# US 11,440,272 B2 · Impregnated veils > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,440,272 B2 - Document ID: US11440272B2 - Status: Granted - Kind: B2 - Application number: 16/061,612 - Filed: 2016-12-14 - Published: 2020-10-01 - Granted: 2022-09-13 - Earliest claimed: 2015-12-14 - Assignees: Magna Exteriors Inc. - Applicants: Magna Exteriors Inc. - Inventors: John A. Ingram; David A. Calder; Daniel P. McNulty; Paul A. Trudeau; Henry E. Moore - Web page: https://patentgrep.com/patent/US11440272B2 ## CPC - B29C 70/34: and shaping or impregnating by compression {, i.e. combined with compressing after the lay-up operation} - B29C 70/345: {using matched moulds} - B29C 70/08: comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers - C08J 5/042: {with carbon fibres} - C08J 5/043: {with glass fibres} - C08J 5/046: {with synthetic macromolecular fibrous material} - C08J 5/24: Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs - C08J 5/243: {using carbon fibres} - B29K 2033/08: {Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate} - B29K 2067/00: Use of polyesters {or derivatives thereof}, as moulding material - B29K 2707/04: Carbon - B29K 2709/08: Glass - C08J 2333/08: Homopolymers or copolymers of acrylic acid esters - C08J 2367/00: Characterised by the use of polyesters obtained by reactions forming a carboxylic ester link in the main chain; Derivatives of such polymers - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS ## Abstract Impregnated veil and compression molding process of reinforcing fiber pre-impregnated continuous and discontinuous thermoset and thermoplastic materials. Veils are incorporated within the process, filming or laminating stages of the pre-pregging, either hotmelt or solvent based processes, in a variety of chosen resins. The veils help to improve visual part quality, reduce fiber splitting, and provide an isolating material in applications where incompatible materials must exist. ## Claims ### Claim 1 A compression molding process for carbon fiber pre-impregnated materials, comprising: providing at least one pre-impregnated first ply; providing a plurality of pre-impregnated sub-plies below the first ply, said first ply and sub-plies have a predetermined orientation of either 0° or 90°; providing at least one impregnated veil incorporated into a predetermined surface of at least one ply of the pre-impregnated first ply and/or pre-impregnated sub-plies; cutting and/or pre-forming the pre-impregnated materials with the at least one impregnated veil to a predetermined shape forming a pre-impregnated blank; and compression molding the pre-impregnated blank under predetermined clamping pressure and temperature ranges to form a part; wherein the fiber content of the at least one impregnated veil is about 12 to 20 GSM, and the first ply and/or each sub-ply has a fiber areal weight of about 190 GSM; wherein the at least one impregnated veil is incorporated into the top surface of the first ply; and wherein the conditioned areal weight of the first ply with the impregnated veil is about 350 GSM and the sub-plies are about 317 GSM. ### Claim 2 (depends on 1) The compression molding process of claim 1, wherein the at least one impregnated veil is incorporated during filming or laminating stages of pre-impregnating of the at least one first ply and/or plurality of sub-plies in a resin. ### Claim 3 (depends on 2) The compression molding process of claim 2, wherein the resin is selected from the group consisting of epoxy, polyurethane, polyester, vinyl ester, nylon 6, nylon 6,6 and combinations thereof. ### Claim 4 (depends on 2) The compression molding process of claim 2, wherein the pre-impregnation of the at least one first ply and/or plurality of sub-plies is a hot melt or solvent based process. ### Claim 5 (depends on 1) The compression molding process of claim 1, wherein the at least one impregnated veil has a resin content of about 1 to 100 GSM of resin areal weight. ### Claim 6 (depends on 1) The compression molding process of claim 1, wherein the resin content of the at least one impregnated veil is about 12 to 20 GSM. ### Claim 7 (depends on 1) The compression molding process of claim 1, wherein the at least one impregnated veil and first ply have at least about a 40% resin weight, wherein the resin weight prevents resin starving from the sub-plies. ### Claim 8 (depends on 1) The compression molding process of claim 1, wherein there are at least two impregnated veils incorporated into different surfaces of the first ply and/or sub-plies at predetermined locations. ### Claim 9 (depends on 8) The compression molding process of claim 8, wherein one of the impregnated veils is located between the first ply and a second ply, and another of the impregnated veils is located between a bottom ply and the ply above the bottom ply. ### Claim 10 (depends on 1) The compression molding process of claim 1, wherein the at least one impregnated veil is incorporated into the bottom surface of a bottom ply, is centrally located, and/or includes at least one other impregnated veil incorporated at another location(s) in the ply stack.