A method of embedding a reinforcing fiber into a thermoplastic resin. The method includes providing a cavity defined by first and second members and a seal and enclosing a ply stack. The ply stack includes at least one thermoplastic resin ply including the thermoplastic resin and at least one reinforcing fiber ply including the reinforcing fiber. The method further includes subjecting the cavity to a vacuum to form a vacuum-sealed cavity to impart an impregnation pressure on the ply stack. The method also includes heating the vacuum-sealed cavity to an impregnation temperature above a glass transition temperature of the thermoplastic resin to form a heated thermoplastic resin impregnating into the reinforcing fiber to form a heated composite. The method also includes cooling the heated composite to form a thermoplastic composite.
B29C 70/44 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
A rigid thermoplastic polymeric sheet material forming process. The process includes heating, while under a heating vacuum range, a rigid thermoplastic polymeric sheet in a heating zone to a forming temperature to form a heated rigid thermoplastic polymeric sheet material. The process further includes transferring, while under a feeding vacuum range, the heated rigid thermoplastic polymeric sheet material from the heating zone to feed the heated rigid thermoplastic polymeric sheet material into a forming zone under the feeding vacuum range. The process also includes forming, in the forming zone, the heated rigid thermoplastic sheet material into a formed article.
A rigid thermoplastic polymeric sheet material forming process. The process includes heating, while under a heating vacuum range, a rigid thermoplastic polymeric sheet in a heating zone to a forming temperature to form a heated rigid thermoplastic polymeric sheet material. The process further includes transferring, while under a feeding vacuum range, the heated rigid thermoplastic polymeric sheet material from the heating zone to feed the heated rigid thermoplastic polymeric sheet material into a forming zone under the feeding vacuum range. The process also includes forming, in the forming zone, the heated rigid thermoplastic sheet material into a formed article.
A heated polymeric sheet material feeding process. The process may include heating a polymeric sheet in a heating zone to a forming temperature to form a heated polymeric sheet material. The process may further include transferring, while under a feeding vacuum range, the heated polymeric sheet from the heating zone to feed the heated polymeric sheet material into a forming zone under the feeding vacuum range.
A pickup truck cargo box subassembly includes a load floor composed of a sandwich structure having an upper skin, a lower skin and a core extending therebetween. The upper skin is formed of a composite material including continuous reinforcing fibers. The pickup truck cargo box subassembly also includes a left inner sidewall panel having a left inner sidewall panel joining channel extending horizontally along at least a portion of a length of the left inner sidewall panel. The pickup truck cargo box subassembly also includes a right inner sidewall panel having a right inner sidewall panel joining channel extending horizontally along at least a portion of a length of the right inner sidewall panel. The left and right inner sidewall panel joining channels join a peripheral portion of the load floor. The pickup truck cargo box subassembly also includes a headboard and a rear cross sill.
B62D 33/077 - Superstructures for load-carrying vehicles characterised by the connection of the superstructure to the vehicle frame
B62D 29/04 - Superstructures characterised by material thereof predominantly of synthetic material
B32B 3/12 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material characterised by a layer of regularly-arranged cells whether integral or formed individually or by conjunction of separate strips, e.g. honeycomb structure
A method of separating carbon fiber tows. The method includes separating two or more first carbon fiber tows from a first tow band onto a second elevation to form two or more second carbon fiber tows from a second tow band. The two or more second carbon fiber tows from the second tow band leave gaps next to first adjacent tows of the two or more first carbon fiber tows remaining from the first tow band after the separating step. The first adjacent tows from the first tow band leave gaps next to second adjacent tows of the two or more second carbon fiber tows from the second tow band.
B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
A pickup truck cargo box subassembly includes a load floor composed of a sandwich structure having an upper skin, a lower skin and a core extending therebetween. The upper skin is formed of a composite material including continuous reinforcing fibers. The pickup truck cargo box subassembly also includes a left inner sidewall panel having an integrated left inner sidewall panel joining surface extending horizontally along at least a portion of a length of the left inner sidewall panel. The pickup truck cargo box subassembly also includes a right inner sidewall panel having an integral right inner sidewall panel joining surface extending horizontally along at least a portion of a length of the right inner sidewall panel. The left and right inner sidewall panel joining surfaces join a peripheral portion of the load floor. The pickup truck cargo box subassembly also includes a headboard and a rear cross sill.
B62D 33/077 - Superstructures for load-carrying vehicles characterised by the connection of the superstructure to the vehicle frame
B32B 3/12 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material characterised by a layer of regularly-arranged cells whether integral or formed individually or by conjunction of separate strips, e.g. honeycomb structure
B62D 29/04 - Superstructures characterised by material thereof predominantly of synthetic material
8.
