Continious fiber reinforced thermoplastic rod and pultrusion method for its manufacture

A composite rod for use in various applications, such as electrical cables (e.g., high voltage transmission cables), power umbilicals, tethers, ropes, and a wide variety of other structural members, is provided. The rod includes a core that is formed from a plurality of unidirectionally aligned fiber rovings embedded within a thermoplastic polymer matrix. The present inventors have discovered that the degree to which the rovings are impregnated with the thermoplastic polymer matrix can be significantly improved through selective control over the impregnation process, and also through control over the degree of compression imparted to the rovings during formation and shaping of the rod, as well as the calibration of the final rod geometry. Such a well impregnated rod has a very small void fraction, which leads to excellent strength properties. Notably, the desired strength properties may be achieved without the need for different fiber types in the rod.

Die and method for impregnating fiber rovings

A die and method for impregnating at least one fiber roving with a polymer resin are disclosed. In one embodiment, the die includes an impregnation section including an impregnation zone configured to impregnate the roving with the resin, the impregnation zone including a plurality of contact surfaces. The die further includes a perturbation positioned on at least one of the plurality of contact surfaces, the perturbation configured to interact with the roving. In one embodiment, the method includes coating a fiber roving with a polymer resin. The method further includes traversing the coated roving through an impregnation zone to impregnate the roving with the resin. The impregnation zone includes a plurality of contact surfaces. The method further includes interacting the coated roving with a perturbation positioned on at least one of the plurality of contact surfaces.

Asymmetric fiber reinforced polymer tape

An asymmetric tape and a system and method for impregnating at least one fiber roving with a polymer resin to form an asymmetric tape are provided. The asymmetric tape includes a polymer resin, and a plurality of fibers embedded in the polymer resin to form a fiber reinforced polymer material. The fiber reinforced polymer material includes a first surface and an opposing second surface. The fibers are disposed in the fiber reinforced polymer material to form a resin rich portion and a fiber rich portion. The resin rich portion includes the first surface and the fiber rich portion includes the second surface.

Die with flow diffusing gate passage and method for impregnating same fiber rovings

A die and a method for impregnating fiber rovings with a polymer resin are disclosed. The die includes a manifold assembly ( 220 ), an impregnation zone ( 250 ), and a gate passage ( 270 ). The manifold assembly ( 220 ) flows the resin therethrough, and includes a channel ( 222 ). The impregnation zone ( 250 ) is in fluid communication with the manifold assembly ( 220 ), and is configured to impregnate the roving with the resin. The gate passage ( 270 ) is between the manifold assembly ( 220 ) and the impregnation zone ( 250 ), and flows the resin from the manifold assembly ( 220 ) such that the resin coats the roving. The gate passage ( 270 ) includes a projection ( 300 ). The projection ( 300 ) is configured to diffuse resin flowing through the gate passage ( 270 ).

Method for forming reinforced pultruded profiles

A method and apparatus for forming a profile that contains at least one layer of continuous fibers and at least one layer of discontinuous fibers. Said method allowing the selective control of features to achieve a profile that has increased transverse strength and flexural modulus. The layer of continuous fibers may be formed from one or more continuous fiber reinforced ribbons (“CFRT”) ( 12 ) that contain fibers embedded within a thermoplastic polymer matrix, whereby a void fraction and in turn is minimized and flexural modulus is optimized Further, the ribbon (s) are consolidated so that the continuous fibers remain fixed in alignment in a substantially longitudinal direction (e.g., the direction of pultrusion). In addition to enhancing the tensile properties of the profile, the use of such ribbons also allows an improved handability when placing them into the desired position within the pultrusion die. The discontinuous fibers are also embedded within a thermoplastic matrix, in such a way as to assist in bonding of the layers to achieve the desired strength. At least a portion of the fibers are oriented in the transverse direction to provide increased transverse strength.

Impregnation section with upstream surface and method for impregnation fiber rovings

An impregnation section of a die and a method for impregnating at least one fiber roving with a polymer resin are disclosed. The impregnation section includes an impregnation zone configured to impregnate the roving with the resin and a gate passage in fluid communication with the impregnation zone for flowing the resin therethrough such that the resin coats the roving. Additionally, the impregnation section includes a surface disposed upstream of the impregnation zone in a run direction of the roving for contacting the roving. The method includes traversing at least one fiber roving over a surface, flowing a polymer resin through a gap, the gap being in the range between approximately 0.1 millimeters and approximately 4 millimeters, coating the roving with the resin, and traversing the coated roving through an impregnation zone to impregnate the roving with the resin.

Reinforced hollow profiles

A hollow lineal profile formed from a continuous fiber reinforced ribbon ("CFRT") that contains a plurality of continuous fibers embedded within a first thermoplastic polymer matrix. To enhance the tensile strength of the profile, the continuous fibers are aligned within the ribbon in a substantially longitudinal direction (e.g., the direction of pultrusion). In addition to continuous fibers, the hollow profile of the present invention also contains a plurality of long fibers that may be optionally embedded within a second thermoplastic matrix to form a long fiber reinforced thermoplastic ("LFRT"). The long fibers may be incorporated into the continuous fiber ribbon or formed as a separate layer of the profile. Regardless, at least a portion of the long fibers are oriented at an angle (e.g., 90 DEG ) to the longitudinal direction to provide increased transverse strength to the profile.

System and method for impregnating fiber rovings

A die and method for impregnating at least one fiber roving with a polymer resin are disclosed. The die includes an impregnation section. The impregnation section includes an impregnation zone configured to impregnate the roving with the resin. The impregnation zone includes a plurality of contact surfaces. At least one of the plurality of contact surfaces is configured such that a normal force of the roving is less than or equal to a lift force of the resin at an impregnation location on the contact surface during impregnation of the roving with the resin by the contact surface.

