Abstract: A sheet molding compound (SMC) is provided with superior conductivity properties based on the use of graphitics. A process for exfoliation of GnP and turbostratic carbon is also provided. By exfoliating the graphitics, a reduced amount of material can confer comparable properties relative to native GnPs or turbostratic carbon thereby reducing the amount of material usage, but also reducing negative effects to the base resin formulation through inclusion of these additives. Particular utility is found in thermoset resin molding to produce articles that are amenable to electrostatic coating and other surface treatments that rely on surface conductivity and especially in the realm of vehicle body parts.

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 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 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 a 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 of compression molding an article from a curable resin is provided that includes opening a mold to an open position by displacing an upper die having an upper mold surface from a lower die having a lower mold surface. Resin is placed a mold surface and the dies are closed to an intermediate start position at a rate of from 1 to 10 cm/sec. The dies are then closed to a start position at a rate of between 25 and 60% of the rate of closure to the intermediate position. A shroud volume is evacuated for at least 3 seconds to a reduced pressure of less than 0.16 atmospheres while continuing to press toward a mold cavity volume at a rate of between 12 and 30% of the rate of closure to the intermediate start. The reduced pressure is removed as the full compression is applied.

Abstract: An underbody assembly for a vehicle includes a plurality of polymer-fiber composite components. The polymer-fiber composite components include a base and a first reinforcement. The base includes a first side and a second side. The base is configured to extend in a longitudinal direction between a front of the vehicle and a rear of the vehicle. The first reinforcement is coupled to the base. The first reinforcement includes a first elongated ridge and a first elongated trough. The first elongated trough is disposed adjacent to the first elongated ridge. The first elongated ridge and the first elongated trough each extend transversely between the first side of the base and the second side of the base. In various aspects, the underbody assembly consists essentially of the polymer-fiber composite components.

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 preform for thermoset resin composition molding is provided that upon cure forms a variety of molded and fiber reinforced articles used in a variety of applications such as vehicle components including bed lines, body components, trim, interior components, and undercar components; architectural components such as trim and doors, marine components including hulls, trim, and cockpit pieces; and similar structures in aerospace settings. A novel slurry composition, a novel centrifugal process, or a combination thereof provide superior quality preforms that are created with greater throughput relative to conventional techniques. The inhibition of fiber movement between the time such a fiber contacts the mold, or fibers already in place on the mold, and the time the fibers are set in position provides a superior fiber homogeneity and randomized orientation relative to existing slurry techniques with attributes of low scrap generation, and process flexibility with respect to part shape and fiber material.

Abstract: An automated process is provided for debundling carbon fiber tow that includes feeding a carbon fiber tow into a chopper. The carbon fiber tow is cut to form lengths of chopped tow portions. The lengths of chopped tow portions are distributed on a moving conveyor. The lengths of chopped tow portions are exposed to a first plasma discharge from a first plasma source on the moving conveyor to create debundled carbon fibers. Alternatively, the carbon fiber tow is exposed to the first plasma discharge prior to being cut into lengths. A system for applying chopped fibers to a sheet of molding compound includes a chopper for cutting a carbon fiber tow into lengths of chopped tow portions. A conveyor belt receives the lengths of chopped tow portions. At least one plasma generating source is arrayed across of the conveyor.

Abstract: A process of formulating a curable thermoset resin formulation is provided that includes reacting a natural cellulosic filler with at least one of: a silsesquioxane, a isocyanate, a base, or an organic acid to form a reduced hydrophilicity filler. By intermixing the resulting reduced hydrophilicity filler with a thermoset cross linkable polymeric resin, a curable thermoset resin formulation is formed that has superior properties to conventional formulations in terms of density and environmental impact. The formulation properties in terms of strength of the cured article are improved relative to untreated natural fillers. The treatment is advantageous relative to plasma treatment. An article is also provided produced upon cure of the formulation.

Abstract: A molded article is provided that has a resin matrix having a surface, the resin matrix formed from cross-linked polyester resin or vinyl-ester resin. Glass fibers are crossed linked to the resin matrix via a silane coupling agent reactive with the matrix. A molded article is provided that has a resin matrix having a surface, the resin matrix formed from cross-linked polyester resin or vinyl-ester resin. Glass fibers each covalently bonded to at least one microspheroid matrix via a silane coupling agent reactive with a surface of the at least one microspheroids are present in increase the fiber pull strength. A sizing composition for treating glass fibers is also provided for use in such articles.