FIBER-REINFORCED COMPOSITES AND METHODS OF FORMING AND USING SAME
A method of forming fiber-reinforced composites. The method includes stabilizing two or more carbon fibers tows together (a) with a stabilizing resin and (b) in-line with a commercial carbon fiber production process to form a semi-finished tape; and impregnating the semi-finished tape with a matrix resin in a process offline of the carbon fiber production process to form a prepreg.
B32B 5/22 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous
D01F 11/10 - Chemical after-treatment of man-made filaments or the like during manufacture of carbon
A method of forming fiber-reinforced composites. The method includes stabilizing two or more carbon fibers tows together (a) with a stabilizing resin and (b) in-line with a commercial carbon fiber production process to form a semi-finished tape; and impregnating the semi-finished tape with a matrix resin in a process offline of the carbon fiber production process to form a prepreg.
B65H 51/005 - Separating a bundle of forwarding filamentary materials into a plurality of groups
B29B 15/12 - Coating or impregnating of reinforcements of indefinite length
D04H 3/12 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
A method of forming a fiber-reinforced molding compound. The method includes establishing a melt stream of a source material including a first polymeric material having a first melt temperature in an extruder and dosing a composite material into the melt stream. The composite material includes pre-impregnated reinforcing fibers comprising reinforcing filaments and a second polymeric material having a second melt temperature greater than the first melt temperature. The composite material has at least 30% of the reinforcing filaments protected by the polymeric material such that the polymeric material surrounds each filament completely forming a barrier between it and an adjacent filament in the at least 30% of the filaments. The temperature of the melt stream at dosing is below the second melt temperature. The method includes forming a molding compound from the source and composite materials. The method includes dispensing the molding compound to produce a part.
B29B 9/06 - Making granules by dividing preformed material in the form of filamentary material, e.g. combined with extrusion
B29B 9/14 - Making granules characterised by structure or composition fibre-reinforced
B32B 5/16 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer formed of particles, e.g. chips, chopped fibres, powder
B29C 43/34 - Feeding the material to the mould or the compression means
B29C 48/00 - Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired formApparatus therefor
B29C 48/285 - Feeding the extrusion material to the extruder
C08K 9/08 - Ingredients agglomerated by treatment with a binding agent
B29B 7/42 - MixingKneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with single shaft with screw or helix
B29B 9/04 - Making granules by dividing preformed material in the form of plates or sheets
B29B 11/02 - Making preforms by dividing preformed material, e.g. sheets, rods
B29B 11/16 - Making preforms characterised by structure or composition comprising fillers or reinforcements
B29C 43/18 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
B29B 7/40 - MixingKneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with single shaft
B29B 7/46 - MixingKneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with more than one shaft
B29K 105/10 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns oriented
B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
B29B 7/48 - MixingKneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with more than one shaft with intermeshing devices, e.g. screws
B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
B29C 48/79 - Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling of preformed parts or layers
Fiber-reinforced molding compounds and methods of forming and using the same. A method may include dosing into a melt stream a composite material including pre-impregnated reinforcing filaments and a second polymeric material (which could have a second melt temperature greater than the first polymeric material). Another method may include dosing into a melt stream a composite material including carbon reinforcing filaments pre-impregnated by a polymeric material. Yet another method may include pre-impregnating carbon reinforcing filaments with a polymeric material offline of an extrusion process to form pre-impregnated strands. Another method may include pre-impregnating reinforcing filaments with a polymeric material offline of an extrusion process to form pre-impregnated tape. An additional method may include forming pre-impregnated flakes of one or more predetermined shapes including reinforcing filaments pre-impregnated by a polymeric material. The polymeric material may protect at least 30% of the reinforcing filaments.
B32B 5/16 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer formed of particles, e.g. chips, chopped fibres, powder
12.
Fiber-reinforced molding compounds and methods of forming and using the same
A method of forming a fiber-reinforced molding compound. The method includes establishing a melt stream of a source material and dosing a composite material into the melt stream. The composite material includes carbon reinforcing fibers pre-impregnated by a polymeric material. The composite material has at least 30% of the fibers protected by the polymeric material. The method further includes forming a molding compound from the source and composite materials, dispensing the molding compound from the extruder, and using the molding compound to produce a part.
B29B 11/16 - Making preforms characterised by structure or composition comprising fillers or reinforcements
B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
A method of forming a fiber-reinforced molding compound. The method includes establishing a melt stream of a source material including a first polymeric material and dosing a composite material into the melt stream. The composite material includes pre-impregnated reinforcing fibers and a second polymeric material. The method further includes forming a molding compound from the source and composite materials and dispensing the molding compound from the extruder. The first and second polymeric materials are different than each other to introduce a functionality into the molding compound that is not present in the second polymeric material. The method further includes using the molding compound to produce a part.
B29C 43/18 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
B29B 7/42 - MixingKneading continuous, with mechanical mixing or kneading devices with movable mixing or kneading devices rotary with single shaft with screw or helix
B29K 105/00 - Condition, form or state of moulded material
B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
patents
