Abstract: A process for applying an overlayer to a cured thermoset molding composition is provided that includes exposing the cured thermoset molding composition to a plasma under conditions that modify the surface energy of a surface of the article without visually modifying the surface. The surface of the article is then overcoated with an overlayer having superior adhesion to a like article absent the intermediate plasma treatment. A component is also provided that is cured thermoset resin article having a shape and a surface. An overlayer is applied to the surface while the surface is still plasma activated. The overlayer is adhesion is unchanged by 4 weeks in a 100% humidity chamber at 30° C. over at least 95 area % of an interface between the overlayer and the surface.

Abstract: A process for debundling a carbon fiber tow into dispersed chopped carbon fibers suitable for usage in molding composition formulations is provided. A carbon fiber tow is fed into a die having fluid flow openings, through which a fluid impinges upon the side of the tow to expand the tow cross sectional area. The expanded cross sectional area tow extends from the die into the path of a conventional fiber chopping apparatus to form chopped carbon fibers, or through contacting tines of a mechanical debundler. Through adjustment of the relative position of fluid flow openings relative to a die bore through which fiber tow passes, the nature of the fluid impinging on the tow, the shape of the bore, in combinations thereof an improved chopped carbon fiber dispersion is achieved. The chopped carbon fiber obtained is then available to be dispersed in molding composition formulations prior to formulation cure.

Abstract: A molding composition formulation is provided that includes polypropylene, glass fiber, and a polypropylene substitute including recycled sheet molding composition transfer film The polypropylene substitute is present from 1 to 35 total weight percent also may include natural cellulosic fibers or powders. A process is provided by which the polypropylene substitute is mixed and homogenized and then mixed with polypropylene and additives, and thereafter glass fiber. A reduction in the amount of virgin polypropylene used is reduced compared to conventional thermoplastic glass fiber filled moldings.

Abstract: A process of formulating a curable thermoset resin formulation is provided that includes reacting a natural cellulosic filler with at least one of: a silsesquioxane, a isocyanate, a base, or an organic acid to form a reduced hydrophilicity filler. By intermixing the resulting reduced hydrophilicity filler with a thermoset cross linkable polymeric resin, a curable thermoset resin formulation is formed that has superior properties to conventional formulations in terms of density and environmental impact. The formulation properties in terms of strength of the cured article are improved relative to untreated natural fillers. The treatment is advantageous relative to plasma treatment. An article is also provided produced upon cure of the formulation.

Abstract: A temperature regulation and management system is provide that has an inner wall and an outer wall forming a space for accommodating a phase change material (PCM) with the space between the walls, in one or both of the walls, or a combination of such locations. The inner wall is in contact with an object that requires temperature regulation within a specified operating range, such as a vehicle battery pack. The inner wall and the outer wall are both formed from sheet molding compound (SMC), or the outer wall if formed of a filled polyurethane.

Abstract: A process for applying an overlayer to a cured thermoset molding composition is provided that includes exposing the cured thermoset molding composition to a plasma under conditions that modify the surface energy of a surface of the article without visually modifying the surface. The surface of the article is then overcoated with an overlayer having superior adhesion to a like article absent the intermediate plasma treatment. A component is also provided that is cured thermoset resin article having a shape and a surface. An overlayer is applied to the surface while the surface is still plasma activated. The overlayer is adhesion is unchanged by 4 weeks in a 100% humidity chamber at 30° C. over at least 95 area % of an interface between the overlayer and the surface.

Abstract: The A process for molding a thermoset sheet- molding composition or bulk-molding composition is provided that includes the exposure of a mold surface to a silsesquioxane monomer or pre-polymer material under conditions to induce polymerization of said material or said monomer to form a mold release coating on the surface. The thermoset sheet-molding composition or bulk-molding composition is then injected into the mold and into contact with said coating under conditions to cure the composition to form an article.