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公开(公告)号：US11987011B2
公开(公告)日：2024-05-21
申请号：US16464552
申请日：2017-11-28
IPC分类号： B29C70/02 , B29B15/10 , B29C70/12 , B29C70/20 , B29C70/46 , B32B5/02 , B32B5/08 , B32B5/10 , B32B5/12 , B32B5/26 , B29K101/12 , B29K105/10 , B29K105/16
CPC分类号： B29C70/025 , B29B15/105 , B29C70/12 , B29C70/202 , B29C70/465 , B32B5/02 , B32B5/022 , B32B5/08 , B32B5/10 , B32B5/12 , B32B5/26 , B29K2101/12 , B29K2105/105 , B29K2105/165 , B32B2262/02 , B32B2262/101 , B32B2262/106 , B32B2264/10 , B32B2398/20
摘要： A process is provided for thermal molding an article with at least one layer of thermoplastic fibers that are non-woven and uni-directionally oriented in combination with at least one layer of reinforcing fibers. The reinforcing fibers including glass, carbon, nature based, and combinations thereof; alone or mixed with chopped thermoplastic fibers. Upon subjecting the layers to sufficient heat to thermally bond in the presence of non-oriented filler fibers, thermoplastic fiber fusion encapsulates the filler fibers. The filler fibers impart physical properties to the resulting article and the residual unidirectional orientation of the thermoplastic melt imparts physical properties in the fiber direction to the article. By combining layers with varying orientations of uni-directional fibers relative to one another, the physical properties of the resulting article may be controlled and extended relative to conventional thermoplastic moldings. The uni-directional fibers may have discontinuities along the length of individual fibers.
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公开(公告)号：US20230407081A1
公开(公告)日：2023-12-21
申请号：US18035945
申请日：2021-10-29
IPC分类号： C08L61/12 , H01M50/227 , C08K7/14 , C08J3/21
CPC分类号： C08L61/12 , H01M50/227 , C08K2003/222 , C08J3/21 , C08K7/14
摘要： A method of building viscosity in a sheet molding composition is provided that includes a thickening agent of at least one of magnesium oxide, magnesium hydroxide, calcium oxide, calcium hydroxides, zinc oxide, borates, aluminum ion chelates, aluminum trihydrate, polyphosphate, epoxides being mixed into a phenolic resin liquid or solution that includes novolac resin. An initial viscosity results for the mixture. The viscosity builds from the initial viscosity to 36 hours, from 36 to 142 hours, and then from 142 hours to 176 hours to define a slope ratio of viscosities in these time ranges of 1.5-8:1:-0.4-2 and a having terminal viscosity as measured at 176 hours. Alternatively, the initial viscosity is between 500 and 50,000 centiPoise (cP) and at 24 hours thereafter builds to between 1 million to 50 million cP, and the terminal viscosity thereafter of between 10 million and 200 million cP.
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公开(公告)号：US11717986B2
公开(公告)日：2023-08-08
申请号：US17206197
申请日：2021-03-19
发明人： Probir Kumar Guha , Philippe Bonte , Marc-Philippe Toitgans , Dominique Boyer , Gaetan Boivin , Anais Harbonnier
IPC分类号： B29B13/08 , B29B15/08 , B29B7/90 , B29C70/08 , B29C70/12 , D04H1/4242 , D06M10/02 , B29B9/14 , B29B9/16 , B32B5/26 , B29C65/00
CPC分类号： B29B7/905 , B29B9/14 , B29B9/16 , B29B13/08 , B29B15/08 , B29C66/028 , B29C70/08 , B29C70/12 , B32B5/26 , D04H1/4242 , D06M10/025 , B29B2009/163 , B32B2310/14
摘要： A process and system are provided for introducing a blend of chopped and dispersed fibers on an automated production line amenable for inclusion in molding compositions as a blended fiber mat for structural applications. The blend of fibers are simultaneously supplied to an automated cutting machine illustratively including a rotary blade chopper disposed above a vortex supporting chamber. The blend of chopped fibers and binder form a chopped mat. The chopped mat has a veil mat placed on either side, and is consolidated with the veil mat using heated rollers maintained at the softening temperature of thermoplastic binder, with consolidated mats being amenable to being stored in rolls or as flat sheets. A charge pattern is made using the consolidated mat, and the charge pattern can be compression molded in a mold maintained at a temperature lower than the melting point of the thermoplastic fibers.
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公开(公告)号：US11655353B2
公开(公告)日：2023-05-23
申请号：US16777923
申请日：2020-01-31
CPC分类号： C08K3/04 , B05D1/007 , C01B32/225 , C08J7/04 , C08K3/26 , C08K7/00 , C01P2004/24 , C08J2333/04 , C08J2367/06 , C08K2003/265 , C08K2201/011
摘要： A sheet molding compound (SMC) is provided with superior conductivity properties based on the use of graphitics. A process for exfoliation of GnP and turbostratic carbon is also provided. By exfoliating the graphitics, a reduced amount of material can confer comparable properties relative to native GnPs or turbostratic carbon thereby reducing the amount of material usage, but also reducing negative effects to the base resin formulation through inclusion of these additives. Particular utility is found in thermoset resin molding to produce articles that are amenable to electrostatic coating and other surface treatments that rely on surface conductivity and especially in the realm of vehicle body parts.