Composite core for electrical transmission cables

A composite core for use in electrical cables, such as high voltage transmission cables is provided. The composite core contains at least one rod that includes a continuous fiber component surrounded by a capping layer. The continuous fiber component is formed from a plurality of unidirectionally aligned fiber rovings embedded within a thermoplastic polymer matrix. The present inventors have discovered that the degree to which the rovings are impregnated with the thermoplastic polymer matrix can be significantly improved through selective control over the impregnation process, and also through control over the degree of compression imparted to the rovings during formation and shaping of the rod, as well as the calibration of the final rod geometry. Such a well impregnated rod has a very small void fraction, which leads to excellent strength properties. Notably, the desired strength properties may be achieved without the need for different fiber types in the rod.

Structural member formed from a solid lineal profile

A structural member that contains a solid lineal profile that is formed from a plurality of consolidated ribbons is provided. Each of the ribbons includes unidirectionally aligned continuous fibers embedded within a thermoplastic polymer matrix. The continuous fiber ribbons are laminated together during pultrusion to form an integral solid profile having very high tensile strength properties. Contrary to conventional wisdom, the present inventors have discovered that careful control over certain aspects of the pultrusion process can allow such high strength profiles to be readily formed without adversely impacting the pultrusion apparatus.

Die and Method for Impregnating Fiber Rovings

A die and method for impregnating at least one fiber roving with a polymer resin are disclosed. The die includes an impregnation section. The impregnation section includes an impregnation zone configured to impregnate the roving with the resin. The impregnation zone includes a plurality of contact surfaces. At least one of the plurality of contact surfaces is configured such that a normal force of the roving is less than or equal to a lift force of the resin at an impregnation location on the contact surface during impregnation of the roving with the resin by the contact surface. 111.-. (canceled)12. A method for impregnating at least one fiber roving with a polymer resin , the method comprising:flowing a polymer resin through a manifold assembly of a die, the manifold assembly comprising a plurality of branched runners;coating at least one fiber roving with the resin; andtraversing the coated roving through an impregnation zone of the die to impregnate the roving with the resin, the impregnation zone comprising a plurality of contact surfaces,wherein at least one of the plurality of contact surfaces is configured such that a normal force of the roving is less than or equal to a lift force of the resin at an impregnation location on the contact surface during impregnation of the roving with the resin by the contact surface.13. The method of claim 12 , wherein the at least one of the plurality of contact surfaces is a final contact surface in a run direction of the roving.14. The method of claim 12 , wherein no contact occurs between the roving and the at least one of the plurality of contact surfaces during impregnation of the roving with the resin by the contact surface.15. The method of claim 12 , wherein the impregnation location comprises a peak of the contact surface.16. The method of claim 12 , wherein the normal three is calculated using the equation:{'br': None, 'i': A', 'h, 'α=sin()*'}wherein a is the normal force, A is an angle at which the roving ...

Methods for impregnating fiber rovings with polymer resin

An impregnation section of a die and a method for impregnating at least one fiber roving with a polymer resin are disclosed. The impregnation section includes an impregnation zone configured to impregnate the roving with the resin and a gate passage in fluid communication with the impregnation zone for flowing the resin therethrough such that the resin coats the roving. Additionally, the impregnation section includes a surface disposed upstream of the impregnation zone in a run direction of the roving for contacting the roving. The method includes traversing at least one fiber roving over a surface, flowing a polymer resin through a gap, the gap being in the range between approximately 0.1 millimeters and approximately 4 millimeters, coating the roving with the resin, and traversing the coated roving through an impregnation zone to impregnate the roving with the resin.

Method for forming reinforced pultruded profiles

A method and apparatus for forming a profile that contains at least one layer of continuous fibers and at least one layer of discontinuous fibers are provided. Various features of the method are selectively controlled to achieve a profile that has increased transverse strength and flexural modulus. For example, the layer of continuous fibers is formed from one or more continuous fiber reinforced ribbons ("CFRT") that contain fibers embedded within a thermoplastic polymer matrix. The fibers are embedded within the matrix by a process that minimizes void fraction and in turn, optimizes flexural modulus. Further, the ribbon(s) are consolidated so that the continuous fibers remain fixed in alignment in a substantially longitudinal direction (e.g., the direction of pultrusion).; In addition to enhancing the tensile properties of the profile, the use of such ribbons also allows the continuous fiber material to be more readily manipulated and placed into the desired position within the pultrusion ...

Impregnation Section with Upstream Surface and Method for Impregnating Fiber Rovings

An impregnation section of a die and a method for impregnating at least one fiber roving with a polymer resin are disclosed. The impregnation section includes an impregnation zone configured to impregnate the roving with the resin and a gate passage in fluid communication with the impregnation zone for flowing the resin therethrough such that the resin coats the roving. Additionally, the impregnation section includes a surface disposed upstream of the impregnation zone in a run direction of the roving for contacting the roving. The method includes traversing at least one fiber roving over a surface, flowing a polymer resin through a gap, the gap being in the range between approximately 0.1 millimeters and approximately 4 millimeters, coating the roving with the resin, and traversing the coated roving through an impregnation zone to impregnate the roving with the resin. 1. An impregnation section of a die for impregnating at least one fiber roving with a polymer resin , the impregnation section comprising:an impregnation zone configured to impregnate the roving with the resin;a gate passage in fluid communication with the impregnation zone for flowing the resin therethrough such that the resin coats the roving; anda surface disposed upstream of the impregnation zone in a run direction of the roving for contacting the roving.2. The impregnation section of claim 1 , wherein the surface has a curvilinear portion proximate the gate passage.3. The impregnation section of claim 1 , wherein a gap is defined between an outlet of the gate passage and an upper surface of the roving claim 1 , and wherein the gap is in the range between approximately 0.1 millimeters and approximately 4 millimeters.4. The impregnation section of claim 1 , wherein the gate passage extends vertically.5. The impregnation section of claim 1 , wherein at least a portion of the gate passage has a decreasing cross-sectional profile in a flow direction of the resin.6. The impregnation section of claim 1 ...

