Abstract: A die and a method for impregnating at least one fiber roving with a polymer resin are disclosed. The die includes an impregnation section comprising an impregnation zone configured to impregnate the roving with the resin. The die further includes a passage at least partially defined in the impregnation section and in fluid communication with the impregnation zone, and a pump in fluid communication with the passage. The method includes coating at least one fiber roving with a polymer resin, traversing the coated roving through an impregnation zone of an impregnation section to impregnate the roving with the resin, and applying an external pressure to the impregnation zone.

Abstract: 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.

Abstract: A prepreg that contains a plurality of unidirectionally aligned continuous fibers embedded within a thermoplastic polymer matrix is provided. In addition to continuous fibers, the prepreg also contains a plurality of long fibers that are combined with the continuous fibers so that they are randomly distributed within the thermoplastic matrix. As a result, at least a portion of the long fibers become oriented at an angle (e.g., perpendicular) relative to the direction of the continuous fibers. Through such orientation, the long fibers can substantially increase the mechanical properties of the prepreg in the transverse direction (e.g., strength) and thus achieve a more isotropic material. Although unique isotropic prepregs are one aspect of the present invention, it should be understood that this is not a requirement.

Abstract: 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.

Abstract: 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.

Abstract: A thermoplastic composition that comprises a low-naphthenic, thermotropic liquid crystalline polymer blended with a flow modifier is provided. The flow modifier is an aromatic carboxylic acid that contains one or more carboxyl functional groups. Without intending to be limited by theory, it is believed that the functional groups can react with the polymer chain to shorten its length and thus reduce melt viscosity. It is also believed that such acids can combine smaller chains of the polymer together after they have been cut during processing. This helps maintain the mechanical properties of the composition even after its melt viscosity has been reduced. As a result of the present invention, the melt viscosity of the thermoplastic composition is generally low enough so that it can readily flow into the cavity of a mold having small dimensions.

Abstract: A method for forming a liquid crystalline thermoplastic composition is provided. The method comprises blending at least one thermotropic liquid crystalline polymer and a plurality of fibers within an extruder. The extruder contains at least one rotatable screw received within a barrel (e.g., cylindrical barrel) and defines a feed section and a melting section located downstream from the feed section along the length of the screw. Relatively long fibers are initially supplied to the feed section of the extruder, but at a location downstream from the liquid crystalline polymer so that the polymer is still in a solid state when it initially contacts the fibers. In this manner, the present inventors have discovered that the polymer can act as an abrasive agent for reducing the length of the fibers.

Abstract: A thermoplastic composition that comprises a naphthenic-rich, thermotropic liquid crystalline polymer blended with a flow modifier is provided. The flow modifier is an aromatic carboxylic acid that contains or more carboxyl functional groups. Without intending to be limited by theory, it is believed that the functional groups can react with the polymer chain to shorten its length and thus reduce melt viscosity. It is also believed that such acids can combine smaller chains of the polymer together after they have been cut during processing. This helps maintain the mechanical properties of the composition even after its melt viscosity has been reduced. As a result of the present invention, the melt viscosity of the thermoplastic composition is generally low enough so that it can readily flow into the cavity of a mold having small dimensions.

Abstract: A thermoplastic composition for use in a compact camera module is provided. The thermoplastic composition contains a liquid crystalline polymer and a plurality of fibers. The volume average length of the fibers in the thermoplastic composition is selectively controlled according to the present invention so that it is within a certain range, such as from about 80 to about 250 micrometers. The fibers also have a narrow length distribution. That is, at least about 70% by volume of the fibers have a length within a certain range. Through the use of a liquid crystalline polymer and fibers of a certain weight average length and narrow length distribution, the present inventors have discovered that the resulting thermoplastic composition is able to achieve a desirable combination of strength and surface smoothness, which enables it to be uniquely suited for a compact camera module.

Abstract: A system and process for injection molding polymer articles is described. The system and process are designed to reduce gate blush. In one embodiment, an injection molding device injects a molten polymer composition into a runner that extends from an injection point to a gate. The gate is positioned adjacent to an opening leading into a mold cavity. In accordance with the present disclosure, the system includes one or more overflow passages that divert flow of the polymer composition so as to temporarily reduce the flow rate and pressure of the polymer composition entering the mold.

Abstract: A thermoplastic composition for use in a fine pitch electrical connector is provided. The thermoplastic composition contains a liquid crystalline polymer and a plurality of fibers. The volume average length of the fibers in the thermoplastic composition is selectively controlled according to the present invention so that it is within a certain range, such as from about 80 to about 250 micrometers. The fibers also have a narrow length distribution. That is, at least about 70% by volume of the fibers have a length within a certain range. Through the use of a liquid crystalline polymer and fibers of a certain weight average length and narrow length distribution, the present inventors have discovered that the resulting thermoplastic composition is able to achieve a desirable combination of strength and flowability, which enables it to be uniquely suited for the walls of a fine pitch connector.

