A method for producing a component includes incorporating a molding compound into a tool for producing the component, where the molding compound includes an artificial resin as a matrix and a filler material embedded in the matrix. The method includes compressing the molding compound by the tool and by the compressing forming the molding compound to a green product. The method further includes providing the green product while disposed in the tool with a layer in a sub-region by incorporating a liquid material for producing the layer into the tool and applying the liquid material to the sub-region. The liquid material is a metallic material and the layer is an electromagnetic shielding on the green product.

A process for producing unsaturated polyester microparticles comprising: melt-mixing an unsaturated polyester and an oil in an extruder; washing the microparticles with an organic solvent to reduce the amount of oil; and removing the organic solvent to form the microparticles.

Disclosed is a cover for a utility vault and a method for making such covers. The cover is formed from fiberglass reinforcement layers, a low-density core, and a polymer mix matrix. The reinforcement layers include a bottom reinforcement layer, one or more edge reinforcement layers, and a top reinforcement layer. A first portion of the edge reinforcement layer overlaps a portion of the bottom reinforcement layer and a second portion of the edge reinforcement layer overlaps a portion of the top reinforcement layer. The core is positioned between the top and bottom reinforcement layers. The reinforcement layers are formed from fiberglass fabric and may include fiberglass layers whose fibers are oriented quadraxially. The polymer mix impregnates the fabric layers, encases the core, and binds the components together. The polymer matrix includes a thermoset polymer resin.

A vehicle component is provided that includes a first cured layer of a molding composition having a predominant fiber filler chopped glass fibers, a second cured layer of molding composition having a predominant fiber filler chopped carbon fibers, and an elastomeric bonding agent with elongation properties configured to accommodate the differential coefficients of linear thermal expansion between the first cured layer and the second cured layer. The second cured layer is substantially devoid of glass fiber. The bonding agent is an elastomeric adhesive, which is operative from 40 to 205 C. The first cured layer forms an outer skin layer surface of a vehicle and the second cured layer forms an interior layer, where the outer skin layer surface has a class-A finish.

A vehicle component is provided that includes a first cured layer of a molding composition having a predominant fiber filler chopped glass fibers, a second cured layer of molding composition having a predominant fiber filler chopped carbon fibers, and an elastomeric bonding agent with elongation properties configured to accommodate the differential coefficients of linear thermal expansion between the first cured layer and the second cured layer. The second cured layer is substantially devoid of glass fiber. The bonding agent is an elastomeric adhesive, which is operative from 40 to 205 C. The first cured layer forms an outer skin layer surface of a vehicle and the second cured layer forms an interior layer, where the outer skin layer surface has a class-A finish.

A method for inspecting a joining surface (14) of a substrate, wherein a component is to be adhered to the joining surface of the substrate by means of an adhesive material (27), wherein the method comprises the following steps: providing at least one planar test textile (20), which has a fiber material (21) and an adhesive primer (22), applying the planar test textile to at least one part of the joining surface of the substrate to which the component is to be adhered so that the adhesive primer of the planar test textile contacts the joining surface of the substrate, at least partially curing the adhesive primer of the planar test textile in order to integrally bond the planar test textile to the substrate by means of the adhesive primer, pulling off the planar test textile after at least partially curing the adhesive primer and inspecting the joining surface by means of a qualitative evaluation of the fracture pattern between the cured adhesive primer and the planar test textile and/or by means of a quantitative evaluation of the pull-off force determined when pulling off the planar test textile.

A method for inspecting a joining surface (14) of a substrate, wherein a component is to be adhered to the joining surface of the substrate by means of an adhesive material (27), wherein the method comprises the following steps: providing at least one planar test textile (20), which has a fiber material (21) and an adhesive primer (22), applying the planar test textile to at least one part of the joining surface of the substrate to which the component is to be adhered so that the adhesive primer of the planar test textile contacts the joining surface of the substrate, at least partially curing the adhesive primer of the planar test textile in order to integrally bond the planar test textile to the substrate by means of the adhesive primer, pulling off the planar test textile after at least partially curing the adhesive primer and inspecting the joining surface by means of a qualitative evaluation of the fracture pattern between the cured adhesive primer and the planar test textile and/or by means of a quantitative evaluation of the pull-off force determined when pulling off the planar test textile.

A resin composition for sealing an electronic control device, which contains (A) at least one type of thermosetting resin selected from among an unsaturated polyester resin and a vinyl ester resin, (B) a polymerizable unsaturated compound, (C) an inorganic filler, (D) glass fibers, (E) an internal mold release agent, (F) a coupling agent, and (G) a curing agent, and in which, relative to a total of 100 parts by mass of the thermosetting resin (A) and the polymerizable unsaturated compound (B), the content of the inorganic filler (C) is 150 to 700 parts by mass, the content of the glass fibers (D) is 0.1 to 60 parts by mass, and the content of the coupling agent (F) is 1.4 to 20 parts by mass.

Co-cured urethane and vinyl ester, epoxy, or unsaturated polyester gel coats having improved toughness and flexibility compared with conventional polyester gel coats are disclosed. The gel coats, which have 10-50 wt. % urethane content, adhere well to structural layers and can be used in a traditional in-mold process. Co-cured elastomeric coatings comprising from 50 to 95 wt. % of a urethane component and an unsaturated polyester, epoxy, or vinyl ester are also disclosed. Unlike conventional urethane coatings, the elastomeric coatings adhere well to structural layers and can be used in a traditional in-mold process. Castings or structural layers comprising a reinforced thermoset of co-cured urethane and vinyl ester, epoxy, or unsaturated polyester components, including 10-95 wt. % of the urethane component, are also described. The invention includes in-mold processes for making laminates that utilize the gel coats, elastomeric coatings, and/or structural layers. The in-mold process gives flexible, durable, urethane-containing laminates having good interlayer adhesion.

The present invention is generally directed to prepreg composites, typically in the form of unidirectional tapes, which contain at least one reinforcing fiber and a thermoplastic polyester matrix. The prepreg composites can be thermally bonded to a wood-containing material in order to improve the structural performance of the material without requiring adhesives. The prepreg composite of the present invention can be applied to a wide range of wood substrates, including various hardwoods, softwoods, and engineered wood composites.