Die and Method for Impregnating Fiber Rovings

A die and method for impregnating at least one fiber roving with a polymer resin are disclosed. In one embodiment, the die includes an impregnation section including an impregnation zone configured to impregnate the roving with the resin, the impregnation zone including a plurality of contact surfaces. The die further includes a perturbation positioned on at least one of the plurality of contact surfaces, the perturbation configured to interact with the roving. In one embodiment, the method includes coating a fiber roving with a polymer resin. The method further includes traversing the coated roving through an impregnation zone to impregnate the roving with the resin. The impregnation zone includes a plurality of contact surfaces. The method further includes interacting the coated roving with a perturbation positioned on at least one of the plurality of contact surfaces. 1. A die for impregnating at least one fiber roving with a polymer resin , the impregnation section comprising:an impregnation section comprising an impregnation zone configured to impregnate the roving with the resin, the impregnation zone comprising a plurality of contact surfaces; anda perturbation positioned on at least one of the plurality of contact surfaces, the perturbation configured to interact with the roving.2. The die of claim 1 , wherein the perturbation is a protrusion claim 1 , the protrusion extending from one of the plurality of contact surfaces and configured to disturb a run direction of the roving.3. The die of claim 1 , wherein the perturbation is a depression claim 1 , the depression defined in one of the plurality of contact surfaces and configured to disturb a run direction of the roving.4. The die of claim 1 , wherein the perturbation is a channel defined in one of the plurality of contact surfaces and positioned for running the roving therethrough.5. The die of claim 1 , further comprising a plurality of perturbations.6. The die of claim 1 , wherein the impregnation zone ...

Reinforced hollow profiles

A hollow lineal profile ( 16 ) formed from a continuous fiber reinforced ribbon (“CFRT”) that contains a plurality of continuous fibers embedded within a first thermoplastic polymer matrix ( 6 ). To enhance the tensile strength of the profile, the continuous fibers are aligned within the ribbon in a substantially longitudinal direction (e.g., the direction of pultrusion). In addition to continuous fibers, the hollow profile of the present invention also contains a plurality of long fibers that may be optionally embedded within a second thermoplastic matrix to form a long fiber reinforced thermoplastic (“LFRT”) ( 4 ). The long fibers may be incorporated into the continuous fiber ribbon or formed as a separate layer of the profile. Regardless, at least a portion of the long fibers are oriented at an angle (e.g., 90°) to the longitudinal direction to provide increased transverse strength to the profile.

Structural Member Formed From A Solid Lineal Profile

A structural member that contains a solid lineal profile () that is formed from a plurality of consolidated ribbons (). Each of the ribbons includes unidirectionally aligned continuous fibers embedded within a thermoplastic polymer matrix. The continuous fiber ribbons () are laminated together during pultrusion to form an integral solid profile () having very high tensile strength properties. 1. A structural member comprising a solid lineal profile , wherein the solid lineal profile contains a first component formed from a consolidated laminate of individual ribbons , wherein each ribbon of the laminate contains a plurality of continuous fibers that are substantially oriented in a longitudinal direction and a resinous matrix that contains one or more thermoplastic polymers and within which the continuous fibers are embedded , the continuous fibers constituting from about 40 wt. % to about 90 wt. % of the ribbon and the thermoplastic polymers constituting from about 10 wt. % to about 60 wt. % of the ribbon , wherein the flexural modulus of the profile is about 10 Gigapascals or more.2. The structural member of claim 1 , wherein the continuous fibers include glass fibers claim 1 , carbon fibers claim 1 , or a combination of glass and carbon fibers.3. The structural member of claim 1 , wherein the thermoplastic polymers include a polyolefin claim 1 , polyether ketone claim 1 , polyetherimide claim 1 , polyarylene ketone claim 1 , liquid crystal polymer claim 1 , polyarylene sulfide claim 1 , fluoropolymer claim 1 , polyacetal claim 1 , polyurethane claim 1 , polycarbonate claim 1 , styrenic polymer claim 1 , polyester claim 1 , polyamide claim 1 , or a combination thereof.4. The structural member of claim 1 , wherein the continuous fibers constitute from about 50 wt. % to about 85 wt. % of the ribbon.5. The structural member of claim 1 , wherein the ribbon has a void faction of about 2% or less.6. The structural member of claim 1 , wherein the laminate is formed from ...

Impregnation Section of Die for Impregnating Fiber Rovings

An impregnation plate and an impregnation section of a die for impregnating at least one fiber roving with a polymer resin are disclosed. The impregnation plate includes an impregnation zone configured to impregnate the roving with the resin. The impregnation zone includes an inner surface. The impregnation plate further includes a sidewall. The sidewall includes an inner surface. The inner surface of the sidewall includes a plurality of peaks and a plurality of valleys. At least one of the plurality of valleys defines a maximum height that is less than a height of the inner surface of the impregnation zone at a neighboring location along a run direction of the roving. 1. An impregnation plate for impregnating at least one fiber roving with a polymer resin , the impregnation plate comprising:an impregnation zone configured to impregnate the roving with the resin, the impregnation zone comprising an inner surface; anda sidewall comprising an inner surface, the inner surface of the sidewall comprising a plurality of peaks and a plurality of valleys, at least one of the plurality of valleys defining a maximum height that is less than a height of the inner surface of the impregnation zone at a neighboring location along a run direction of the roving.2. The impregnation plate of claim 1 , wherein at least one of the plurality of peaks defines a maximum height that is greater than a height of the inner surface of the impregnation zone at a neighboring location along a run direction of the roving.3. The impregnation plate of claim 1 , wherein each of the plurality of valleys defines a maximum height that is less than a height of the inner surface of the impregnation zone at a neighboring location along a run direction of the roving.4. The impregnation plate of claim 1 , further comprising a plurality of sidewalls.5. The impregnation plate of claim 1 , wherein the sidewall has a waveform cross-sectional profile.6. The impregnation plate of claim 1 , wherein the inner ...

