Sheet molding compound having improved surface characteristics
OwnerMichael Janderinventor
Life of this patent
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Abstract
A composite part made from a sheet molding compound is disclosed as having improved characteristics over traditional sheet molding compound composite parts. The composite part may be made from a unique sheet molding compound material having a resin impregnated filamentized fiber layer and a resin impregnated fiber layer prior to compaction. The resin impregnated filamentized fiber layer side prevents the movement of partially filamentized or unfilamentized fibers to the visible surface of the composite part when the part is molded. The resin impregnated filamentized fiber layer may be contain a conductive filamentized fiber such that the surface of a sheet molding compound may be conductive and be capable of being electrostatically sprayed.
Claims44
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A method for making a single ply of a sheet molding composite sheet comprising the steps of:
- introducing a first carrier film layer;
- introducing a first resin paste layer onto said first carrier film layer using a paste dispensing device, said first resin paste layer comprising a resin and a plurality of filamentized fibers;
- introducing a layer of chopped filamentized or unfilamentized fibers onto the top surface of said first resin paste layer;
- introducing a second resin paste layer onto said layer of chopped or unfilamentized fibers using a second paste dispensing device;
- introducing a top carrier film layer onto said second resin paste layer to form a sheet molding composite sheet;
- and
- compacting said sheet molding composite sheet to form a single ply of sheet molding compound.
A method for making a composite part having improved surface characteristics comprising:
- forming a single ply of a sheet molding composite sheet, the method of forming said single ply comprising the steps of:
- (a) introducing a first carrier film layer;
- (b) introducing a first resin paste layer onto said first carrier film layer using a paste dispensing device, said first resin paste layer comprising a resin paste and a plurality of filamentized fibers;
- (c) introducing a layer of chopped filamentized or unfilamentized fibers onto the top surface of said first resin paste layer;
- (d) introducing a second resin paste layer onto said layer of chopped or unfilamentized fibers using a second paste dispensing device;
- (e) introducing a top carrier film layer onto said second resin paste layer to form a sheet molding composite sheet;
- (f) compacting said sheet molding composite sheet to form a single ply of sheet molding compound.
- thickening said single ply;
- cutting said single ply into a plurality of moldable plies having a desired shape;
- introducing at least one of said plurality of moldable plies into a mold, wherein said first resin paste layer is closer to a visible surface than said second resin paste layer in a top ply of said at least one of said plurality of moldable plies;
- and
- curing said at least one of said plurality of moldable plies at a first pressure and a first temperature for a sufficient time to form the composite part.
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A single ply of a compacted sheet molding composite sheet used for making composite parts having an improved surface characteristics comprising:
- an upper carrier film layer;
- a first resin paste layer;
- a resin impregnated chopped unfilamentized fiber layer;
- a resin impregnated filamentized fiber layer;
- and
- a bottom carrier film layer.
A single ply of a compacted sheet molding composite sheet used for making composite parts having an improved surface characteristics comprising:
- an upper carrier film layer;
- a first resin paste layer;
- a resin impregnated chopped partially filamentized fiber layer;
- a resin impregnated filamentized fiber layer;
- and
- a bottom carrier film layer.
Dependencies are inferred from the claim text.