Continental Structural Plastics, Inc.

Teijin Automotive Technologies, Inc.

J & P Coats Limited

Coats Group Plc

Other

Coats & Clark, Inc.

Thyssenkrupp Budd Company

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

Continental Structure Plastics, Inc.

Continential Structural Plastics, Inc.

Probir Kumar Guha

Michael J Siwajek

Michael Joseph Hiltunen

Dominique Boyer

Marc-Philippe Toitgans

Philippe Bonte

Shane Michael Skop

Brad Anthony Haskell

Michael Z Asuncion

Brian A Beach

Gaetan Boivin

Swati Neogi

Kim Robert Hamner

David J Krug

Christopher Hiltunen

Mayur S Shah

Patrick Hale

Adam Craig Burley

Satish Haryadi

Robert C Yen

Hugh C Foran

George Han

MIchael J Siwajek

Rahul Rane

Jack Douglas Dunagan

Ohiole Ake

Ashley B Hartmann

Anais Harbonnier

Frank Macher

Anais Harbonner

Scott Eldor Pflughoeft

Marc-Phillippe Toitgans

SudarSan Neogi

Gokhan K Coban

Joseph A Bodary

Michael J Hiltunen

Adam Burley

Christopher Johnston

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.

Hybrid fiber based molding thermoplastic article and process of forming same

A process and system are provided for introducing chopped and dispersed carbon fibers on an automated production line amenable for inclusion in molding compositions, including the debundling of many carbon fibers collectively forming a tow into dispersed chopped carbon fibers that form a filler that undergoes plasma treatment prior to introducing coating silanes to uniformly increase bonding sites for coupling to a thermoset matrix. By exposing carbon tow to a plasma discharge, the carbon tow debundles and is used to form sheets of molding compositions with chopped dispersed fibers added to the composition, as the sheets move along a conveyor belt on the automated production line and at least one plasma generator mounted above the conveyor belt ionizes the carbon fibers. With resort to deionized air to mix plasma-treated chopped fibers, still further dispersion results.

Dispersed fiber mat formation

A two dimensional unitary preform sheet including a substrate and a fiber bundle arranged on the substrate and attached to the substrate by a plurality of stitches of a thread, which may be a thermoplastic thread. The two dimensional unitary preform sheet is configurable into a three dimensional preform. According to embodiments, the fiber bundle includes carbon fibers, glass fibers, aramid fibers, or a combination thereof. According to embodiments, the two dimensional unitary preform sheet is cut in a pattern that is foldable into the three dimensional preform. A method for making a three dimensional preform is also provided, which includes forming a two dimensional unitary preform sheet and placing the two dimensional unitary preform in a press to bend the two dimensional unitary preform into the shape of the three dimensional preform.

Three dimensional preform created by preconsolidation of thermal plastic stitched sheet

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.

Blended fiber mat formation for structural applications

A form for a thin reinforced composite material includes a plurality of separate linear fiber strips, each having a rectangular cross section composed of reinforcement fibers. The linear fiber strips laid out in a two-dimensional base layer defining a shape of the form. A first successive layer formed with the plurality of separate linear fiber strips contacting the base layer, the linear fiber strips laid out in the first successive layer interspersed from the separate linear fiber strips in the two-dimensional base layer. A method of forming the form includes arranging the plurality of separate linear fiber strips on a substrate and tacking the plurality of separate linear fiber strips to the substrate with a plurality of stitches. A method of forming a unitary reinforced composite component from the form is further provided. The resulting component having high strength and light weight and being efficient to manufacture.

Multiple layer article with interactive reinforcements linear ribbon fiber reinforcement for composite forms

A fiber preform for use in a resin transfer molding or liquid composite molding process and process of making the same are provided. The preform includes a substrate, a fiber bundle arranged on the substrate in a predetermined pattern and attached to the substrate by a plurality of stitches of a thread. The fiber preform is capable of being pre-formed into a three-dimensional shape. The fiber preform along with a sheet of preformed thermoset resin that impregnates at least a portion of the fiber preform forms a composite material. The fiber preform reinforces areas of stress concentration of a core to form a vehicle component.