Abstract: A thermoplastic composition that comprises a low-naphthenic, thermotropic liquid crystalline polymer blended with a combination of flow modifiers is provided. More particularly, one of the flow modifiers is a hydroxy-functional compound that contains or more hydroxyl functional groups. Without intending to be limited by theory, it is believed that the hydroxyl functional groups can react with the polymer chain to shorten its length and thus reduce melt viscosity. Aromatic dicarboxylic acids are also employed as a flow modifier in the thermoplastic composition. Again, without intending to be limited by theory, it is believed that such acids can combine smaller chains of the polymer together after they have been cut by hydroxy-functional compounds. This helps maintain the mechanical properties of the composition even after its melt viscosity has been reduced.

Abstract: A liquid crystalline polymer composition having a relatively high comparative tracking index (“CTI”) is provided. The present inventors have discovered that high CTI values can be achieved through the use of inorganic particles in combination with a functional aromatic compound. While not fully understood, it is believed that the functional compound can react with the liquid crystalline polymer and create smaller degraded polymer chains. In combination with the inorganic particles, these smaller chains can potentially form insulated regions at the surface of the polymer that hinder the formation of conductive carbonaceous deposits during the tracking process, which could otherwise lead to failure during testing.

Abstract: A thermoplastic composition that contains a unique combination of a thermotropic liquid crystalline polymer, dielectric material, laser activatable additive, and a fibrous filler is provided. The nature of the components and/or their concentration are selectively controlled in the present invention to maintain a high dielectric constant, good mechanical properties (e.g., deflection under load), and good processibility (e.g., low viscosity), yet still be laser activatable. Thus, the thermoplastic composition can be readily shaped into a thin substrate and subsequently applied with one or more conductive elements using a laser direct structuring process (“LDS”).

Abstract: Polymer springs are described having a closed cell geometry. The polymer springs are well adapted for replacing metal springs in various applications, such as in seat cushions. In one embodiment, the polymer springs include columns of closed cells, in which each cell has a curvilinear shape. A method for designing polymer springs is also described.

Abstract: A multi-stage process for forming a liquid crystalline polymer is provided. More particularly, the process includes acetylating one or more precursor monomers and melt-polymerizing the acetylated monomers to form a prepolymer in the form of a solid particulate material. Thereafter, the prepolymer is solid-state polymerized in a fluidized bed reactor that contains a porous surface (e.g., bed, plate, grate, etc.) on which the prepolymer is supported. While supported by this porous surface, the prepolymer can become “fluidized” with a heated stream of a gas (e.g., nitrogen). In this manner, a sufficient degree of turbulence is created to distribute heat evenly around the prepolymer and cause it to rapidly reach the target reaction temperature.

Abstract: A conduit that contains an elongate member that defines a hollow passageway is provided. The conduit may be used to convey electricity (e.g., jacket of a communication cable, raceway for protecting a communication cable, etc.), fluids (e.g., pipes), etc. In one embodiment, for example, the conduit may be a raceway for use in a plenum of a building structure. Regardless of the type of conduit, at least a portion of the elongate member is formed from a thermoplastic composition that contains a polyarylene sulfide and fire-resisting system. Due in part to the specific nature and concentration of these components, the present inventors have discovered that the resulting thermoplastic composition may have a relatively high melting temperature.

Abstract: Polyoxymethylene polymer compositions are disclosed that contain an impact modifier. In accordance with the present disclosure, the impact modifier is attached to the polyoxymethylene polymer and comprises a thermoplastic elastomer containing carbonate groups, such as polycarbonate groups. In one embodiment, a coupling agent bonds the impact modifier to the polyoxymethylene polymer. Incorporation of an impact modifier containing carbonate groups has been found to produce articles having good impact resistance properties while also preserving the permeability of the material. The polymer composition is well suited to producing containment devices, especially fuel tanks.

Abstract: An electrical conduit that contains a jacket that defines a hollow passageway is provided. At least a portion of the jacket is formed from a thermoplastic composition that contains a polyarylene sulfide and fire-resisting system. Due in part to the specific nature and concentration of these components, the present inventors have discovered that the resulting thermoplastic composition may have a relatively high melting temperature, such as from about 200° C. to about 500° C.

Abstract: A polymer composition containing a polyacetal resin, a metallic pigment, and an ultraviolet light stabilizer is disclosed that exhibits a metallic brilliant appearance. The metallic pigment, the ultraviolet light stabilizer and the polyacetal resin can be mixed in a high intensity mixer prior to being used to mold polymer articles.