Abstract: A temperature regulation and management system is provide that has an inner wall and an outer wall forming a space for accommodating a phase change material (PCM) with the space between the walls, in one or both of the walls, or a combination of such locations. The inner wall is in contact with an object that requires temperature regulation within a specified operating range, such as a vehicle battery pack. The inner wall and the outer wall are both formed from sheet molding compound (SMC), or the outer wall if formed of a filled polyurethane.

Abstract: A molding composition formulation is provided of a thermoset cross-linkable polyol having unsaturated backbone comprising the structure defined by formula 1: (1) a reinforcing filler; and optionally, a flame retardant, a UV stabilizer or a composition comprising one of the foregoing.

Abstract: A process is provided for overmolding an insert or substrate with non-oriented thermoplastic fibers present in an amount that allows them to thermally bond in the presence of non-oriented filler fibers. The thermoplastic fiber fusion retains the filler fibers within the insert upon cooling. The filler fibers are selected to modify the properties of the insert and an overmolded article formed with the insert therein. Such overmolded articles are used in applications including vehicle components such as automotive interior light bases, posts, undercar components, cross members, chassis components, and frame components; architectural components such as home door interiors, sound damping panels, and weather resistant wood replacement. Articles formed with the inventive process yield weight reductions compared to conventional insert overmoldings, along with low scrap generation, process flexibility with respect to part shape and fiber material.

Abstract: Pressurized air is conveyed through a manifold into contact with the first member via apertures having hole diameters of from 0.8 to 2.5 mm that are spaced apart at a distance of from 10 to 30 mm along the manifold to achieve a turbulent air flow pattern with a Reynolds number of greater than 2200 at a temperature of between 150 and 315° C. and at an air pressure between 0.5 and 10 pounds per square inch (psi) over ambient pressure onto the outer surfaces of the first member and the second member for heat curing a curable adhesive between the members to achieve adhesive cure in 60 to 90 seconds and free of any bond-line read-out visible to an unaided normal human eye.

Abstract: A process of formulating a curable thermoset resin formulation is provided that includes reacting a natural cellulosic filler with at least one of: a silsesquioxane, a isocyanate, a base, or an organic acid to form a reduced hydrophilicity filler. By intermixing the resulting reduced hydrophilicity filler with a thermoset cross linkable polymeric resin, a curable thermoset resin formulation is formed that has superior properties to conventional formulations in terms of density and environmental impact. The formulation properties in terms of strength of the cured article are improved relative to untreated natural fillers. The treatment is advantageous relative to plasma treatment. An article is also provided produced upon cure of the formulation.

Abstract: A molding composition formulation includes a thermoset cross-linkable 12 to 45 micron polymeric resin. Hollow glass microspheroids are present from 2 to 12 total weight percent. An article formed from such a composition is further strengthened by the addition of a surface activating agent bonded to the surface of the glass microspheroids. Conventional particulate fillers when added to an inventive formulation provide enhanced performance when the filler particle has a size sufficiently small to insert within adjacent microspheroid interstitial voids. An unsaturated polyester resin so formed is particularly well suited for the formation of sheet molding compound formulations.

Abstract: A molding composition formulation is provided that includes polypropylene, glass fiber, and a polypropylene substitute including recycled sheet molding composition transfer film. The polypropylene substitute is present from 1 to 35 total weight percent also may include natural cellulosic fibers or powders. A process is provided by which the polypropylene substitute is mixed and homogenized and then mixed with polypropylene and additives, and thereafter glass fiber. A reduction in the amount of virgin polypropylene used is reduced compared to conventional thermoplastic glass fiber filled moldings.

Abstract: A vehicle front end load bearing bolster is provided with improved structural performance and a lower component weight, while also minimizing material, tooling, and production costs. The front end assembly is formed with a hydro-formed cross car reinforcement tube secured or bonded with mechanical fasteners and room temperature adhesive to a bolster, thereby improving stress distribution and increasing cross car system stiffness. The bonded hydro-form tube/bolster assembly provides increased torsion stiffness and dimensional stability to the vehicle frame. The hydro-formed cross car reinforcement tube have flattened terminal ends with apertures for integrated attachment to a bolster. The hydro-formed cross car reinforcement tube is formed of aluminum, brass, carbon, steel, stainless steel, copper and high strength alloys.

Abstract: A vehicle roof water runoff management system is provided with an improved seal that has a constant seal gap between removable vehicle roof top panels and an adjoining fixed roof. The constant seal gap is maintained in the B-pillar interface area with the vehicle's roofing components. The vehicle roof water runoff management system offers improved manufacture and long term performance reliability over previous designs.