Abstract: In an embodiment, an energy-absorbing device can comprise: a polymer reinforcement structure, wherein the polymer reinforcement structure comprises a polymer matrix and chopped fibers; and a shell comprising 2 walls extending from a back and forming a shell channel, wherein the shell comprises continuous fibers and a resin matrix; wherein the polymer reinforcement structure is located in the shell channel.

Abstract: In an embodiment, an energy-absorbing device can comprise: a polymer reinforcement structure, wherein the polymer reinforcement structure comprises a polymer matrix and chopped fibers; and a shell comprising 2 walls extending from a back and forming a shell channel, wherein the shell comprises continuous fibers and a resin matrix; wherein the polymer reinforcement structure is located in the shell channel.

Abstract: A fiber-reinforced thermoplastic composition includes a polypropylene polymer component including a low flow grade polypropylene and a high flow grade polypropylene, and a fiber reinforcement component. The fiber-reinforced thermoplastic composition is capable of being vacuum formed. In another aspect a thermoplastic composition includes a homopolymer component including polypropylene, a co-polymer component, an impact modifier, and one or more of a flame retardant component and a fiber reinforcement component. The thermoplastic composition is capable of being vacuum formed. The fiber-reinforced thermoplastic composition may be formed into an article such as an enclosure for an electrical component, and it may be chemically resistant to a medical grade cleaner.

Abstract: A housing for an electronic device comprising: a core layer comprising a first thermoplastic material; a first skin layer comprising a second thermoplastic material located on a first side of the core layer; a second skin layer comprising the second thermoplastic material located on a second side of the core layer opposite the first side; wherein the core layer comprises a foam structure, a honeycomb structure, or combinations thereof; and wherein the thickness of the core layer is 30% to 75% of the total thickness of the housing.

Abstract: A fiber-reinforced thermoplastic composition includes a polypropylene polymer component including a low flow grade polypropylene and a high flow grade polypropylene, and a fiber reinforcement component. The fiber-reinforced thermoplastic composition is capable of being vacuum formed. In another aspect a thermoplastic composition includes a homopolymer component including polypropylene, a co-polymer component, an impact modifier, and one or more of a flame retardant component and a fiber reinforcement component. The thermoplastic composition is capable of being vacuum formed. The fiber-reinforced thermoplastic composition may be formed into an article such as an enclosure for an electrical component, and it may be chemically resistant to a medical grade cleaner.

Abstract: A method of making an article includes: heating a plaque formed from a thermoplastic composition; and vacuum forming the heated plaque to form the article. The thermoplastic composition includes a polypropylene polymer component and a fiber reinforcement component. The heating is implemented using one or more heaters having a maximum temperature output of between 1500-3000° C. and maximum intensity between 0.80 ?m and 2 ?m. The article may include a surgical tray having a bottom surface having side walls disposed around a periphery thereof and extending from the bottom surface.

Abstract: In an embodiment, an A-B-A structure, can comprise: a core layer comprising a first thermoplastic material having a first density (Y), wherein the core layer has a core thickness and wherein the core layer comprise at least one of (i) a through plane thermal conductivity of greater than equal to 0.1 W/m K, and (ii) a core layer density (X) that is X?0.8Y; a first outer layer comprising a second thermoplastic material located on a first side of the core layer; and a second outer layer comprising the second thermoplastic material located on a second side of the core layer opposite the first side; wherein the core thickness is 30% to 75% of a total thickness of the A-B-A structure.

Abstract: A mold apparatus comprising: a core portion comprising a core surface, a first induction coil, and an inner core, and wherein the core portion has a core portion mass; a cavity portion comprising a second induction coil and a cavity surface, and wherein the cavity portion has a cavity portion mass; wherein the inner core comprises a non-magnetic material, the core surface comprises a magnetic material, and a density of the non-magnetic material is less than a density of the magnetic material; and wherein the core portion mass and the cavity portion mass differ by less than or equal to than 5%.

Abstract: A surgical article formed from a fiber-reinforced thermoplastic composition includes a polypropylene polymer component and a fiber reinforcement component. The surgical article is formed using a vacuum forming process. The surgical article may include a surgical tray including a bottom surface having side walls disposed around a periphery thereof and extending from the bottom surface. The vacuum forming may include a heater profile configured to heat a surface area at a perimeter of a plaque such that a plaque thinning at the bottom surface is minimized and radius stretch through the side walls is minimized, thereby retaining maximum wall thickness.