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5.发明授权公开(公告)号：US11529851B2
公开(公告)日：2022-12-20
申请号：US16332235
申请日：2017-09-11
摘要： A lightweight and simplified vehicle door assembly is provided with four main components, an upper frame positioned about the window, an inner frame structure, an outer body panel, and a composite reinforcement component. The composite reinforcement component provides an all-in-one solution for a side impact cross beam, as well as an upper door reinforcement, a front door pillar reinforcement, and a rear door pillar reinforcement. The composite reinforcement component acts to reinforce the overall door structure, offers resistance to a side impact that limits the intrusion into the passenger compartment, and offers resistance to a frontal impact by maintaining the spacing between the vehicle A and B pillars (for a front door) and pillar C and D for a back door. A coupe vehicle door in which there is no window frame may be reinforced with the composite reinforcement component. The composite reinforcement component may have continuous or chopped fibers.
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公开(公告)号：US11407187B2
公开(公告)日：2022-08-09
申请号：US16472740
申请日：2017-12-20
摘要： A process for resin transfer molding (RTM) with injection and overflowing of a resin through one or more troughs is provided that includes the injection of resin into a plurality of injection ports feeding the one or more troughs and overflowing the resin in into a mold. The temperature and pressure are controlled as applied to the mold. The injection ports are activated for injecting the resin in any order of individually, in groups, or pairings. A resin transfer molding (RTM) system for performing the process includes a mold having a cavity. A set of injection ports feed one or more continuous channels between the cavity and a reservoir of resin. A numerical controller selectively activates the injection ports to overflow the resin into the cavity in any order of individually, in groups, or pairing.
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公开(公告)号：US11312317B2
公开(公告)日：2022-04-26
申请号：US16862654
申请日：2020-04-30
发明人： Thomas A. Engelhardt
IPC分类号： B60R13/02
摘要： A headliner for use in a vehicle having a roof, the headliner including a sheet and a plurality of first snap portions adapted to couple with a plurality of corresponding second snap portions fixed to the vehicle roof to mount the sheet to an interior side the vehicle roof through the interaction of the plurality of first snap portions and the corresponding second snap portions. A method for installing a headliner on a vehicle roof structure includes providing a headliner comprising a sheet having an upper surface, a lower surface, and a plurality of first snap portions fixed to the sheet, and joining the plurality of first snap portions to a plurality of second snap portions fixed to the roof structure, the plurality of second snap portions adapted to couple with the plurality of first snap portions to mount the sheet to the interior side the vehicle roof structure.
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公开(公告)号：US20220024183A1
公开(公告)日：2022-01-27
申请号：US17299467
申请日：2019-11-03
发明人： Patrick Durham , Yuhei Konagai , Yutaka Yagi , Matthew Plauman , Evan Freeman-Gibb , Hugh Foran
IPC分类号： B32B17/04 , B32B3/12 , B32B7/12 , B32B37/14 , C09J175/04 , B32B37/10 , B32B27/12 , B29C70/18
摘要： A composite sandwich panel assembly including an open area core, a high gloss surface sheet, and a structural skin. The open are core defines a plurality of pores and has a first face and an opposing second face. The high gloss surface sheet is adhered to the first face of the open area core by a first adhesive layer. The high gloss surface sheet has a high gloss surface. The structural skin is adhered to the second face of the open area core by a second adhesive layer. A process for forming the composite sandwich panel assembly includes positioning the high gloss surface sheet, joining the first face of the open area core to the high gloss surface sheet with a first adhesive layer intermediate therebetween, and joining the structural skin to the second face of the open area core with a second adhesive layer intermediate therebetween.
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公开(公告)号：US11214894B2
公开(公告)日：2022-01-04
申请号：US15847581
申请日：2017-12-19
发明人： Probir Kumar Guha , Michael J. Siwajek , Michael J. Hiltunen , Shane Skop , Christopher Hiltunen , Patrick Hale
IPC分类号： D02J1/18 , B65H51/005 , C08J5/24 , B29C70/08 , B32B5/26 , B29B15/08 , B32B9/04 , B32B17/00 , B32B17/06 , D01G1/04 , B29K307/04
摘要： 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.
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10.发明授权公开(公告)号：US11161311B2
公开(公告)日：2021-11-02
申请号：US16472702
申请日：2017-12-18
摘要： A dual layer cured composite article is provided that has an outer part having an outer part thickness composed of a first resin matrix having between 50 and 70 total weight percent of the outer part being an outer part mixed fiber filler, the outer part mixed fiber filler having an outer part primary fiber:carbon fiber ratio of 0.05-20:1. An inner part complementary to the outer part is provided and has an inner part thickness composed of a second resin matrix having between 40 and 60 total weight percent of the inner part of an inner mixed fiber filler, the inner mixed fiber filler having an inner part primary fiber:carbon fiber ratio of less than said outer part primary fiber:carbon fiber ratio. A joinder between the outer part and the inner part is provided. A process for producing such an article is also provided.
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