Abstract: A system for forming a cross-directional fiber reinforcement layer has a feeder for feeding an array of continuous fiber and a chopped fiber dispenser for distributing generally aligned, closely spaced chopped fibers onto the array of continuous fibers in a cross-directional manner.

Abstract: A system for forming a cross-directional fiber reinforcement layer has a feeder for feeding an array of continuous fiber and a chopped fiber dispenser for distributing generally aligned, closely spaced chopped fibers onto the array of continuous fibers in a cross-directional manner.

Abstract: A composite part made from a sheet molding compound is disclosed as having improved characteristics over traditional sheet molding compound composite parts. The fibrous material is introduced as a veil layer adjacent a paste layer, the veil flows well during the molding process. The improved flow and surface characteristics of a composite part are attributed to the elongation of the veil during molding and to the improved filling capabilities.

Abstract: The present invention is directed towards an apparatus for guiding continuous materials. In one embodiment of the invention, the apparatus comprises first and second conveyors, each comprising a continuous conveyor belt carried by a set of pulleys including a drive pulley and an idler pulley. The conveyor belts have opposing inner surfaces that are oriented to travel substantially parallel to one another to sandwich continuous materials therebetween. The ratio of the diameters of the idler pulleys to the drive pulleys is greater than about 8:1. In another embodiment of the invention, a chopper is provided. The chopper comprises a cutting roll and a cot member defining a nip region therebetween. The cutting roll has an axis of rotation that is aligned substantially parallel to an axis of rotation of a cot member. The small turning radii permit the conveyor belts to extend within the nip region.

Abstract: A composite part made from a sheet molding compound is disclosed as having improved characteristics over traditional sheet molding compound composite parts. The composite part may be made from a unique sheet molding compound material having a resin impregnated filamentized fiber layer and a resin impregnated fiber layer prior to compaction. The resin impregnated filamentized fiber layer side prevents the movement of partially filamentized or unfilamentized fibers to the visible surface of the composite part when the part is molded. The resin impregnated filamentized fiber layer may be contain a conductive filamentized fiber such that the surface of a sheet molding compound may be conductive and be capable of being electrostatically sprayed.

Abstract: A method for filling a muffler shell with a fibrous material includes providing an outer muffler shell, applying a temporary form to the outer shell to define a muffler chamber within the outer muffler shell, and wetting the fibrous material by forcing moisturized compressed air into contact with the fibrous material. The wetted fibrous material is inserted into the muffler chamber, and the temporary form is removed from the outer muffler shell.

Abstract: A composite part made from a sheet molding compound is disclosed as having improved characteristics over traditional sheet molding compound composite parts. The fibrous material is introduced as a veil layer adjacent a paste layer, the veil flows well during the molding process. The improved flow and surface characteristics of a composite part are attributed to the elongation of the veil during molding and to the improved filling capabilities.

Abstract: A composite part made from a sheet molding compound is disclosed as having improved characteristics over traditional sheet molding compound composite parts. The composite part may be made from a unique sheet molding compound material having a resin impregnated filamentized fiber layer and a resin impregnated fiber layer prior to compaction. The resin impregnated filamentized fiber layer side prevents the movement of partially filamentized or unfilamentized fibers to the visible surface of the composite part when the part is molded. The resin impregnated filamentized fiber layer may be contain a conductive filamentized fiber such that the surface of a sheet molding compound may be conductive and be capable of being electrostatically sprayed.

Abstract: An apparatus for chopping continuous materials comprises a chopper comprising a cutting roll and a cot belt, the cutting roll and the cot belt both being rotatably mounted on substantially parallel axes. The cutting roll has at least one cutting blade for cutting continuous materials, and the cot belt engages the cutting roll.

Abstract: The present invention is directed towards an apparatus for guiding continuous materials. In one embodiment of the invention, the apparatus comprises first and second conveyors, each comprising a continuous conveyor belt carried by a set of pulleys including a drive pulley and an idler pulley. The conveyor belts have opposing inner surfaces that are oriented to travel substantially parallel to one another to sandwich continuous materials therebetween. The ratio of the diameters of the idler pulleys to the drive pulleys is greater than about 8:1. In another embodiment of the invention, a chopper is provided. The chopper comprises a cutting roll and a cot member defining a nip region therebetween. The cutting roll has an axis of rotation that is aligned substantially parallel to an axis of rotation of a cot member. The small turning radii permit the conveyor belts to extend within the nip region.

Abstract: The present invention is directed toward an apparatus for processing continuous materials. The apparatus comprises a frame and a chopper mounted relative to the frame. The chopper comprises a cutting roll for cutting the continuous material and a cot member for backing up the cutting roll. The cutting roll and the cot member are selectively movable to separate the cuffing roll and cot member from one another and engage the cutting roll and the cot member with one another.

Abstract: The present invention is directed towards an apparatus for automatically doffing or changing out the cutting roll of a chopper. The apparatus comprises a storage station and a mechanical arm. The storage station is provided for storing a plurality of cutting rolls. The mechanical arm is adapted to support a chopper and is displaceable between an operating position and a storage and retrieval position. In the operating position, the chopper is operable to produce chopped materials. In the storage and retrieval position, an operable cutting roll is stored to the storage station and a stored cutting roll is retrieved from the storage station.

Abstract: A method of dispensing a reinforcement strand includes the steps of chopping the reinforcement strand into discrete reinforcement fibers, directing the discrete reinforcement fibers into a dispensing nozzle so that the discrete reinforcement fibers travel along a path extending generally along a longitudinal axis of the nozzle, introducing a fluid into the nozzle in a circumferential direction with respect to the longitudinal axis, thereby creating a vortex of the fluid surrounding the discrete reinforcement fibers in the nozzle, dispensing the discrete length reinforcement fibers from the nozzle as a flow, and controlling the flow of fibers dispensed from the nozzle by controlling the fluid introduced into the nozzle.

Abstract: A method for dispensing reinforcement fibers to make a preform or laminate includes winding a continuous length of a reinforcement fiber into coils around a form having a longitudinal axis, moving the coils axially with respect to the form to engage a cutter, cutting the coils to form discrete length reinforcement fibers, and dispensing the discrete length reinforcement fibers.

Abstract: A method for dispensing reinforcement fibers to make a preform or laminate includes winding a continuous length of a reinforcement fiber into coils around a form having a longitudinal axis, moving the coils axially with respect to the form to engage a cutter, cutting the coils to form discrete length reinforcement fibers, applying a resinous material to the discrete fibers, and dispensing the discrete length reinforcement fibers.