Die and Method for Impregnating Fiber Rovings

A die and method for impregnating at least one fiber roving with a polymer resin are disclosed. The die includes an impregnation section. The impregnation section includes an impregnation zone configured to impregnate the roving with the resin. The impregnation zone includes a plurality of contact surfaces. At least one of the plurality of contact surfaces is configured such that a normal force of the roving is less than or equal to a lift force of the resin at an impregnation location on the contact surface during impregnation of the roving with the resin by the contact surface. 1. A die for impregnating at least one fiber roving with a polymer resin , the die comprising:an impregnation section, the impregnation section comprising an impregnation zone configured to impregnate the roving with the resin, the impregnation zone comprising a plurality of contact surfaces,wherein at least one of the plurality of contact surfaces is configured such that a normal force of the roving is less than or equal to a lift force of the resin at an impregnation location on the contact surface during impregnation of the roving with the resin by the contact surface.2. The die of claim 1 , wherein the at least one of the plurality of contact surfaces is a final contact surface in a run direction of the roving.3. The die of claim 1 , wherein no contact occurs between the roving and the at least one of the plurality of contact surfaces during impregnation of the roving with the resin by the contact surface.4. The die of claim 1 , wherein the impregnation location comprises a peak of the contact surface.7. The die of claim 1 , wherein each of the plurality of contact surfaces is configured such that the roving traverses the contact surface at an angle in the range between 1 degree and 30 degrees.8. The die of claim 1 , wherein the at least one of the plurality of contact surfaces is configured such that the roving traverses the at least one of the plurality of contact surfaces at an angle ...

Impregnation Section and Method for Impregnating Fiber Rovings

An impregnation section of a die and a method for impregnating at least one fiber roving with a polymer resin are disclosed. The impregnation section includes an impregnation zone configured to impregnate the roving with the resin. The impregnation zone includes a plurality of contact surfaces, at least one of the plurality of contact surfaces defining a cut-away portion downstream in a run direction of the roving of a point-of-contact for the at least one of the plurality of contact surfaces. The at least one of the plurality of contact surfaces further includes an edge defined by the cut-away portion. Excess material build up is reduced by the cut-away portion. 1. An impregnation section of a die for impregnating at least one fiber roving with a polymer resin , the impregnation section comprising:an impregnation zone configured to impregnate the roving with the resin, the impregnation zone comprising a plurality of contact surfaces, at least one of the plurality of contact surfaces defining a cut-away portion downstream in a run direction of the roving of a point-of-contact for the at least one of the plurality of contact surfaces, the at least one of the plurality of contact surfaces further comprising an edge defined by the cut-away portion,wherein excess material build up is reduced by the cut-away portion.2. The impregnation section of claim 1 , wherein the at least one of the plurality of contact surfaces further comprises a lobe-shaped portion for impregnated the roving with the resin claim 1 , the lobe-shaped portion disposed upstream of the cut-away portion in the run direction of the roving and defining the point-of-contact.3. The impregnation section of claim 1 , wherein a face of the at least one of the plurality of contact surfaces defined by the cut-away portion extends vertically.4. The impregnation section of claim 1 , wherein a face of the at least one of the plurality of contact surfaces defined by the cut-away portion extends at an angle to ...

Method for Forming Reinfoced Pultruded Profiles

A method and apparatus for forming a profile that contains at least one layer of continuous fibers and at least one layer of discontinuous fibers. Said method allowing the selective control of features to achieve a profile that has increased transverse strength and flexural modulus. The layer of continuous fibers may be formed from one or more continuous fiber reinforced ribbons (“CFRT”) () that contain fibers embedded within a thermoplastic polymer matrix, whereby a void fraction and in turn is minimized and flexural modulus is optimized Further, the ribbon (s) are consolidated so that the continuous fibers remain fixed in alignment in a substantially longitudinal direction (e.g., the direction of pultrusion). In addition to enhancing the tensile properties of the profile, the use of such ribbons also allows an improved handability when placing them into the desired position within the pultrusion die. The discontinuous fibers are also embedded within a thermoplastic matrix, in such a way as to assist in bonding of the layers to achieve the desired strength. At least a portion of the fibers are oriented in the transverse direction to provide increased transverse strength. 1. A method for forming a pultruded profile having a cross-sectional shape , the method comprising:pulling a continuous fiber ribbon through a pultrusion die in a longitudinal direction, wherein the continuous fiber ribbon contains continuous fibers that are substantially oriented in the longitudinal direction and embedded within a first thermoplastic polymer matrix;introducing a discontinuous fiber material into the pultrusion die, wherein the discontinuous fiber material contains discontinuous fibers embedded within a second thermoplastic matrix; andwithin the pultrusion die, combining the discontinuous fiber material and the continuous fiber ribbon to form first and second layers of the profile, wherein the first layer is positioned adjacent to the second layer and includes the discontinuous ...

Asymmetric Fiber Reinforced Polymer Tape

An asymmetric tape and a system and method for impregnating at least one fiber roving with a polymer resin to form an asymmetric tape are provided. The asymmetric tape includes a polymer resin, and a plurality of fibers embedded in the polymer resin to form a fiber reinforced polymer material. The fiber reinforced polymer material includes a first surface and an opposing second surface. The fibers are disposed in the fiber reinforced polymer material to form a resin rich portion and a fiber rich portion. The resin rich portion includes the first surface and the fiber rich portion includes the second surface. 1. An asymmetric tape , comprising:a polymer resin; anda plurality of fibers embedded in the polymer resin to form a fiber reinforced polymer material, the fiber reinforced polymer material comprising a first surface and an opposing second surface,wherein the fibers are disposed in the fiber reinforced polymer material to form a resin rich portion and a fiber rich portion, the resin rich portion including the first surface, the fiber rich portion including the second surface.2. The asymmetric tape of claim 1 , wherein the resin rich portion comprises at least 75% resin by volume.3. The asymmetric tape of claim 1 , wherein the resin rich portion comprises at least 95% resin by volume.4. The asymmetric tape of claim 1 , wherein the fiber reinforced polymer material has a fiber volume fraction of between approximately 40% and approximately 60%.5. The asymmetric tape of claim 1 , wherein the fiber reinforced polymer material has a void fraction of approximately 2% or less.6. The asymmetric tape of claim 1 , wherein the polymer resin is a thermoplastic resin.7. The asymmetric tape of claim 1 , wherein the polymer resin is polyether ether ketone.8. The asymmetric tape of claim 1 , wherein the fibers are carbon fibers.9. The asymmetric tape of claim 1 , wherein the thermoplastic resin is a polyamide.10. The asymmetric tape of claim 1 , wherein the fibers are S-glass ...

