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: 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 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 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: 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: Vacuum assisted molding apparatus provides reliable sealing about the mold cavity while minimizing the area of the plant floor space occupied by the mold. The apparatus includes an upper die, a lower die, a vacuum source, and a sealing assembly. The upper die includes a generally horizontal molding surface and vertically extending sides. The lower die includes a generally horizontal molding surface cooperating with the upper die to form a mold cavity. The sealing assembly is operable to create a vacuum surrounding the mold cavity.

Abstract: Vacuum assisted molding apparatus provides reliable sealing about the mold cavity while minimizing the area of the plant floor space occupied by the mold.