Abstract: A method for forming a polyarylene sulfide is provided. The method comprises supplying a waste composition to a vessel, the waste composition containing arylene sulfide byproducts, such as an arylene sulfide oligomer, cyclic polyarylene sulfide, and/or fine polyarylene sulfide particles. The arylene sulfide byproducts are heated to a temperature of from about 260° C. to about 285° C. in the presence of a sulfur reactant, thereby forming a high molecular weight polyarylene sulfide having a number average molecular weight of about 2,000 Daltons or more.

Abstract: Polymer compositions containing a polyoxymethylene base polymer that is compounded with a conductive filler and pigment carbon black are disclosed that exhibit electrostatic dissipative (ESD) capabilities while also being laser weldable. The polymer composition can be formed into shaped or molded articles such as filters, flanges, connectors, etc. for use in fuel systems where conductivity, ductility, weldability, and resistance to aggressive fuels are required. The compositions can be compounded into a pellet product which can then be formed into a shaped article that complies with the ESD capabilities required by SAE J1645. At the same time, parts produced from the compositions can absorb laser energy sufficiently to form a high quality welded interface with parts produced from other compositions that are transparent to laser radiation and cannot absorb laser energy sufficiently.

Abstract: A polymer composition that contains a polyaryletherketone and thermotropic liquid crystalline polymer, which are melt processed in the presence of a flow modifier. The flow modifier is a functional compound that contains one or more hydroxyl functional groups.

Abstract: Methods of forming a polyarylene sulfide and systems as may be utilized in carrying out the methods are described. Included in the formation method is a filtration process for treatment of a mixture, the mixture including a polyarylene sulfide, a salt byproduct of the polyarylene sulfide formation reaction, and a solvent. The filtration process includes maintaining the downstream side of the filter medium at an increased pressure. The downstream pressure can such that the boiling temperature of the mixture at the downstream pressure can be higher than the temperature at which the polyarylene sulfide is insoluble in the solvent.

Abstract: 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.

Abstract: A polymer composition that comprises an aromatic polyester, a laser activatable additive, and a mineral filler is provided. The mineral filler has a median size of about 35 micrometers or less and the laser activatable additive has a mean size of about 1000 nanometers or less.

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 method for formation of a semi-crystalline polyarylene sulfide is described. The method can include reaction of sulfur-containing monomer with a dihaloaromatic monomer in an organic amide solvent to form a polymer following by combination of the polymer with a crystallization solution. The crystallization solution is pre-heated and the mixture formed is slowly cooled to crystallize the polymer.

Abstract: A camera module that comprises a molded part is provided. The molded part includes a polymer composition that has an in-plane thermal conductivity of about 2.0 W/m-K or more. The polymer composition includes an aromatic polymer and a thermally conductive particulate material.

Abstract: A camera module containing a molded part (e.g., generally planar base, lens barrel mounted on the base, etc.) that is formed from a polymer composition is provided. The polymer composition includes a liquid crystalline polymer and inorganic particles that have a hardness value of about 2.5 or more based on the Mohs hardness scale.

Abstract: A method for forming a high melt viscosity polyarylene sulfide is provided. The method comprises reacting a sulfur source with a dihaloaromatic compound during a first stage to form an arylene sulfide prepolymer having halogen end groups; and thereafter, reacting the arylene sulfide prepolymer with a secondary sulfur source during a second stage to form the polyarylene sulfide.

Abstract: A method for washing a polyarylene sulfide with a washing solution that contains a carefully controlled solvent content is provided. More particularly, the washing solution typically contains water (e.g., deionized water) in an amount of from about 30 wt. % to about 70 wt. % and an aprotic organic solvent in an amount of from about 30 wt. % to about 70 wt. %. Within such carefully controlled ranges, the present inventors have discovered that the polyarylene sulfide can retain a relatively high oligomer content, which in turn, helps minimize the melt viscosity.