Abstract: Laminated parts having selective perforations and methods for producing laminated parts using selective perforations are disclosed. Also disclosed are hybrid parts having sequenced plies of unequal dimensions and methods for producing hybrid parts using sequenced plies of unequal dimensions.

Abstract: A device for producing a composite part includes a first platen structure, a second platen structure, a first plate structure, a second plate structure, a first press pad, and a second press pad. The first platen structure, the first plate structure, and the first press pad form a first assembly. The second platen structure, the second plate structure, and the second press pad form a second assembly. A cavity for receiving a laminate is arranged between the first assembly and the second assembly, the cavity including a wall structure arranged to surround the laminate. The wall structure includes an insulating material. A process for the device is also described.

Abstract: A molding process and device produce a hybrid composite part. The process includes configuring a mold cavity (102) to receive a prepreg material (116), configuring the mold cavity further to receive an injection of material, and providing a mold core (104) including at least one main core (112). The at least one main core (112) are configured to move with respect to the mold core (104). The process includes moving the mold core (104) with respect to the mold cavity (102) with a first actuator mechanism, moving the mold core to take a first configuration, forming with the mold core in the first configuration a preform from the prepreg material, moving the mold core to take a second configuration, and over molding onto the preform with the injection of the material with the mold core in the second configuration.

Abstract: In an embodiment, an A-B-A structure, can comprise: a core layer comprising a first thermoplastic material having a first density (Y), wherein the core layer has a core thickness and wherein the core layer comprise at least one of (i) a through plane thermal conductivity of greater than equal to 0.1 W/m K, and (ii) a core layer density (X) that is X?0.8Y; a first outer layer comprising a second thermoplastic material located on a first side of the core layer; and a second outer layer comprising the second thermoplastic material located on a second side of the core layer opposite the first side; wherein the core thickness is 30% to 75% of a total thickness of the A-B-A structure.

Abstract: In an embodiment, an energy-absorbing device can comprise: a polymer reinforcement structure, wherein the polymer reinforcement structure comprises a polymer matrix and chopped fibers; and a shell comprising 2 walls extending from a back and forming a shell channel, wherein the shell comprises continuous fibers and a resin matrix; wherein the polymer reinforcement structure is located in the shell channel.

Abstract: A mold apparatus comprising: a core portion comprising a core surface, a first induction coil, and an inner core, and wherein the core portion has a core portion mass; a cavity portion comprising a second induction coil and a cavity surface, and wherein the cavity portion has a cavity portion mass; wherein the inner core comprises a non-magnetic material, the core surface comprises a magnetic material, and a density of the non-magnetic material is less than a density of the magnetic material; and wherein the core portion mass and the cavity portion mass differ by less than or equal to than 5%.

Abstract: A composition for the manufacture of a porous, compressible article, the composition comprising a combination of: a plurality of reinforcing fibers; a plurality of thermoplastic fibers; optionally a plurality of polymeric binder fibers; and continuous spaced carrier fibers; wherein the polymeric binder fibers have a melting point lower than the thermoplastic fibers; methods for forming the porous, compressible article; and articles containing the porous, compressible article. An article comprising a thermoformed composite is also disclosed, wherein the composite is not supported by a scrim layer and the composite exhibits improved conformation to fine mold details to which the scrim layer could not accurately conform.

Abstract: A consolidated fibrous mat comprises 20 to 50 weight percent of reinforcing fibers; and a continuous phase connecting the reinforcing fibers, comprising 50 to 70 weight percent of a polymer having a melt temperature at least 20° C. lower than the reinforcing fibers, and 5 to 10 weight percent of a binder having a melt temperature lower than the polymer; wherein the weight percent of each of the reinforcing fibers, the polymer, and the binder is based on the combined total weight of the reinforcing fibers, the polymer, and the binder.

Abstract: A shaped composite article is prepared by a process wherein an aesthetic laminate having a clear outer arylate layer and a colored compatible resin layer is thermoformed into a desired shape, and then compression molded together with a reinforced resin material containing compatible resin to form a color composite of the desired shape having an outer layer of clear arylate polyester polymer with the compatible resin layer forming an adherent bond with the compatible resin in the resin reinforced material.

Abstract: A shaped composite article is prepared by a process wherein an aesthetic laminate having a clear outer arylate layer and a colored compatible resin layer is thermoformed into a desired shape, and then compression molded together with a reinforced resin material containing compatible resin to form a color composite of the desired shape having an outer layer of clear arylate polyester polymer with the compatible resin layer forming an adherent bond with the compatible resin in the resin reinforced material.