Abstract: A powder coated roving material for making structural parts is provided. The powder coated roving includes a bundle of fibers at least substantially coated with a powder coating material. The bundle is formed of a plurality of inner fibers and a plurality of outer fibers surrounding the inner fibers. The size composition maintains the fibers in a bundled orientation during processing and releases the fibers during molding. The size composition includes an epoxy resin emulsion containing at least one surfactant and a solid epoxy resin having an epoxy equivalent weight from about 450 to about 950, at least one epoxy silane coupling agent, at least one non-ionic lubricant, at least one cationic lubricant, and at least one organic acid. In addition, the size composition may have an acetone solubility from about 30% to about 75%. A method of making a composite roving is also provided.

Abstract: A strand forming and chopping apparatus includes a bushing for forming a continuous strand, a size applicator for applying a size to the strand, a chopping device for chopping the strand into individual segments and a thread-up apparatus for directing the strand into the chopping device. The thread-up apparatus includes a cot incorporating a cot shoe and a strand guide displaceable between a rest position and a thread-up position where the strand guide holds the strand in a feed position from which the strand is engaged by the cot shoe and delivered to the chopping device.

Abstract: A powder coated roving material for making structural parts is provided. The powder coated roving includes a bundle of fibers at least substantially coated with a powder coating material. The bundle is formed of a plurality of inner fibers and a plurality of outer fibers surrounding the inner fibers. The size composition maintains the fibers in a bundled orientation during processing and releases the fibers during molding. The size composition includes an epoxy resin emulsion containing at least one surfactant and a solid epoxy resin having an epoxy equivalent weight from about 450 to about 950, at least one epoxy silane coupling agent, at least one non-ionic lubricant, at least one cationic lubricant, and at least one organic acid. In addition, the size composition may have an acetone solubility from about 30% to about 75%. A method of making a composite roving is also provided.

Abstract: A polymer composite multiend roving material used to make structural composite parts includes a bundle of fibers held together by a high integrity sizing composition and surrounded by a powder coating polymer material. The powder coating material is approximately 10-80% of the dry weight of the multiend composite roving weight. The multiend composite roving material may then be easily processed further to form a molded composite part having good mechanical properties and high fiber content.

Abstract: A strand forming and chopping apparatus includes a bushing for forming a continuous strand, a size applicator for applying a size to the strand, a chopping device for chopping the strand into individual segments and a thread-up apparatus for directing the strand into the chopping device. The thread-up apparatus includes a cot incorporating a cot shoe and a strand guide displaceable between a rest position and a thread-up position where the strand guide holds the strand in a feed position from which the strand is engaged by the cot shoe and delivered to the chopping device.

Abstract: A composite material is provided. The composite material includes a continuous roving made from a material selected from a group consisting of natural fibers, mineral fibers, synthetic fibers, kenaf fibers, hemp fibers, carbon fibers, glass fibers, aramid fibers and mixtures thereof impregnated with a water-based matrix binder including gypsum, a polymer and water.

Abstract: Disclosed are a series of composite polymer composite structures formed by the coextrusion of at least two distinct polymeric components. A first polymeric component includes a structural composition and a second polymeric component includes a coating composition. The primary structural frame formed from the structural composition includes at least one longitudinal recess. These recesses may be filled with a third polymeric composition that may include wood byproducts and/or a blowing agent. The first polymeric component may include reinforcing fibers at least partially coated with a size composition that includes a film forming agent, a lubricant, one or more additives, and first and second coupling agents. The additives may be chosen to achieve selective or desired properties in the end product.

Abstract: A chopped strand mat formed of bundles of dielectrically dried reinforcing fibers and bonding fibers is provided. The reinforcing fibers may be formed as bundles of wet reinforcing fibers with a bundle tex of about 10 to about 500. The reinforcing fibers may be formed of a single chop length of about 1 to about 1½ inches or a multi-chop length of fibers of about ½ to about 2 inches. The bonding materials may be any thermoplastic or thermosetting material having a melting point less than the reinforcing fiber. The chopped strand mat may be formed by dielectrically drying the wet reinforcement fibers, blending the reinforcement and bonding fibers, bonding the reinforcement and bonding fibers to form a chopped strand mat, compacting the mat, cooling the mat, and winding the mat into a continuous roll. The chopped strand mat contains a uniform or nearly uniform distribution of bonding fibers and bundles of dried reinforcement fibers.

