Granted Patent B2

US 12,515,385 · App. 18/466,172 · Granted Jan 6, 2026

Inventor: Stephen S. Gleason (Burr Ridge, IL)

Assignee: Composite Technologies International, LLC

B29C45/0001B29K2101/10B29K2105/0014B29K2309/08

Abstract

Claims (42)

1 . A method of making a molded part, comprising:

withdrawing a filled resin from a container, the filled resin including a flock fiber material, wherein the flock fiber material includes one or both of a natural flock fiber material and a synthetic flock fiber material, and wherein the natural flock fiber material and the synthetic flock fiber material include one or more of nanofibers, microfibers, and short-strand fibers having a length ranging between 200 μm and 600 μm;

adding a catalyst to the filled resin;

mixing the catalyst and the filled resin to create an uncured catalyzed, filled resin;

adding the uncured catalyzed, filled resin to a mold; and

allowing the uncured catalyzed, filled resin to harden in the mold.

2 . The method of claim 1 , wherein adding the uncured catalyzed, filled resin to the mold comprises injecting the uncured catalyzed, filled resin into the mold.

3 . The method of claim 1 , wherein adding the uncured catalyzed, filled resin to the mold comprises spraying the uncured catalyzed, filled resin into the mold.

4 . The method of claim 3 , wherein the mold is free of fiberglass reinforcements.

5 . The method of claim 3 , wherein the uncured catalyzed, filled resin is sprayed with a spray gun.

6 . The method of claim 5 , wherein the spray gun comprises a chopper gun.

7 . The method of claim 6 , further comprising adding glass fibers to the uncured catalyzed, filled resin with the chopper gun prior to spraying the uncured catalyzed, filled resin into the mold.

8 . The method of claim 7 , wherein withdrawing the filled resin comprises pumping the filled resin into a hose coupled to the chopper gun.

9 . The method of claim 8 , wherein adding the catalyst comprises introducing the catalyst to a flow of the filled resin within the hose.

10 . The method of claim 9 , wherein mixing the catalyst comprises using an inline mixer in a flow path of the filled resin within the hose.

11 . The method of claim 10 , wherein the catalyst comprises methyl ethyl ketone peroxide (MEKP).

12 . The method of claim 10 , wherein the catalyst comprises benzoyl peroxide (BPO).

13 . The method of claim 10 , wherein the catalyst comprises a thermoset resin initiator.

14 . A method of applying resin, comprising:

withdrawing a filled resin from a container, the filled resin comprising a flock fiber material, wherein the flock fiber material includes one or both of a natural flock fiber material and a synthetic flock fiber material, and wherein the natural flock fiber material and the synthetic flock fiber material include one or more of nanofibers, microfibers, and short-strand fibers having a length ranging between 200 μm and 600 μm;

adding a catalyst to the filled resin;

mixing the catalyst and the filled resin to create an uncured catalyzed, filled resin;

spraying the uncured catalyzed, filled resin onto a surface; and

allowing the uncured catalyzed, filled resin to harden.

15 . The method of claim 14 , wherein the mold is free of fiberglass reinforcements.

16 . The method of claim 14 , wherein the uncured catalyzed, filled resin is sprayed with a chopper gun.

17 . The method of claim 16 , further comprising adding glass fibers to the uncured catalyzed, filled resin with the chopper gun prior to spraying the uncured catalyzed, filled resin onto the surface.

18 . The method of claim 14 , wherein withdrawing the filled resin comprises pumping the filled resin into a hose coupled to the chopper gun.

19 . The method of claim 14 , wherein adding the catalyst comprises introducing the catalyst to a flow of the filled resin within a hose coupled to a spray gun.

20 . The method of claim 14 , wherein the catalyst comprises methyl ethyl ketone peroxide (MEKP).

21 . The method of claim 14 , wherein the catalyst comprises benzoyl peroxide (BPO).

22 . The method of claim 14 , wherein the catalyst comprises a thermoset resin initiator.

23 . A method of making a molded part, comprising:

pumping a filled resin from a container into a hose to create a flow of filled resin, the filled resin comprising a polyester resin and a flock fiber material, the hose having an end coupled to a spray gun, wherein the flock fiber material includes one or both of a natural flock fiber material and a synthetic flock fiber material, and wherein the natural flock fiber material and the synthetic flock fiber material include one or more of nanofibers, microfibers, and short-strand fibers having a length ranging between 200 μm and 600 μm;

adding a catalyst to the flow of the filled resin;

mixing the catalyst and the filled resin using an inline, static mixer coupled to the hose to create an uncured catalyzed, filled resin;

pumping the uncured catalyzed, filled resin to the spray gun;

spraying the uncured catalyzed, filled resin into an empty cavity of a mold; and

allowing the uncured catalyzed, filled resin to harden in the mold.

24 . The method of claim 23 , wherein the catalyst comprises methyl ethyl ketone peroxide (MEKP).

25 . The method of claim 23 , wherein the catalyst comprises benzoyl peroxide (BPO).

26 . The method of claim 23 , wherein the catalyst comprises a thermoset resin initiator.

Assignments (1)

Continuity (2)

References Cited (20)