Die and Method for Impregnating Fiber Rovings

A die and a method for impregnating fiber rovings () with a polymer resin () are disclosed. The die includes a manifold assembly (), an impregnation zone, and a gate passage (). The manifold assembly flows the resin () therethrough, and includes a plurality of branched runners (). The impregnation zone is in fluid communication with the manifold assembly, and is configured to impregnate the roving with the resin. The gate passage () is between the manifold assembly and the impregnation zone (), and flows the resin from the manifold assembly such that the resin coats the roving. The method includes flowing a polymer resin through a manifold assembly. The method further includes coating at least one fiber roving with the resin, and traversing the coated roving through an impregnation zone to impregnate the roving with the resin. The roving is under a tension of from about 5 Newtons to about Newtons within the impregnation zone. 1. A die for impregnating at least one fiber roving with a polymer resin , the die comprising:a manifold assembly for flowing the resin therethrough, the manifold assembly comprising a plurality of branched runners;an impregnation zone in fluid communication with the manifold assembly, the impregnation zone configured to impregnate the roving with the resin; anda gate passage between the manifold assembly and the impregnation zone for flowing the resin from the manifold assembly such that the resin coats the roving.2. The die of claim 1 , wherein the plurality of branched runners have a symmetrical orientation along a central axis.3. The die of claim 1 , wherein the plurality of branched runners comprises a first branched runner group.4. The die of claim 3 , wherein the plurality of branched runners further comprises a second branched runner group diverging from the first branched runner group.5. The die of claim 4 , wherein the plurality of branched runners further comprises a third branched runner group diverging from the second branched ...

Umbilical for Use in Subsea Applications

An umbilical ( 600 ) for the transfer of fluids and/or electric current/signals, particularly between the sea surface and equipment deployed on the sea bed (e.g., in deep waters), is provided. The umbilical contains a plurality of elongated umbilical elements (e.g., two or more), such as a channel element ( 603 ), fluid pipe ( 604 ), electric conductor/wire ( 606 ) (e.g., optic fiber cable), armoring wire, etc., enclosed within an outer sheath (e.g., plastic sheath). The umbilical also contains at least one reinforcing rod ( 607 ) formed from a plurality of unidirectionally aligned fiber rovings embedded within a thermoplastic polymer matrix. The present inventors have discovered that the degree to which the ravings are impregnated with the thermoplastic polymer matrix can be significantly improved through selective control over the impregnation process, and also through control over the degree of compression imparted to the ravings during formation and shaping of the rod, as well as the calibration of the final rod geometry. Such a well impregnated rod has a very small void fraction, which leads to excellent strength properties for reinforcing the umbilical elements.

Impregnation Section of Die and Method for Impregnating Fiber Rovings

An impregnation section () and a method for impregnating fiber rovings () with a polymer resin () are disclosed. The impregnation section () includes an impregnation zone () and a gate passage (). The impregnation zone () is configured to impregnate the plurality of rovings () with the resin (). The gate passage () is in fluid communication with the impregnation zone () for flowing the resin therethrough such that the resin impinges on a surface () of each of the plurality of rovings () facing the gate passage () and substantially uniformly coats the plurality of rovings. The method includes impinging a polymer resin () onto a surface of a plurality of fiber rovings (), and substantially uniformly coating the plurality of rovings with the resin. The method further includes traversing the plurality of coated rovings through an impregnation zone (). Each of the plurality of rovings () is under a tension of from about 5 Newtons to about 300 Newtons within the impregnation zone (). 1. An impregnation section of a die for impregnating a plurality of fiber rovings with a polymer resin , the impregnation section comprising:an impregnation zone configured to impregnate the plurality of rovings with the resin; anda gate passage in fluid communication with the impregnation zone for flowing the resin therethrough such that the resin impinges on a surface of each of the plurality of rovings facing the gate passage and substantially uniformly coats the plurality of rovings.2. The impregnation section of claim 1 , wherein the gate passage extends vertically to the impregnation zone.3. The impregnation section of claim 1 , wherein at least a portion of the gate passage has a decreasing cross-sectional profile in a flow direction of the resin.4. The impregnation section of claim 1 , wherein the impregnation zone comprises a plurality of contact surfaces.5. The impregnation section of claim 4 , wherein the impregnation zone comprises between 2 and 50 contact surfaces.6. The ...

Composite Core for Electrical Transmission Cables

A composite core for use in electrical cables, such as high voltage transmission cables is provided. The composite core contains at least one rod that includes a continuous fiber component surrounded by a capping layer. The continuous fiber component is formed from a plurality of unidirectionally aligned fiber rovings embedded within a thermoplastic polymer matrix. The present inventors have discovered that the degree to which the rovings are impregnated with the thermoplastic polymer matrix can be significantly improved through selective control over the impregnation process, and also through control over the degree of compression imparted to the rovings during formation and shaping of the rod, as well as the calibration of the final rod geometry. Such a well impregnated rod has a very small void fraction, which leads to excellent strength properties. Notably, the desired strength properties may be achieved without the need for different fiber types in the rod. 1. An electrical transmission cable core , wherein the core extends in a longitudinal direction and comprises:at least one rod that contains a continuous fiber component comprising a plurality of consolidated thermoplastic impregnated ravings, the rovings containing continuous fibers oriented in the longitudinal direction and a thermoplastic matrix that embeds the fibers, said fibers having a ratio of ultimate tensile strength to mass per unit length of greater than about 1,000 Megapascals per gram per meter, wherein the continuous fibers constitute from about 25 wt. % to about 80 wt. % of the rod and the thermoplastic matrix constitutes from about 20 wt. % to about 75 wt. % of the rod; anda capping layer surrounding the continuous fiber component, wherein the capping layer is free of continuous fibers;wherein the rod has a minimum flexural modulus of about 10 Gigapascals.2. The core of claim 1 , wherein the continuous fibers have a ratio of ultimate tensile strength to mass per unit length of from about 5 ...

