Abstract: The present invention refers to multi-layered decorative laminates including a decorative layer, such as a wood veneer layer, and one or more reinforced polymer layer(s), such as a reinforced polyvinyl chloride (PVC) layer. Methods of making and using such laminates and of producing overly and underlay layers, which supplement the decorative layer, are described herein. The invention also relates to laminates of improved fire resistance including reinforced polymer layers.

Abstract: The present invention refers to multi-layered decorative laminates including a decorative layer, such as a wood veneer layer, and one or more reinforced polymer layer(s), such as a reinforced polyvinyl chloride (PVC) layer. Methods of making and using such laminates and of producing overly and underlay layers, which supplement the decorative layer, are described herein. The invention also relates to laminates of improved fire resistance including reinforced polymer layers.

Abstract: A process is disclosed for the manufacture of reinforced composites. This method provides a process that allows for the direct mixing of discontinuous reinforcement such as wet chopped strands of glass fiber or continuous reinforcement such as glass strands, with an aqueous suspension of a solution polymerized polymer, such as polyvinyl chloride. The process results in a cost-effective means for reinforcing polymers such as PVC while simultaneously substantially improving properties such as impact strength, stiffness, and moldability without the need for a binder.

Abstract: A fire resistant thermosetting resin composite formulation comprising an effective amount of a flame suppressant additive. The thermosetting resin used in the formulation can be a polyester resin. The flame suppressant additive is a polyvinyl chloride powder which may be obtained as a reaction product of an emulsion polymerization, or alternatively, it may be obtained from recycled products containing significant amounts of polyvinyl chloride. The additive can be used in an amount of from 1% by weight to about 75% by weight based on the amount of an inorganic filler material that may be present in the formulation.

Abstract: A process is disclosed for the manufacture of reinforced composites. This method provides a process that allows for the direct mixing of discontinuous reinforcement such as wet chopped strands of glass fiber or continuous reinforcement such as glass strands, with an aqueous suspension of a solution polymerized polymer, such as polyvinyl chloride. The process results in a cost-effective means for reinforcing polymers such as PVC while simultaneously substantially improving properties such as impact strength, stiffness, and moldability without the need for a binder.

Abstract: A method and apparatus for resin injected pultrusion is provided. The method comprises injecting a resin material into a reinforcement pack at a sufficiently high pressure such that the pressure in the injection area or weir of the injection die is substantially equal to the compression pressure applied by the exit portion of the injection die. An apparatus for achieving the method is also provided.

Abstract: A method and apparatus is provided for the in-line production of composite strand material and the conversion of at least a portion of the strand material into a composite product. The apparatus (10) includes a combining station (48) where glass fibers (14) with a second polymeric material (66) are combined to form composite strand material (16), and at least one mold (54) for receiving a portion of the composite strand material and forming the portion into a composite product. The apparatus also includes transfer equipment for moving the composite strand material from the combining station to the mold, which may include a computer-controlled robotic arm (52). In another embodiment, the apparatus includes a collecting device (18) for accumulating the composite strand material (16) in looped form and equipment for delivering the accumulated portion from the collecting device to the mold (54).

Abstract: A method for performing resin injected pultrusion employing different resin materials is provided. The method comprises impregnating the interior layers of a pultrusion reinforcement pack with a first resin material, adding the exterior layers to form a pultrusion pack and impregnating the pack with a resin material substantially nonidentical to the first resin material.

Abstract: A method and apparatus for resin injected pultrusion is provided. The method comprises injecting a resin material into a reinforcement pack at a sufficiently high pressure such that the pressure in the injection area or weir of the injection die is substantially equal to the compression pressure applied by the exit portion of the injection die. An apparatus for achieving the method is also provided.

Abstract: A method and apparatus are provided for producing composite strands. The apparatus comprises a heated bushing for supplying streams of molten glass to be drawn into continuous first fibers; a drawing device adapted to draw the streams into the first fibers; supply equipment for supplying one or more second fibers of a second material; one or more applicators for applying a size to the first and second fibers; and a device for gathering the first and second fibers into one or more composite strands. The composite stands are made by drawing glass fibers from the bushing; applying sizing to the glass fibers and the second fibers; contacting the fibers with a heated contact plate to dry the fibers; and then commingling the fibers to form one or more composite strands.

Abstract: This development provides crystalline unsaturated polyesters having unreacted olefinically unsaturated monomer entrapped within its crystal lattice. The crystalline polyester can be used in high performance, structural SMC products or as a size or binder for glass fiber reinforcements or mats.

Abstract: A process is provided for manufacturing ballistic resistant composites of an isophthalic thermoset polyester and woven roving made of magnesia aluminosilicate glass fibers. An impregnating solution is provided whereby pregregs can be conveniently formed and then vacuum bag molded. The ingredients in the impregnating solution are critically selected to provide prescribed viscosities after the elapse of certain periods of time and thereby allow the final articles to be formed in an economical and expedient manner.

Abstract: A process is provided for manufacturing ballistic resistant composites of an isophthalic thermoset polyester and woven roving made of magnesia aluminosilicate glass fibers. An impregnating solution is provided whereby prepregs can be conveniently formed and then vacuum bag molded. The ingredients i the impregnating solution are critically selected to provide prescribed viscosities after the elapse of certain periods of time and thereby allow the final articles to be formed in an economical and expedient manner.