Abstract: A polymer composite multiend roving material used to make structural composite parts is comprised bundle of fibers held together by a high integrity sizing composition and surrounded by a powder coating polymer material. The powder coating material is approximately 10-80% of the dry weight of the multiend composite roving weight. The multiend composite roving material may then be easily processed further to form a molded composite part having good mechanical properties and high fiber content.

Abstract: A glass preform having a living hinge section that is formed by introducing a continuous strand of fibrous material onto a portion of a screen and overspraying the strand and the rest of the screen with a chopped string binder material, therein forming a matted structure. The matted structure is subsequently heated to fuse together the binder material of adjacent chopped string binders to form the preform having a living hinge section. The preform may then be molded to form a three dimensional composite part such as a truck box. The living hinge section of the preform improves the flexibility of the preform during the molding process, thereby allowing for the preparation of complex three dimensional shapes.

Abstract: A self-supporting package of strand is disclosed. The disclosed method of manufacturing a package of strand is directed to the bulk collection of the strand. The disclosed strand collection system includes an attenuator that attenuates filaments from a bushing. The attenuator includes a pair of belts between which the strand is pinched to pull the filaments from the bushing. The attenuator directs the strand to a deflector assembly that slows down and imparts a degree of movement to the strand. The deflector assembly includes primary and secondary deflector surfaces which the strand engages. After the strand deflects off the secondary deflector surface, it is directed into a container assembly. The attenuator and deflector assembly traverse above the container assembly to deposit the strand. The container assembly is periodically vibrated by a vibrating mechanism as it collects strand. The vibrations settle and shift the strand in the container assembly for better strand distribution.

Abstract: A process and apparatus for making densified glass fiber pellets substantially encapsulated in a polymeric shell from chopped segments of multi-filament glass strand is described. The densified pellets may be advantageously produced by hydrating chopped glass strands and then pelletizing them by tumbling in a rotary drum, densifying the resulting pellets by tumbling in a rotating zig-zag or undulating tube, drying the pellets and encapsulating them in a polymeric composition. The resulting pellets exhibit enhanced degradation resistance during bulk storage and handling.

Abstract: A polymer composite multiend roving material used to make structural composite parts is comprised bundle of fibers held together by a high integrity sizing composition and surrounded by a powder coating polymer material. The powder coating material is approximately 10-80% of the dry weight of the multiend composite roving weight. The multiend composite roving material may then be easily processed further to form a molded composite part having good mechanical properties and high fiber content.

Abstract: A process and apparatus for making densified glass fiber pellets substantially encapsulated in a polymeric shell from chopped segments of multi-filament glass strand is described. The densified pellets may be advantageously produced by hydrating chopped glass strands and then pelletizing them by tumbling in a rotary drum, densifying the resulting pellets by tumbling in a rotating zig-zag or undulating tube, drying the pellets and encapsulating them in a polymeric composition. The resulting pellets exhibit enhanced degradation resistance during bulk storage and handling.

Abstract: A process and apparatus for making densified glass fiber pellets substantially encapsulated in a polymeric shell from chopped segments of multi-filament glass strand is described. The densified pellets may be advantageously produced by hydrating chopped glass strands and then pelletizing them by tumbling in a rotary drum, densifying the resulting pellets by tumbling in a rotating zig-zag or undulating tube, drying the pellets and encapsulating them in a polymeric composition. The resulting pellets exhibit enhanced degradation resistance during bulk storage and handling.

Abstract: A system for making densified glass fiber pellets from chopped segments of multi-filament glass strand is described. The densified pellets may be advantageously produced by hydrating chopped glass strands and then pelletizing them by tumbling in a rotary drum, and densifying the resulting pellets by tumbling in a rotating zig-zag or undulating tube for a period of time sufficient to increase their density but insufficient to degrade the fibers to a point where composite articles formed from such pellets have lower tensile or impact strengths than comparable composite articles formed from unpelletized strand segments.

Abstract: A system for making densified glass fiber pellets from chopped segments of multi-filament glass strand is described. The densified pellets may be advantageously produced by hydrating chopped glass strands and then pelletizing them by tumbling in a rotary drum, and densifying the resulting pellets by tumbling in a rotating zig-zag or undulating tube for a period of time sufficient to increase their density but insufficient to degrade the fibers to a point where composite articles formed from such pellets have lower tensile or impact strengths than comparable composite articles formed from unpelletized strand segments.