Continuous Fiber Reinforced Thermoplastic Rod and Pultrusion Method for Its Manufacture

A composite rod for use in various applications, such as electrical cables (e.g., high voltage transmission cables), power umbilicals, tethers, ropes, and a wide variety of other structural members, is provided. The rod includes a core that is formed from a plurality of unidirectionally aligned fiber rovings embedded within a thermoplastic polymer matrix. The present inventors have discovered that the degree to which the rovings are impregnated with the thermoplastic polymer matrix can be significantly improved through selective control over the impregnation process, and also through control over the degree of compression imparted to the rovings during formation and shaping of the rod, as well as the calibration of the final rod geometry. Such a well impregnated rod has a very small void fraction, which leads to excellent strength properties. Notably, the desired strength properties may be achieved without the need for different fiber types in the rod. 1. A composite rod extending in a longitudinal direction , wherein the rod contains a core comprising a plurality of thermoplastic impregnated rovings , the rovings containing continuous fibers oriented in the longitudinal direction and a thermoplastic matrix that embeds the fibers , the fibers having a ratio of ultimate tensile strength to mass per unit length of greater than about 1 ,000 Megapascals per gram per meter , wherein the continuous fibers constitute from about 25 wt. % to about 80 wt. % of the core and the thermoplastic matrix constitutes from about 20 wt. % to about 75 wt. % of the core , and wherein the rovings are distributed generally symmetrically about a longitudinal center of the core.2. The composite rod of claim 1 , wherein the continuous fibers have a ratio of ultimate tensile strength to mass per unit length of from about 5 claim 1 ,500 to about 20 claim 1 ,000 Megapascals per gram per meter.3. The composite rod of claim 1 , wherein the continuous fibers are carbon fibers.4. The composite rod ...

Composite Core for Electrical Transmission Cables

A composite core for use in electrical cables, such as high voltage transmission cables is provided. The composite core contains at least one rod that includes a continuous fiber component surrounded by a capping layer. The continuous fiber component is formed from a plurality of unidirectionally aligned fiber rovings embedded within a thermoplastic polymer matrix. The present inventors have discovered that the degree to which the rovings are impregnated with the thermoplastic polymer matrix can be significantly improved through selective control over the impregnation process, and also through control over the degree of compression imparted to the rovings during formation and shaping of the rod, as well as the calibration of the final rod geometry. Such a well impregnated rod has a very small void fraction, which leads to excellent strength properties. Notably, the desired strength properties may be achieved without the need for different fiber types in the rod.

Die with Flow Diffusing Gate Passage and Method for Impregnating Same Fiber Rovings

A die and a method for impregnating fiber rovings with a polymer resin are disclosed. The die includes a manifold assembly (), an impregnation zone (), and a gate passage (). The manifold assembly () flows the resin therethrough, and includes a channel (). The impregnation zone () is in fluid communication with the manifold assembly (), and is configured to impregnate the roving with the resin. The gate passage () is between the manifold assembly () and the impregnation zone (), and flows the resin from the manifold assembly () such that the resin coats the roving. The gate passage () includes a projection (). The projection () is configured to diffuse resin flowing through the gate passage (). 1. A die for impregnating at least one fiber roving with a polymer resin , the die comprising:a manifold assembly for flowing the resin therethrough, the manifold assembly comprising a channel;an impregnation zone in fluid communication with the manifold assembly, the impregnation zone configured to impregnate the roving with the resin; anda gate passage between the manifold assembly and the impregnation zone for flowing the resin from the manifold assembly such that the resin coats the roving, the gate passage comprising a projection configured to diffuse resin flowing through the gate passage.2. The die of claim 1 , further comprising a plurality of projections.3. The die of claim 2 , wherein the plurality of projections are spaced apart to define a plurality of passages therebetween.4. The die of claim 1 , wherein the projection has a tapered cross-sectional profile in a flow direction of the resin through the gate passage.5. The die of claim 1 , wherein the projection includes an outer surface and at least one side surface claim 1 , the at least one side surface extending between the outer surface and an inner wall of the gate passage claim 1 , and wherein the at least one side surface is tapered towards the outer surface.6. The die of claim 1 , wherein the manifold ...

Reinforced Hollow Profiles

A hollow lineal profile formed from a continuous fiber reinforced ribbon (“CFRT”) that contains a plurality of continuous fibers embedded within a first thermoplastic polymer matrix. To enhance the tensile strength of the profile, the continuous fibers are aligned within the ribbon in a substantially longitudinal direction (e.g., the direction of pultrusion). In addition to continuous fibers, the hollow profile of the present invention also contains a plurality of long fibers that may be optionally embedded within a second thermoplastic matrix to form a long fiber reinforced thermoplastic (“LFRT”). The long fibers may be incorporated into the continuous fiber ribbon or formed as a separate layer of the profile. Regardless, at least at a portion of the long fibers are oriented at an angle (e.g., 90°) to the longitudinal direction to provide increased transverse strength to the profile. 131-. (canceled)32. A method for forming a hollow profile that extends in a longitudinal direction , the method comprising:impregnating a plurality of continuous fibers with a thermoplastic matrix within an extrusion device;consolidating the impregnated fibers to form a first ribbon in which the continuous fibers are oriented in the longitudinal direction;pultruding the first ribbon and a plurality of long fibers through a die to form the hollow profile.33. The method of claim 32 , wherein the continuous fibers claim 32 , long fibers claim 32 , or both claim 32 , include glass fibers claim 32 , carbon fibers claim 32 , or a combination of glass and carbon fibers.34. The method of claim 32 , wherein the thermoplastic polymer matrix includes a polyolefin claim 32 , polyether ketone claim 32 , polyetherimide claim 32 , polyarylene ketone claim 32 , liquid crystal polymer claim 32 , polyarylene sulfide claim 32 , fluoropolymer claim 32 , polyacetal claim 32 , polyurethane claim 32 , polycarbonate claim 32 , styrenic polymer claim 32 , polyester claim 32 , polyamide claim 32 , or a ...

