Abstract: A fiber reinforced polypropylene composite vehicle body panel. The vehicle body panel includes a substrate molded from a composition comprising at least 30 wt % polypropylene based resin, from 10 to 60 wt % organic fiber, from 0 to 40 wt % inorganic filler, and optionally lubricant (typically present at from 0 to 0.1 wt %), based on the total weight of the composition, the substrate having an outer surface and an underside surface. A process for producing a body panel for a vehicle is also provided. The process includes the step of molding a composition to form the body panel for a vehicle, the body panel having at least an outer surface and an underside surface, wherein the composition comprises at least 30 wt % polypropylene, from 10 to 60 wt % organic fiber, from 0 to 40 wt % inorganic filler, and optionally lubricant (typically present at from 0 to 0.1 wt %), based on the total weight of the composition.

Abstract: The present invention is directed generally to cloth-like fiber reinforced polypropylene compositions, and the beneficial mechanical and aesthetic properties imparted by such compositions. The cloth-like fiber reinforced polypropylene compositions include at least 25 wt % polypropylene based polymer, from 5 to 60 wt % organic reinforcing fiber, from 0 to 60 wt % inorganic filler, and from 0.1 to 2.5 wt % colorant fiber. A method of making fiber reinforced polypropylene compositions and molding articles there from is also disclosed and includes the steps of twin screw extrusion compounding the composition to form a resin and injection molding the resin to form a cloth-like article. Articles molded from these fiber reinforced polypropylene compositions have a flexural modulus of at least 300,000 psi, exhibit ductility during instrumented impact testing, and exhibit a cloth-like appearance.

Abstract: A fiber reinforced polypropylene composite headliner substrate panel. The headliner substrate panel is molded from a composition comprising at least 30 wt % polypropylene based resin, from 10 to 60 wt % organic fiber and from 0 to 40 wt % inorganic filler, based on the total weight of the composition, the headliner substrate panel having an outer surface and an underside surface. A process for producing a headliner substrate panel for a vehicle is also provided. The process includes the step of molding a composition to form the composite headliner substrate panel, the headliner substrate panel having at least an outer surface and an underside surface, wherein the composition comprises at least 30 wt % polypropylene, from 10 to 60 wt % organic fiber and from 0 to 40 wt % inorganic filler, based on the total weight of the composition.

Abstract: A fiber reinforced polypropylene composite door core module. The door core module includes a module plate molded from a composition comprising at least 30 wt % polypropylene based resin, from 10 to 60 wt % organic fiber, from 0 to 40 wt % inorganic filler, and optionally lubricant (typically present at from 0 to 0.1 wt %), based on the total weight of the composition, the module plate having at least a first side and a second side. A process for producing a door core module is also provided. The process includes the step of injection molding a composition to form the door core module, the door core module having a module plate having at least a first side and a second side, wherein the composition comprises at least 30 wt % polypropylene, from 10 to 60 wt % organic fiber, from 0 to 40 wt % inorganic filler, and from 0 to 0.1 wt % lubricant, based on the total weight of the composition.

Abstract: A fiber reinforced polypropylene composite interior trim cover panel. The interior trim cover panel is molded from a composition comprising at least 30 wt % polypropylene based resin, from 10 to 60 wt % organic fiber, from 0 to 40 wt % inorganic filler, and optionally from 0 to 0.1 wt % lubricant, based on the total weight of the composition, the interior trim cover panel having an outer surface and an underside surface. A process for producing an interior trim cover panel for a vehicle is also provided. The process includes the step of injection molding a composition to form the interior trim cover panel for a vehicle, the interior trim cover panel having at least an outer surface and an underside surface, wherein the composition comprises at least 30 wt % polypropylene, from 10 to 60 wt % organic fiber, from 0 to 40 wt % inorganic filler, and optionally from 0 to 0.1 wt % lubricant, based on the total weight of the composition.

Abstract: The present invention relates to new laminates formed from at least one ionomer layer including a metallized ionomer layer, one or more tie layers, and optionally a backing layer. The present invention also relates to new composite articles made from these laminates in combination with optional substrate materials.

