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: 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: A transfer/injection molding apparatus is defined that includes a charge forming unit, a molding unit and a charge overflow unit. The charge is formed so that the fibers therein are randomly oriented in substantially parallel horizontal planes such that they are always substantially parallel to the direction of initial flow into the cavity of the molding unit. Excess charge from the cavity is forced into the charge overflow unit, which is selectively located in an area where surface finish is less critical. The excess charge displaces an overflow pin, which is kept upwardly biased, under molding pressure, to be flush with the lower inside wall of the molding unit cavity.

Abstract: An efficient, low cost method and apparatus for controlling fiber deposition in a fiber reinforced preform is provided. In the method, a main screen is placed in a tank filled with liquid. The main screen has a major surface, upright side walls and a plurality of openings formed therein. Reinforcing fibers are added to the liquid to create a slurry. The main screen is raised through the slurry to a level beneath the top of the slurry, thereby causing the reinforcing fibers to be deposited on the main screen. A retainer screen is inserted into the slurry so that the reinforcing fibers are sandwiched between the main screen and the retainer screen. Both the main screen and retainer screen are raised out of the tank effectively forming a preform with minimal deformation. An alternative embodiment includes a bubbler zone control device for mixing the slurry. The tank is divided into separate areas or zones whereby the supply of fluid to each bubbler zone is controlled.

Abstract: An efficient, low cost method and apparatus for controlling fiber deposition in a fiber reinforced preform is provided. In the method, a main screen is placed in a tank filled with liquid. The main screen has a major surface, upright side walls and a plurality of openings formed therein. Reinforcing fibers are added to the liquid to create a slurry. The main screen is raised through the slurry to a level beneath the top of the slurry, thereby causing the reinforcing fibers to be deposited on the main screen. A retainer screen is inserted into the slurry so that the reinforcing fibers are sandwiched between the main screen and the retainer screen. Both the main screen and retainer screen are raised out of the tank effectively forming a preform with minimal deformation. An alternative embodiment includes a bubbler zone control device for mixing the slurry. The tank is divided into separate areas or zones whereby the supply of fluid to each bubbler zone is controlled.

Abstract: An automated transfer/injection molding apparatus and process is defined that includes a charge forming unit, a shuttle unit, and a molding unit. The charge is formed from one or more slabs of reinforcing fibers and a resinous material. Once formed, the charge is preheated in the charge shuttle unit and is delivered to the molding unit, whereupon the preheated charges are forced by the pressure of a movable platform under vacuum into a mold cavity for polymerization. The fibers within the slabs are randomly oriented in parallel horizontal planes such that they are always parallel to the direction of initial flow into the cavity.

Abstract: An automated transfer/injection process is defined that includes a charge forming unit, a shuttle unit, and a molding unit. The charge is formed from one or more slabs of reinforcing fibers and a resinous material. Once formed, the charge is preheated in the charge shuttle unit and is delivered to the molding unit, whereupon the preheated charges are forced by the pressure of a movable platform under vacuum into a mold cavity for polymerization. The fibers within the slabs are randomly oriented in parallel horizontal planes such that they are always parallel to the direction of initial flow into the cavity.