Hanwha Azdel, Inc.

Azdel, Inc.

Sabic Innovative Plastics IP B.v.

Jesse Guy Hipwell

Thomas Arnold Ebeling

Paul Anthony Bristow

Erich James Vorenkamp

Erich Otto Teutsch

Scott Michael Davis

Ruomiao Wang

Randall Todd Myers

Kumar Kunal

Coray Harper

Brian Timothy Good

Richard D Hemstreet

Mark O Mason

Venkat Krishna Raghavendran

Daniel Scott Woodman

Richard Hausman

Stephen Senkow

Huda Abdul Jerri

Venkatrishna Raghavendran

Certain embodiments described herein are directed to composite materials effective for use in deep draw processes. In some examples, the composites can be used to provide vehicle panels such as, for example, vehicle underbody panels. In some configurations, the composite comprises a fiber reinforced polymer core and a skin material disposed on at least some portion of the fiber reinforced polymer core, in which the skin material comprises a basis weight of at least 65 g/m2 and an elongation at break of at least 20%.

Method of using a deep drawn composite

Certain embodiments described herein are directed to articles that provide less sag. In some examples, the articles can include a fiber reinforced thermoplastic polymer core layer comprising reinforcing fibers and a thermoplastic polymer, and a frim disposed on the fiber reinforced polymer core layer. In certain examples, the frim comprises a film coupled to a scrim comprising an effective basis weight to prevent substantial sag of the article, e.g., during a forming operation.

Method of producing automotive interior articles including frims

A moldable composite sheet having improved thermal and mechanical property characteristics. In one aspect, the composite sheet may be a porous fiber-reinforced thermoplastic resin comprising discontinuous mineral reinforcing fibers, and one or more skin layer materials. 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/mto about 4000 g/m(gsm), a mineral fiber content from about 20% to about 80% by weight, and a thermoplastic resin content from about 20% to about 80% by weight of the composite sheet. 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 and construction articles having improved thermal and mechanical properties in addition to other beneficial characteristics.

Thermoplastic composites with improved thermal and mechanical properties

Certain embodiments described herein are directed to composite materials comprising untwisted fibers. In some embodiments, the article can include a core layer comprising a thermoplastic polymer and reinforcing fibers. In other embodiments, untwisted fibers can be disposed on the core layer. In certain examples, the article is effective to provide a Class A finish when painted.

Articles including untwisted fibers and methods of using them

Deep draw composites and methods of using them

A method of forming a layered article, the method comprises thermoforming a substrate sheet to form a shaped substrate, wherein the shaped substrate is a fiber-reinforced plastic material having a void content sufficient to allow a vacuum to be applied through the shaped substrate; pulling a vacuum through the shaped substrate; and pulling a film layer onto a surface of the shaped substrate to form the layered article.

Methods of forming a layered article

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.

Decorative interior sound absorbing panel

A twin-sheet thermoforming process for the manufacture of vehicle headliners. In the process a first sheet and second sheet of SuperLite material are mounted onto respective frames. The frames transfer the sheets into an oven, where they are heated to a desired temperature using IR. The first sheet is combined with a cover-stock material using compression molding forming a covered first headliner part. The covered first headliner part is then transferred to a second mold station. The second sheet is heated and then transferred from the oven to the second mold station where it is vacuum-formed on the upper half mold, forming a second headliner part. The upper and lower mold halves are pressed together fusing and sealing the first and second headliner parts into a unified part. The unified part is then unloaded and trimmed as necessary forming a headliner. The SuperLite material used to form the headliner is a sheet of low pressure, thermoformable, thermoplastic composite comprised of polypropylene and long chopped glass fibers.

Twin-sheet thermoformed products

Twin-sheet thermoforming process

Growing community of inventors

Grand Blanc, MI, United States of America

Jesse Guy Hipwell