Fiber preform of commingled fiber bundle for overmolding

A process for forming a mat containing a fiber filler including providing one or more sources of extended length fiber; feeding the one or more sources of extended length fiber simultaneously to an automated cutting machine to produce chopped tow fibers; separating the chopped fiber tow into individual chopped fibers that form a fiber filler; coating the fiber filler with a binder; depositing the fiber filler on a first sheet of thermoplastic; covering the fiber filler with a second sheet of thermoplastic to form a stack; and moving the stack to a treatment chamber to form a fiber mat.

Fiber mat formation for structural applications

A process of forming the fiber preform includes providing a substrate, applying a first layer of a fiber bundle to the substrate in a predetermined pattern having a principal orientation, stitching the first layer of the fiber bundle to the substrate using a thread, building up subsequent layers of the fiber bundle from the first layer, and stitching each of the subsequent layers to a preceding layer using the thread. A process of forming a unitary reinforced composite material includes the fiber preform. The process of forming a unitary reinforced composite component includes placing the fiber preform a mold platen, heating the perform to promote fusion of the thermoplastic fibers therein, cooling the perform until solidified with contours of the component, and removing the vehicle component from the mold platen.

Process of making a fiber preform of commingled fiber bundle for overmolding

A vehicle component that includes at least one fiber preform. The fiber preform includes a substrate, a fiber bundle having one or more types of reinforcing fibers, and a thread. The fiber bundle is arranged on the substrate and attached to the substrate by a plurality of stitches of the thread to form a first preform layer having a principal orientation. The vehicle component includes a core having a geometry with at least one edge and at least one the fiber preforms positioned along the at least one edge, the core and the fiber preform being overmolded in a resin. A process of making the vehicle component includes providing the core having the at least one edge, positioning the at least one fiber preform along the at least one edge, and overmolding the core and the at least one fiber preform in the resin.

Vehicle component made from a fiber preform of commingled fiber bundle for overmolding

A process is provided for forming a pre-consolidated fiber preform for use in a molding process. The process includes layering a plurality of preform sheets on a pre-consolidation mold. Heating the plurality of preform sheets to a first temperature. Applying a first pressure to the plurality of preform sheets using the pre-consolidated mold. Maintaining the first temperature and the first pressure and heating for a first duration of time. A second pressure and a second temperature are then applied to the plurality of preform sheets for a second duration of time.

Pre-consolidation of thermoplastic fiber preforms and method of making the same

A process for automated sanding of a vehicle component surface is provided and includes providing a sanding mechanism having a sanding head engaged with a housing, a rotary motor contained within the housing, the rotary motor having a drive shaft rotatable about an axis and extending outwardly therefrom, a radial plate attached to a first end of the drive shaft, and a sanding disk having an abrasive surface releasably attached to the radial plate; attaching the sanding head to a gimbal having a pressure sensor; powering the rotary motor driving rotation of the drive shaft, the radial plate and the sanding disk in at least one of a clockwise or counterclockwise direction; movably applying the sanding disk to the surface at a maintained constant pressure; and achieving a desired finish on the surface prepared to be primed and painted to a class A auto high sheen surface finish.

Process for automated sanding of a vehicle component surface

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 polyurea additive is provided that strengthens a given base sheet molding composition (SMC) An isocyanate containing species and an amine containing species are introduced into an uncured polymeric resin of a sheet molding compound (SMC) under conditions suitable for the formation of a polyurea polymer network. Upon cure of the SMC base resin, an interpenetrating network is formed that is stronger than the base SMC absent the polyurea. As a result, an article is formed from the SMC that is stronger at the same dimensions than a conventional article or thinned to achieve the same properties to obtain a lightweight article compared to that formed from conventional SMC. The properties of the article are also attractive relative to aluminum for the formation of vehicle body and exterior panels.

High strength sheet molding composition formed with an interpenetrating polymer network

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 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.

Combined primary fiber and carbon fiber component for production of reinforced polymeric articles

Growing community of inventors

Troy, MI, United States of America

Probir Kumar Guha