Abstract: A method for forming a polyaryletherketone is described. More particularly, a reaction mixture is initially supplied to the reactor vessel that contains one or more precursor monomers. A heteroaryl compound is also added to the reaction mixture. The reaction can be carried out according to, e.g., an electrophilic aromatic substitution reaction or a nucleophilic aromatic substitution reaction. The heteroaryl compound can serve as a dispersant to the polymer as it is formed. This minimizes the likelihood of gelling of the product polymer within the reactor vessel and limits the impact of process disruptions on the production of the polyaryletherketone.

Abstract: Components for heavy duty trucks are described that exhibit high strength and flexibility. The components are formed from a polyarylene sulfide that exhibits high strength and flexibility characteristics. Methods for forming the components are also described. Formation methods include dynamic vulcanization of a polyarylene sulfide composition that includes an impact modifier dispersed throughout the polyarylene sulfide. A crosslinking agent is combined with the other components of the composition following dispersal of the impact modifier throughout the composition. The heavy duty truck components can include tubular member such as pipes and hoses that can be utilized in exhaust systems, charge air systems, urea tanks, fuel systems, and so forth.

Abstract: Flowlines for use in oil and gas applications are described. The flowlines include a barrier layer that includes polyarylene sulfide composition that exhibits high strength and flexibility characteristics. Methods for forming the flowlines are also described. Formation methods include dynamic vulcanization of a polyarylene sulfide composition that includes an impact modifier dispersed throughout the polyarylene sulfide. A crosslinking agent is combined with the other components of the composition following dispersal of the impact modifier throughout the composition. The flowlines can include production fluid flowlines, supporting fluid flowlines, bundled flowlines, etc. and can be utilized as risers, pipelines, jumpers, and the like.

Abstract: 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.

Abstract: Thermoplastic compositions are described that exhibit resistance to hydrocarbon absorption. Methods for forming the thermoplastic compositions are also described. Formation methods include combining a polyarylene sulfide with a first impact modifier and a second impact modifier such that the impact modifiers are dispersed throughout the polyarylene sulfide. A crosslinking agent can be combined with the other components of the composition following dispersal of the additives throughout the composition to dynamically crosslink at least one of the first and second impact modifiers.

Abstract: Polymer compositions are described that contain at least two different immiscible phases for producing molded articles having a swirl-like or marble-like appearance. The first phase, for instance, may contain one or more polyoxymethylene polymers. The second phase, on the other hand, contains one or more polymers that together have a melting point that is from about 5° to about 30° different than the melting point of the polyoxymethylene polymer. In one embodiment, the second phase may contain a thermoplastic elastomer, a glycol-modified polyethylene terephthalate, or a polyimide and may have a melting point that is higher than the melting point of the polyoxymethylene polymer. The second phase is present in the polymer composition in relatively low amounts, such as in amounts less than about 5% by weight. The second phase can contain a high concentration of colorants that creates a contrast of colors when the molded article is produced.

Abstract: A polymer composition is disclosed containing a coupling agent and an impact modifier that renders the composition resistant to ultraviolet light degradation. The polymer composition contains an aliphatic coupling agent, an aliphatic impact modifier, or both an aliphatic coupling agent and an aliphatic impact modifier. The polymer composition is well suited to producing molded articles, especially articles that will later be exposed to substantial amounts of ultraviolet light. For example, molded articles made according to the present disclosure are well suited for use on the interior of vehicles where the parts are not only exposed to ultraviolet light, but are also exposed to repeated thermal cycles.

Abstract: Injection molded parts with a small dimension that exhibit high heat resistance are described. Thermoplastic compositions that can be utilized to form the injection molded parts are described. The thermoplastic composition includes a polyarylene sulfide and a crosslinked impact modifier. The thermoplastic composition can also include siloxane polymers, thermoplastic elastomers, or other additives that can further improve the characteristics of the injection molded parts.