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 polyurea additive is provided that strengthens a given base sheet molding composition (SMC) An isocyanate containing species and an amine containing species are introduced into an uncured polymeric resin of a sheet molding compound (SMC) under conditions suitable for the formation of a polyurea polymer network. Upon cure of the SMC base resin, an interpenetrating network is formed that is stronger than the base SMC absent the polyurea. As a result, an article is formed from the SMC that is stronger at the same dimensions than a conventional article or thinned to achieve the same properties to obtain a lightweight article compared to that formed from conventional SMC. The properties of the article are also attractive relative to aluminum for the formation of vehicle body and exterior panels.

Abstract: A vehicle component is provided that includes a first cured layer of a molding composition having a predominant fiber filler chopped glass fibers, a second cured layer of molding composition having a predominant fiber filler chopped carbon fibers, and an elastomeric bonding agent with elongation properties configured to accommodate the differential coefficients of linear thermal expansion between the first cured layer and the second cured layer. The second cured layer is substantially devoid of glass fiber. The bonding agent is an elastomeric adhesive, which is operative from ?40 to 205° C. The first cured layer forms an outer skin layer surface of a vehicle and the second cured layer forms an interior layer, where the outer skin layer surface has a class-A finish.

Abstract: A process is provided for molding a resin matrix around a distribution of well distributed epoxy coated glass fibers to produce an article. The article is mass produced by the molding process based on a one or more layer structure, with an outer panel having a high degree of surface smoothness common to automotive body panels and a comparatively high tensile strength joinder thereto. The epoxy coated glass fibers are present in a single panel of an article or all such panels of a multiple layer article. The epoxy coated glass fibers can be present in an articles in a form of: chopped glass fibers that are intermixed and vary in orientation, a woven roving containing predominately epoxy glass fibers with carbon fibers dispersed there through, or non-woven fiber mats.

Abstract: A molding composition formulation is provided that includes polypropylene, glass fiber, and a cellulosic powder used as a filler. The filler may be at least one of coconut shell powder, walnut shell powder, or rice hull. The molding composition formulation may further include natural cellulosic fiber illustratively including at least one of coconut fibers, bamboo fibers, sugar cane fibers, or banana skin fibers. The molding composition may be compression moldable long fiber thermoplastic (LFTD). The molding composition formulation may be used in thermoforming. In a specific embodiment of the molding composition, the formulation proportion of the polypropylene is 50 to 60 percent of the formulation; and the polypropylene substitute is 5 to 15 percent of the formulation, and in an alternative embodiment, the formulation proportion of the polypropylene is 40 to 80 percent, the cellulosic powder is 1 to 25 percent, and the glass fiber is 1 to 50 percent.

Abstract: A vehicle component is provided that includes a first cured layer of a molding composition having a predominant fiber filler chopped glass fibers, a second cured layer of molding composition having a predominant fiber filler chopped carbon fibers, and an elastomeric bonding agent with elongation properties configured to accommodate the differential coefficients of linear thermal expansion between the first cured layer and the second cured layer. The second cured layer is substantially devoid of glass fiber. The bonding agent is an elastomeric adhesive, which is operative from ?40 to 205° C. The first cured layer forms an outer skin layer surface of a vehicle and the second cured layer forms an interior layer, where the outer skin layer surface has a class-A finish.

Abstract: A vehicle component is provided that includes a first cured layer of a molding composition having a predominant fiber filler chopped glass fibers, a second cured layer of molding composition having a predominant fiber filler chopped carbon fibers, and a bonding agent with elongation properties configured to accommodate the differential coefficients of linear thermal expansion between the first cured layer and the second cured layer. The second cured layer is substantially devoid of glass fiber. The bonding agent is an elastomeric adhesive, which is operative from ?40 to 205° C. The first cured layer forms an outer skin layer surface of a vehicle and the second cured layer forms an interior layer, where the outer skin layer surface has a class-A finish.