Die and Method for Impregnating Fiber Rovings

A die and method for impregnating at least one fiber roving with a polymer resin are disclosed. In one embodiment, the die includes an impregnation section including an impregnation zone configured to impregnate the roving with the resin, the impregnation zone including a plurality of contact surfaces. The die further includes a perturbation positioned on at least one of the plurality of contact surfaces, the perturbation configured to interact with the roving. In one embodiment, the method includes coating a fiber roving with a polymer resin. The method further includes traversing the coated roving through an impregnation zone to impregnate the roving with the resin. The impregnation zone includes a plurality of contact surfaces. The method further includes interacting the coated roving with a perturbation positioned on at least one of the plurality of contact surfaces. 117-. (canceled)18. A method for impregnating at least one fiber roving with a polymer resin , the method comprising:coating a fiber roving with a polymer resin;traversing the coated roving through an impregnation zone to impregnate the roving with the resin, the impregnation zone comprising a plurality of contact surfaces; and,interacting the coated roving with a perturbation positioned on at least one of the plurality of contact surfaces.19. The method of claim 18 , wherein interacting the coated roving with a perturbation comprises traversing the coated roving over a protrusion claim 18 , the protrusion extending from one of the plurality of contact surfaces and configured to disturb a run direction of the roving.20. The method of claim 18 , wherein interacting the coated roving with a perturbation comprises traversing the coated roving through a depression claim 18 , the depression defined in one of the plurality of contact surfaces and configured to disturb a run direction of the roving.21. The method of claim 18 , wherein interacting the coated roving with a perturbation comprises traversing ...

Structural Member Formed from a Solid Lineal Profile

A structural member that contains a solid lineal profile that is formed from a plurality of consolidated ribbons is provided. Each of the ribbons includes unidirectionally aligned continuous fibers embedded within a thermoplastic polymer matrix. The continuous fiber ribbons are laminated together during pultrusion to form an integral solid profile having very high tensile strength properties. Contrary to conventional wisdom, the present inventors have discovered that careful control over certain aspects of the pultrusion process can allow such high strength profiles to be readily formed without adversely impacting the pultrusion apparatus. 114-. (canceled)15. A method for forming a solid lineal profile , the method comprising:supplying a plurality of individual ribbons, wherein each ribbon contains a plurality of continuous fibers that are substantially oriented in a longitudinal direction and a resinous matrix that contains one or more thermoplastic polymers and within which the continuous fibers are embedded, the continuous fibers constituting from about 40 wt. % to about 90 wt. % of the ribbon and the thermoplastic polymers constituting from about 10 wt. % to about 60 wt. % of the ribbon;heating the ribbons to a temperature at or above the softening temperature of the resinous matrix;pulling the heated ribbons through a first die to consolidate the ribbons together and form a laminate and through a second die to shape the laminate; andcooling the shaped laminate to form the solid profile.16. The method of claim 15 , wherein the continuous fibers include glass fibers claim 15 , carbon fibers claim 15 , or a combination of glass and carbon fibers.17. The method of claim 15 , wherein the thermoplastic polymers include a polyolefin claim 15 , polyether ketone claim 15 , polyetherimide claim 15 , polyarylene ketone claim 15 , liquid crystal polymer claim 15 , polyarylene sulfide claim 15 , fluoropolymer claim 15 , polyacetal claim 15 , polyurethane claim 15 , ...

Impregnation Section with Upstream Surface for Impregnating Fiber Rovings

An impregnation section of a die and a method for impregnating at least one fiber roving with a polymer resin are disclosed. The impregnation section includes an impregnation zone configured to impregnate the roving with the resin and a gate passage in fluid communication with the impregnation zone for flowing the resin therethrough such that the resin coats the roving. Additionally, the impregnation section includes a surface disposed upstream of the impregnation zone in a run direction of the roving for contacting the roving. The method includes traversing at least one fiber roving over a surface, flowing a polymer resin through a gap, the gap being in the range between approximately 0.1 millimeters and approximately 4 millimeters, coating the roving with the resin, and traversing the coated roving through an impregnation zone to impregnate the roving with the resin.

Impregnation Section And Method For Impregnating Fiber Rovings

An impregnation section of a die and a method for impregnating at least one fiber roving with a polymer resin are disclosed. The impregnation section includes an impregnation zone configured to impregnate the roving with the resin. The impregnation zone includes a plurality of contact surfaces, at least one of the plurality of contact surfaces defining a cut-away portion downstream in a run direction of the roving of a point-of-contact for the at least one of the plurality of contact surfaces. The at least one of the plurality of contact surfaces further includes an edge defined by the cut-away portion. Excess material build up is reduced by the cut-away portion.

Impregnation Section of Die and Method for Impregnating Fiber Rovings

An impregnation section and a method for impregnating fiber rovings with a polymer resin are disclosed. The impregnation section includes an impregnation zone and a gate passage. The impregnation zone is configured to impregnate the plurality of rovings with the resin. The gate passage is in fluid communication with the impregnation zone for flowing the resin therethrough such that the resin impinges on a surface of each of the plurality of rovings facing the gate passage and substantially uniformly coats the plurality of rovings. The method includes impinging a polymer resin onto a surface of a plurality of fiber rovings, and substantially uniformly coating the plurality of rovings with the resin. The method further includes traversing the plurality of coated rovings through an impregnation zone. Each of the plurality of rovings is under a tension of from about 5 Newtons to about 300 Newtons within the impregnation zone. 120-. (canceled)21. An impregnation section of a die for impregnating a plurality of fiber rovings with a polymer resin , the impregnation section comprising:an impregnation zone configured to impregnate the plurality of rovings with the resin; anda gate passage in fluid communication with the impregnation zone for flowing the resin therethrough such that the resin impinges on a surface of each of the plurality of rovings facing the gate passage and substantially uniformly coats the plurality of rovings,wherein the impregnation section further comprises a first plate defining a first inner surface and a second plate spaced apart from the first plate and defining a second opposing inner surface, wherein the impregnation zone is defined between the first plate and the second plate, and wherein the impregnation zone comprises a plurality of contact surfaces defined on only one of the first inner surface or the second inner surface.22. The impregnation section of claim 21 , wherein the gate passage extends vertically to the impregnation zone.23. The ...

