Abstract: Articles having improved properties are disclosed. The articles are formed from a composition obtained by dry blending: a) 70-95 wt. % of a polyolefin polymer selected from polypropylene homopolymers, polypropylene copolymers, polypropylene impact copolymers, and mixtures thereof; and b) 5 to 30 wt. % of a free-flowing styrenic block copolymer coated with a functional dusting agent having a maximum particle size of 100 microns. The free-flowing styrenic block copolymer requires less than 400 lbs/ft2 of force to break in a blocking test. The molded article has improved impact strength and haze.

Abstract: Articles having improved properties are disclosed. The articles are formed from a composition obtained by dry blending: a) 70-95 wt. % of a polyolefin polymer selected from polypropylene homopolymers, polypropylene copolymers, polypropylene impact copolymers, and mixtures thereof; and b) 5 to 30 wt. % of a free-flowing styrenic block copolymer coated with a functional dusting agent having a maximum particle size of 100 microns. The free-flowing styrenic block copolymer requires less than 400 lbs/ft2 of force to break in a blocking test. The molded article has improved impact strength and haze.

Abstract: A fiber reinforced thermoplastic composite having an improved combination of flexural, impact, and heat distortion characteristics. The composite comprises a fiber reinforced thermoplastic core containing fibers bonded together with a first thermoplastic resin in which the core has a first surface and a second surface and at least one first skin applied to the first surface. The first skin comprises one or more bi-directional continuous fiber tapes having a plurality of continuous fibers bonded together with one or more thermoplastic resins. The fibers in each first skin are arranged in a first and a second direction, with the fibers in each direction being unidirectionally oriented within the skin. Bi-directional orientation of the continuous fiber tapes is present in at least one of the tapes, or is achieved through the use of two or more tapes having unidirectional continuous fibers.

Abstract: A lightweight fiber reinforced thermoplastic composite having an improved combination of flexural, impact, and heat distortion characteristics. The composite generally comprises a fiber reinforced thermoplastic core containing reinforcing fibers bonded together with a first thermoplastic resin in which the core has a first surface and a second surface and at least one first skin applied to the first surface. The first skin comprises one or more bi-directional continuous fiber tapes having a plurality of continuous fibers bonded together with one or more thermoplastic resins. The fibers in each first skin are arranged in a first principal direction and a second principal direction, with the fibers in each direction being aligned in a unidirectional orientation within the skin.

Abstract: A moldable composite sheet having improved adhesion characteristics, particularly at elevated service temperatures, as well as improved sound absorption and attenuation of transmitted sound intensities. In one aspect, the composite sheet may be a porous fiber-reinforced thermoplastic comprising discontinuous reinforcing fibers and having an adhesive skin layer covering. Generally, the-composite sheet may have a void content or porosity from about 5% to about 95% by volume of the sheet, an areal weight between about 400 g/m2 to about 4000 g/m2 and a fiber content from about 20% to about 98% by weight. The composite sheet can be molded via low pressure processes, such as thermoforming, match metal molding on stops, vacuum forming and pressure forming, to produce durable automotive interior trim parts capable of withstanding service temperatures exceeding 100° C. for extended periods of time along with improved sound absorption capabilities exceeding a noise reduction coefficient (NRC) rating of 0.5.

Abstract: A lightweight fiber reinforced thermoplastic composite having an improved combination of surface roughness, flexural and shear characteristics. The composite generally comprises a fiber reinforced thermoplastic core containing reinforcing fibers bonded together with a first thermoplastic resin in which the core has a first surface and a second surface and at least one first skin applied to the first surface. The first skin comprises a plurality of fibers bonded together with a second thermoplastic resin, with the fibers in each first skin aligned in a unidirectional orientation within the first skin. The composite satisfies at least one of the conditions: an average surface roughness of the outer surface of the first skin is equal to or less than about 4.0 ?m/10 mm; the flexural modulus and strength are greater than about 10,000 MPa and greater than about 180 MPa, respectively; and the shear modulus and strength are greater than about 3,000 MPa and greater than about 100 MPa, respectively.

Abstract: A composite sheet material in one embodiment includes a porous core layer. The porous core layer includes a thermoplastic polymer, about 20 weight percent to about 80 weight percent of reinforcing fibers based on a total weight of the porous core layer, and an effective amount of a flame retardant agent.

Abstract: A composite sheet material includes, in an exemplary embodiment a porous core that includes at least one thermoplastic material and from about 20 weight percent to about 80 weight percent of natural fibers based on a total weight of the porous core. The natural fibers include at least one of kenaf fibers, jute fibers, flax fibers, hemp fibers, cellulosic fibers, sisal fibers, and coir fibers.

Abstract: A composition of a fiber reinforced multi-layered laminate that when compression-molded forms a composite having a Class-A surface that is resin rich. The fiber reinforced multi-layered laminate has an outer layer of a cyclic polyester oligomer containing a latent polymerization catalyst; a glass mat; a core layer of a cyclic polyester oligomer containing a latent polymerization catalyst; a second glass mat, and another outer layer of a cyclic polyester oligomer containing a latent polymerization catalyst. When compression molded, the combination of heat and pressure force the core layer through the permeable glass mats and toward the surface. The latent polymerization catalyst initiates polymerization of the cyclic polyester oligomer forming a Class-A surface that is resin rich. The core layer of a cyclic polyester oligomer thoroughly permeates the reinforcing fiber forming a composite having a middle, with a nearly uniform mixture of reinforced glass fiber and thermoplastic in situ polymerized resin.

Abstract: A multi-layered fiber reinforced thermoplastic sound absorbing panel includes a porous fiber reinforced thermoplastic core layer having a first surface and a second surface, and includes a thermoplastic material and from about 20 weight percent to about 80 weight percent fibers, a tie layer covering the second surface of the core layer and including a thermoplastic material, and a barrier layer covering the tie layer. The barrier layer includes a thermoplastic material having a melting temperature higher than the melting temperature of the core layer thermoplastic material. The tie layer bonds the barrier layer to the core layer. The panel also includes a non-woven layer including a fabric bonded to the barrier layer. The non-woven layer forms an outer surface of the panel.

Abstract: A composition of a fiber reinforced laminate material that when thermoformed or compression molded forms a composite having a Class-A surface that is resin rich. The laminate material has a layer of a thermoplastic resin with an initiator and catalyst; a glass mat; an intra-layer of a polymerizable component that is a lower viscosity mixture of oligomers, monomers and thermoplastic resin; a second glass mat, and another layer of a thermoplastic resin with an initiator and catalyst. When thermoformed or compression molded, the combination of heat and pressure force the low viscosity polymerizable component through the permeable glass mats and toward the surface. The initiator and catalyst cause the polymerizable component to polymerize forming a Class-A surface that is resin rich. The thermoplastic resin thoroughly permeates the reinforcing fiber forming a composite having a core with a nearly uniform mixture of reinforced glass fiber and thermoplastic resin.