Continental Structural Plastics, Inc.

Other

Teijin Automotive Technologies, Inc.

Thyssenkrupp Budd Company

Bank of America, N.a., As Administrative Agent

Continental Structure Plastics, Inc.

Continential Structural Plastics, Inc.

Michael J Siwajek

Probir Kumar Guha

Michael Joseph Hiltunen

Shane Michael Skop

Brad Anthony Haskell

Brian A Beach

Michael Z Asuncion

David J Krug

Swati Neogi

Dominique Boyer

Philippe Bonte

Christopher Hiltunen

Patrick Hale

Satish Haryadi

Adam Craig Burley

Robert C Yen

Marc-Philippe Toitgans

Ashley B Hartmann

Marc-Phillippe Toitgans

Scott Eldor Pflughoeft

Frank Macher

SudarSan Neogi

Rahul Rane

Nicholas T Kamar

Jack Douglas Dunagan

Adam Burley

Michael J Hiltunen

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.

Graphene nanoplatelet modified sheet molding compositions

A process for resin transfer molding (RTM) with staggered injection of a resin is provided that injects resin into a plurality of injection ports of a mold. The temperature and pressure applied to the mold are controlled during injection to limit promote rapid filling of the mold cavity. The injection ports are activated for injecting the resin in any order of individually, in groups, or pairings. Fibers are readily added to the mold separately or within the resin. Cycle times of from 1 to 5 minutes are provided for the process.

Resin transfer molding with rapid cycle time

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.

Process of debundling carbon fiber tow and molding compositions containing such fibers

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 &#x2212;40 to 205&#xb0; 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.

Two piece bonded assembly vehicle components

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.

Vehicle components formed with epoxidized chopped glass bonded to a thermoset matrix

A process is provided to reclaim carbon fiber from a cured vinyl ester, crosslinked unsaturated polyester, or epoxy thermoset matrix. The composite pieces are added to a polyol solvent composition under to conditions to free more than 95% by weight of the carbon fiber from the composite. The freed carbon fibers are washed and dried to reclaim carbon fiber reusable to reinforce a polymer to form a new FRC article. Solvents are chosen that are low cost and low toxicity. Processing is further facilitated by techniques such as solvent pre-swell of the particles, microwave heating, and sonication to promote thermoset matrix digestion to free reinforcing carbon fibers.

Recycling carbon fiber based materials

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.

Thermoplastic formed with renewable content

A monomer is provided for a thermoset molding compound. The monomer is also polymerized with conventional monomers to form thermoplastic polymers. Graphene oxide is used to chelate metal ions to form a graphene oxide chelate that is coupled to a monomer retaining an aliphatic unsaturation capable of free radical polymerization reaction. Inclusion of a metal ion chelated to the graphene oxide affords control over the conductivity of the resultant article. In some embodiments, the monomer is found polymerized into a resulting article proximal to the article surface.

Graphene oxide modified thermoset monomer and synthesis thereof

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 &#x2212;40 to 205&#xb0; 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.

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.

In-line plasma source for introducing pieces of spread carbon fiber tow into molding compositions on a compounding production line

A process of formulating a curable thermoset resin formulation is provided that includes reacting a natural cellulosic filler with at least one of: a silsesquioxane, a isocyanate, a base, or an organic acid to form a reduced hydrophilicity filler. By intermixing the resulting reduced hydrophilicity filler with a thermoset cross linkable polymeric resin, a curable thermoset resin formulation is formed that has superior properties to conventional formulations in terms of density and environmental impact. The formulation properties in terms of strength of the cured article are improved relative to untreated natural fillers. The treatment is advantageous relative to plasma treatment. An article is also provided produced upon cure of the formulation.

Enhanced thermoset resins containing pre-treated natural origin cellulosic fillers

A molded article is provided that has a resin matrix having a surface, the resin matrix formed from cross-linked polyester resin or vinyl-ester resin. Glass fibers are crossed linked to the resin matrix via a silane coupling agent reactive with the matrix. A molded article is provided that has a resin matrix having a surface, the resin matrix formed from cross-linked polyester resin or vinyl-ester resin. Glass fibers each covalently bonded to at least one microspheroid matrix via a silane coupling agent reactive with a surface of the at least one microspheroids are present in increase the fiber pull strength. A sizing composition for treating glass fibers is also provided for use in such articles.

Sheet molding composition containing surface modified glass filler

A molded article is provided that includes a resin matrix having a surface, the resin matrix formed from cross-linked polyester resin or vinyl-ester resin. Microspheroids having a mean diameter of from 16 to 45 microns are embedded in the resin matrix. The microspheroids having a specific gravity of between 0.19 and 0.6 and an isotactic crush strength of greater than or equal to 2750 kilopascals (kPa). Surface activating agent alkoxysilane molecules are covalently bonded to each of the microspheroids. Filler particles are also present in the resin matrix. Fibers are also present in the resin matrix. The fibers being natural fibers, glass fibers, carbon fibers, or a combination thereof. The article has a specific gravity of between 0.80 and 1.25.

Low-density molding compound containing surface derivatized microspheres

A temperature regulation and management system is provide that has an inner wall and an outer wall forming a space for accommodating a phase change material (PCM) with the space between the walls, in one or both of the walls, or a combination of such locations. The inner wall is in contact with an object that requires temperature regulation within a specified operating range, such as a vehicle battery pack. The inner wall and the outer wall are both formed from sheet molding compound (SMC), or the outer wall if formed of a filled polyurethane.

Growing community of inventors

Rochester Hills, MI, United States of America

Michael J Siwajek