Method for forming reinforced pultruded profiles

A method and apparatus for forming a profile that contains at least one layer of continuous fibers and at least one layer of discontinuous fibers. Said method allowing the selective control of features to achieve a profile that has increased transverse strength and flexural modulus. The layer of continuous fibers may be formed from one or more continuous fiber reinforced ribbons ("CFRT") (12) that contain fibers embedded within a thermoplastic polymer matrix, whereby a void fraction and in turn is, is minimized and flexural modulus is optimized. Further, the ribbon (s) are consolidated so that the continuous fibers remain fixed in alignment in a substantially longitudinal direction (e.g., the direction of pultrusion). In addition to enhancing the tensile properties of the profile, the use of such ribbons also allows an improved handability when placing them into the desired position within the pultrusion die. The discontinuous fibers are also embedded within a thermoplastic matrix, in such a way as to assist in bonding of the layers to achieve the desired strength. At least a portion of the fibers are oriented in the transverse direction to provide increased transverse strength.

Coated, long fiber reinforcing composite structure and process of preparation thereof

A process for the continuous preparation of a coated, long fiber reinforcing composite structure suitable for the preparation of shaped articles. The process is characterized by impregnating a plurality of continuous lengths of reinforcing fiber strands with a first thermoplastic resin material while continuously drawing the fiber strands to produce a long fiber reinforcing composite structure followed by coating a second thermoplastic resin material containing additives onto the long fiber reinforcing composite structure to produce a coated, long fiber reinforcing composite structure. The coating additives may be selected from mineral reinforcing agents, lubricants, flame retardants, blowing agents, foaming agents, ultraviolet light resistant agents, heat sensitive pigments, etc. The coated, long fiber reinforcing composite structure prepared according to the process is suitable for the preparation of shaped articles exhibiting good physical and chemical properties.

Die and method for impregnating fiber rovings

A die and method for impregnating at least one fiber roving with a polymer resin are disclosed. In one embodiment, the die includes an impregnation section including an impregnation zone configured to impregnate the roving with the resin, the impregnation zone including a plurality of contact surfaces. The die further includes a perturbation positioned on at least one of the plurality of contact surfaces, the perturbation configured to interact with the roving. In one embodiment, the method includes coating a fiber roving with a polymer resin. The method further includes traversing the coated roving through an impregnation zone to impregnate the roving with the resin. The impregnation zone includes a plurality of contact surfaces. The method further includes interacting the coated roving with a perturbation positioned on at least one of the plurality of contact surfaces.

Die and method for impregnating fiber rovings

A die and method for impregnating at least one fiber roving with a polymer resin are disclosed. In one embodiment, the die includes an impregnation section including an impregnation zone configured to impregnate the roving with the resin, the impregnation zone including a plurality of contact surfaces. The die further includes a perturbation positioned on at least one of the plurality of contact surfaces, the perturbation configured to interact with the roving. In one embodiment, the method includes coating a fiber roving with a polymer resin. The method further includes traversing the coated roving through an impregnation zone to impregnate the roving with the resin. The impregnation zone includes a plurality of contact surfaces. The method further includes interacting the coated roving with a perturbation positioned on at least one of the plurality of contact surfaces.

Coated, long fiber reinforcing composite structure and process of preparation thereof

A process for the continuous preparation of a coated, long fiber reinforcing composite structure suitable for the preparation of shaped articles. The process is characterized by impregnating a plurality of continuous lengths of reinforcing fiber strands with a first thermoplastic resin material while continuously drawing the fiber strands to produce a long fiber reinforcing composite structure followed by coating a second thermoplastic resin material containing additives onto the long fiber reinforcing composite structure to produce a coated, long fiber reinforcing composite structure. The coating additives may be selected from mineral reinforcing agents, lubricants, flame retardants, blowing agents, foaming agents, ultraviolet light resistant agents, heat sensitive pigments, etc. The coated, long fiber reinforcing composite structure prepared according to the process is suitable for the preparation of shaped articles exhibiting good physical and chemical properties.

Impregnation section of die for impregnating fiber rovings

An impregnation plate and an impregnation section of a die for impregnating at least one fiber roving with a polymer resin are disclosed. The impregnation plate includes an impregnation zone configured to impregnate the roving with the resin. The impregnation zone includes an inner surface. The impregnation plate further includes a sidewall. The sidewall includes an inner surface. The inner surface of the sidewall includes a plurality of peaks and a plurality of valleys. At least one of the plurality of valleys defines a maximum height that is less than a height of the inner surface of the impregnation zone at a neighboring location along a run direction of the roving.

Composite core for electrical transmission cables

A composite core for use in electrical cables, such as high voltage transmission cables is provided. The composite core contains at least one rod that includes a continuous fiber component surrounded by a capping layer. The continuous fiber component is formed from a plurality of unidirectionally aligned fiber rovings embedded within a thermoplastic polymer matrix. The present inventors have discovered that the degree to which the rovings are impregnated with the thermoplastic polymer matrix can be significantly improved through selective control over the impregnation process, and also through control over the degree of compression imparted to the rovings during formation and shaping of the rod, as well as the calibration of the final rod geometry. Such a well impregnated rod has a very small void fraction, which leads to excellent strength properties. Notably, the desired strength properties may be achieved without the need for different fiber types in the rod.

Structural member formed from a solid lineal profile

A structural member that contains a solid lineal profile (516, 600, 700) that is formed from a plurality of consolidated ribbons (12). Each of the ribbons includes unidirectionally aligned continuous fibers embedded within a thermoplastic polymer matrix. The continuous fiber ribbons (12) are laminated together during pultrusion to form an integral solid profile (516, 600, 700) having very high tensile strength properties.

Impregnation section with upstream surface and method for impregnating fiber rovings

Impregnation section with upstream surface and method for impregnation fiber rovings