Abstract: The present invention includes a laminate and formation of a laminate having at least one layer of an ionomer and at least one layer of an acid polymer or blend of acid polymer and a thermoplastic polyolefin that can be thermoformed to form a shaped laminate. The shaped laminate can then be contacted with a plastic substrate such as a thermoplastic polyolefin to form a composite article by such means as, for example, injection molding. The laminate can be pigmented to eliminate the need to paint the surface of the plastic substrate. Impact and scratch resistant articles can be formed from the laminated substrate such as automotive parts, appliance body parts and sporting equipment.

Abstract: A co-extruded laminate of at least one layer of an ionomer and at least one layer of an acid polymer that can be thermoformed with a plastic substrate such as a polyolefin. The laminate can be pigmented to eliminate the need to paint the surface of the plastic substrate. Articles can be formed from the laminated substrate such as automotive parts and sporting equipment.

Abstract: An article and a method for making the same are provided. In one aspect, the article includes a formable metal substrate, and at least one ionomer layer at least partially disposed on the formable metal substrate. In one aspect, the method includes disposing one or more pigmented ionomer layers at least partially on a first surface of a formable metal substrate, disposing one or more transparent ionomer layers at least partially on the one or more pigmented ionomer layers, and shaping the formable metal substrate having the ionomer layers disposed thereon.

Abstract: Embodiments of the present invention include a composition formed from (a) 50 wt % to 85 wt % of at least one impact copolymer relative to the total weight of the composition, the impact copolymer comprising up to 25 wt % of an ethylene-propylene rubber, the rubber having a content of ethylene-derived units of from 40 wt % to 60 wt % relative to the rubber; and (b) 50 wt % to 15 wt % of at least one plastomer relative to the total weight of the composition, wherein the plastomer is a copolymer of ethylene derived units and at least one of C3 to C8 ?-olefin derived units from 5 wt % to 30 wt % of the plastomer. The composition is useful for automotive components, especially interior automotive components such as airbag covers, the composition having a secant flexural modulus of at least 50 kpsi (345 MPa) and 100% ductility down to ?40° C.

Abstract: The present invention relates to new backing layers and/or new substrates for making (1) new multilayer structures formed from one or more ionomers and one or more tie-layers, and optionally a new backing layer to form laminates, (2) new composite articles made from these laminates in combination with optional new substrate materials, and (3) new methods of making composite articles from these laminates by shaping and subsequently contacting them with a substrate material.

Abstract: The present invention includes a laminate and formation of a laminate having at least one layer of an ionomer and at least one layer of an acid polymer or blend of acid polymer and a thermoplastic polyolefin that can be thermoformed to form a shaped laminate. The shaped laminate can then be contacted with a plastic substrate such as a thermoplastic polyolefin to form a composite article by such means as, for example, injection molding. The laminate can be pigmented to eliminate the need to paint the surface of the plastic substrate. Impact and scratch resistant articles can be formed from the laminated substrate such as automotive parts, appliance body parts and sporting equipment.

Abstract: A laminate structure having at least one layer of an ionomer resin (a) and at least one layer of an acid polymer or a blend of an acid polymer and a thermoplastic polyolefin (b) that can be thermoformed to form a shaped article and additional polyolefin substrate can be provided. The laminate can be pigmented to eliminate the need to paint the surface of the plastic substrate. The laminate is useful in the production of automotive parts and sports equipment.

Abstract: A polymeric material suitable for fabrication into an article and particularly a polymeric material suitable for fabrication into an article suitable for receiving paint is provided. The polymeric material may be a blend of impact copolymer and plastomer. The impact copolymer includes between 95 and 78 wt % homopolypropylene and between 5 and 22 wt % of ethylene-propylene rubber, wherein ethylene propylene rubber may have less than about 50 wt % ethylene. The plastomer may be an ethylene/hexene plastomer. The ethylene/hexene plastomer may have a density in the range from 0.88 to 0.915 g/cc and a melt index (dg/min) from 0.8 to 10. The impact copolymer may be present in the blend in a range of 95 to 70 wt % and the ethylene/hexene plastomer may be present in the blend in a range from 5 to 30 wt %. The propylene, ethylene and hexene components may be present in the blend in respective ranges of 73.2 to 84.2 wt %, 14.3 to 23.1 wt % and 1.5 to 3.7 wt %.