Patent ID: 8057614

Claim:
A method of forming a sheet molding compound material, the method comprising: depositing a first thermosetting resin paste onto a first carrier film; forming a molding mat; placing said molding mat on said first thermosetting resin paste, said molding mat including dehydrated reinforcement fiber bundles and a bonding material having a melting point less than the melting point of said dehydrated reinforcement fiber bundles; depositing a second thermosetting resin paste onto a second carrier film; positioning said second carrier film containing said second thermosetting resin paste such that said second thermosetting resin paste is positioned on said molding mat to form a sandwiched material; and compacting said sandwiched material to form said sheet molding compound material, wherein said molding mat is formed by: at least partially opening bales of wet reinforcement fibers; removing water from said at least partially opened bales of wet reinforcement fibers to form said dehydrated reinforcement fiber bundles; mixing said dehydrated reinforcement fiber bundles with said bonding material to form a substantially uniform mixture of said dehydrated reinforcement fiber bundles and said bonding material; forming said mixture of dehydrated reinforcement fiber bundles and said bonding material into a sheet; and bonding said dehydrated reinforcement fiber bundles and said bonding material to form said molding mat.