a treatment chamber.

Abstract: A system for debundling fiber tow into chopped fibers is provided that has one or more reels of fiber tow, a cutting element configured to receive the fiber tow to form chopped fiber, and a tube with introduced gas flow configured to receive the chopped fiber. A moving belt is positioned under the tube to collect the chopped fiber. A dispenser is positioned along the moving belt for applying a binder or additive. A treatment chamber receives the treated chopped fiber. A process for debundling fiber tow into chopped fibers is provided that supplies one or more reels of fiber tow to a cutting system, drops the chopped fiber into a tube with introduced gas flow to debundle the chopped fiber with a vortex, collects the chopped fiber exiting the tube onto a moving belt, chemically treats the chopped fiber, and provides the chemically treated chopped to a treatment chamber.