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 process is provided for molding a resin matrix around a distribution of well distributed epoxy coated glass fibers to produce an article. The article is mass produced by the molding process based on a one or more layer structure, with an outer panel having a high degree of surface smoothness common to automotive body panels and a comparatively high tensile strength joinder thereto. The epoxy coated glass fibers are present in a single panel of an article or all such panels of a multiple layer article. The epoxy coated glass fibers can be present in an articles in a form of: chopped glass fibers that are intermixed and vary in orientation, a woven roving containing predominately epoxy glass fibers with carbon fibers dispersed there through, or non-woven fiber mats.

Abstract: A polyurea additive is provided that strengthens a given base sheet molding composition (SMC) An isocyanate containing species and an amine containing species are introduced into an uncured polymeric resin of a sheet molding compound (SMC) under conditions suitable for the formation of a polyurea polymer network. Upon cure of the SMC base resin, an interpenetrating network is formed that is stronger than the base SMC absent the polyurea. As a result, an article is formed from the SMC that is stronger at the same dimensions than a conventional article or thinned to achieve the same properties to obtain a lightweight article compared to that formed from conventional SMC. The properties of the article are also attractive relative to aluminum for the formation of vehicle body and exterior panels.

Abstract: An automated process is provided for debundling carbon fiber tow that includes feeding a carbon fiber tow into a chopper. The carbon fiber tow is cut to form lengths of chopped tow portions. The lengths of chopped tow portions are distributed on a moving conveyor. The lengths of chopped tow portions are exposed to a first plasma discharge from a first plasma source on the moving conveyor to create debundled carbon fibers. Alternatively, the carbon fiber tow is exposed to the first plasma discharge prior to being cut into lengths. A system for applying chopped fibers to a sheet of molding compound includes a chopper for cutting a carbon fiber tow into lengths of chopped tow portions. A conveyor belt receives the lengths of chopped tow portions. At least one plasma generating source is arrayed across of the conveyor.

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 cellulosic powder used as a filler. The filler may be at least one of coconut shell powder, walnut shell powder, or rice hull. The molding composition formulation may further include natural cellulosic fiber illustratively including at least one of coconut fibers, bamboo fibers, sugar cane fibers, or banana skin fibers. The molding composition may be compression moldable long fiber thermoplastic (LFTD). The molding composition formulation may be used in thermoforming. In a specific embodiment of the molding composition, the formulation proportion of the polypropylene is 50 to 60 percent of the formulation; and the polypropylene substitute is 5 to 15 percent of the formulation, and in an alternative embodiment, the formulation proportion of the polypropylene is 40 to 80 percent, the cellulosic powder is 1 to 25 percent, and the glass fiber is 1 to 50 percent.

Abstract: An automated process is provided for debundling carbon fiber tow that includes feeding a carbon fiber tow into a chopper. The carbon fiber tow is cut to form lengths of chopped tow portions. The lengths of chopped tow portions are distributed on a moving conveyor. The lengths of chopped tow portions are exposed to a first plasma discharge from a first plasma source on the moving conveyor to create debundled carbon fibers. Alternatively, the carbon fiber tow is exposed to the the first plasma discharge prior to being cut into lengths. A system for applying chopped fibers to a sheet of molding compound includes a chopper for cutting a carbon fiber tow into lengths of chopped tow portions. A conveyor belt receives the lengths of chopped tow portions. At least one plasma generating source is arrayed across of the conveyor.

Abstract: A vehicle component is provided that includes a first cured layer of a molding composition having a predominant fiber filler chopped glass fibers, a second cured layer of molding composition having a predominant fiber filler chopped carbon fibers, and a bonding agent with elongation properties configured to accommodate the differential coefficients of linear thermal expansion between the first cured layer and the second cured layer. The second cured layer is substantially devoid of glass fiber. The bonding agent is an elastomeric adhesive, which is operative from ?40 to 205° C. The first cured layer forms an outer skin layer surface of a vehicle and the second cured layer forms an interior layer, where the outer skin layer surface has a class-A finish.

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.