Hanwha Azdel, Inc.

Mark O Mason

Anthony J Messina

Erich James Vorenkamp

Thomas Arnold Ebeling

Yankai Yang

Ruomiao Wang

Liqing Wei

Coray Harper

Kumar Kunal

Shriram Joshi

Hong Xu

Jesse Guy Hipwell

Peter T Evers, Jr

Peng Cheng

Andrew Anderson

Mark Fero

Jonathan Rosin

Yune Seo Park

Stephen Senkow

Ziniu Yu

Yu-Tsan Tseng

Troy D Robertz

Prepregs, composites and articles comprising expandable graphite materials dispersed in a thermoplastic layer are described. In some instances, a thermoplastic composite article comprises a porous core layer comprising a plurality of reinforcing fibers and a thermoplastic material, and the porous core layer further comprises expandable graphite particles homogeneously dispersed in the porous core layer.

Prepregs, cores and articles including expandable graphite materials

Prepregs, cores and composite articles are described that comprise lighter weight materials and/or lower amounts of adhesive than commonly used. In some instances, one or more components of the articles may comprise a repellent material or repellent treatment to reduce the overall absorption rate of adhesive into the components of the article.

Prepregs, cores, composites and articles including repellent materials

A thermoplastic composite article comprising a porous core layer comprising a plurality of reinforcing fibers, a lofting agent and a thermoplastic material is provided. In certain instances, the article further comprises a skin layer disposed on the core layer and an adhesive layer between the core layer and the skin layer. In some configurations, the adhesive layer comprises a thermoplastic polymer and an effective amount of a thermosetting material to provide a post-molding peel strength between the skin layer and the post lofted core layer of at least 0.5 N/cm (in either or both of the machine direction or cross direction) as tested by DIN 53357 A dated Oct. 1, 1982.

Underbody shield compositions and articles that provide enhanced peel strength and methods of using them

Prepregs, composites and articles are described that comprise a porous core layer and a surface layer comprising bi-component fibers which can enhance formability of the article without breakthrough. The enhanced formability can permit forming or drawing of the article to increased depths without breakthrough. Interior and exterior automotive components including the articles are described.

Composite articles including surface layers that provide enhanced formability

A thermoplastic composite article comprising a porous core layer and a textured film disposed on a first surface of the porous core layer is described. The composite article can be configured as a recreational vehicle building substrate such as a ceiling or interior wall panel.

Composite articles including textured films and recreational vehicle articles including them

Methods of producing core layers with a variable basis weight across a width of the core layer are described. The core layers can be used in vehicle headliners to permit proper side air bag deployment in the vehicles during crashes. Systems and various materials used to produce the core layers are also described.

Core layers and composite articles with a variable basis weight

Composite articles comprising a porous prepreg or core layer and a powder coated layer thereon are described. In some instances, a thermoplastic composite article comprises a porous core layer comprising a web of reinforcing fibers held together by a thermoplastic material, and a powder coated layer disposed on the porous core layer, in which a particle size of the powder coated layer is selected to provide an interface between the powder coated layer and the porous core layer, wherein at least 50% by weight of the disposed powder coated layer is present above the interface.

Prepregs, cores and composite articles including powder coated layers

Underbody shield compositions and articles that provide enhanced peel strength

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

Certain embodiments described herein are directed to composite materials comprising one or more high melt flow index resins. In some examples, the composites can be used to provide automotive parts such as, for example, vehicle interior parts and vehicle exterior parts. In some configurations, the composite comprises a fiber reinforced polymer core comprising reinforcing fibers and a resin comprising a high melt flow index of greater than 325 g/10 min. as measured by ASTM D1238, condition L.

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Covington, VA, United States of America

Mark O Mason