Azdel, Inc.

Sabic Innovative Plastics IP B.v.

General Electric Company

General Electric Corporation Gmbh

Paul Anthony Bristow

Jesse Guy Hipwell

Erich Otto Teutsch

Scott Michael Davis

Randall Todd Myers

Richard D Hemstreet

Thomas Paul Dunton

Ralph Robert Buoniconti

Minquan Cheng

Glen Robert Tryson

Daniel Scott Woodman

Venkatkrishna Raghavendran

Benny Ezekiel David

Daniel Wardell Sowle

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 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

A composite sheet material that includes at least one porous core layer including a thermoplastic material and from about 20 weight percent to about 80 weight percent fibers based on a total weight of the porous core layer, and at least one skin covering a surface of the core layer. The skin includes at least one of a thermoplastic film, a fiber based scrim, a non-woven fabric, and a woven fabric.

Fiber reinforced thermoplastic sheets with surface coverings

Twin-sheet thermoforming process

A laminate composite is formed by forming a layer of a first thermoplastic resin in contact with a second compatible thermoplastic resin where the first layer comprising an acrylonitrile-butadiene-styrene layer and said second layer comprises a thermoplastic resin selected from the group consisting of comprises polycarbonate resin, phenylene ether resins, and polyamides.

Composite and process for making

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Brighton, MI, United States of America

Paul Anthony Bristow