Abstract: 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.

Abstract: A method and system for formation of a polyarylene sulfide is described. The method includes a first stage in which a complex is formed in a reactor. The complex includes the hydrolysis product of an organic amide solvent and an alkali metal hydrosulfide. The complex formation reaction also forms hydrogen sulfide as a by-product. The method also includes treating a fluid stream that is pulled off of the reactor. The treatment includes scrubbing the fluid stream to recover hydrogen sulfide from the stream and return the hydrogen sulfide to the reactor. The recovery and recycle of the hydrogen sulfide can prevent loss of sulfur from a polyarylene sulfide formation process.

Abstract: Methods, devices, and systems that can be utilized in separating a polymer from other compounds of a polymer formation process are described. The methods utilize multiple sedimentors in a countercurrent flow design in conjunction with different solvent solutions in the multiple sedimentors to separate a product polymer from other compounds of a polymer formation process. The sedimentors include feed inlets that can encourage contact between countercurrent flows and improve mass transfer rates between the countercurrent flows.

Abstract: A multi-stage process and system for formation of a polyarylene sulfide is described. The multi-stage process can include at least three separate formation stages that can take place in three different reactors. The first stage of the formation process can include reaction of an alkali metal sulfide with an organic amide solvent to form a complex including a hydrolysis product of the solvent and an alkali metal hydrogen sulfide. The second stage of the formation process can include reaction of the complex formed in the first stage with a dihaloaromatic monomer to form a prepolymer, and the third stage can include further polymerization of the prepolymer with additional monomers to form the final product.

Abstract: Polymer compositions are described that are well suited for producing reflectors for light-emitting devices, such as light-emitting diodes. In one particular embodiment, the polymer composition contains a polymer resin, a white pigment, a silicone compound, and a nucleating agent. The polymer resin may comprise, for instance, a poly(1,4-cyclohexanedimethanol terephthalate). In accordance with the present disclosure, the composition also contains at least one silicone compound and at least one nucleating agent. The silicone compound and nucleating agent have been found to improve the molding processability and reflectance stability of the polymer composition.

Abstract: A multi-stage process and system for formation of a polyarylene sulfide is described. A first polymerization stage of the formation process can include reaction of a sulfide monomer with a dihaloaromatic monomer to form a prepolymer. A second polymerization stage can include further polymerization of the prepolymer with a sulfur-containing monomer and a dihaloaromatic monomer to form a low halogen content polyarylene sulfide. The amount of sulfur utilized in the second polymerization stage is a low fraction of the total amount of sulfur utilized in the multi-stage process.

Abstract: Polymer compositions are described containing a poly(1,4-cyclohexanedimethanol terephthalate) polymer in combination with a white pigment and optionally one or more reinforcing fillers. In accordance with the present disclosure, the composition also contains one or more reactive viscosity stabilizers. In order to prevent against yellowing, the composition is free of various aromatic epoxy resins, such as novolac epoxy resins. The polymer composition has excellent reflectance properties making the composition well suited for producing reflectors for light sources, such as LED assemblies.

Abstract: 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.

Abstract: A liquid crystalline polymer composition that contains a conductive filler (e.g., carbon fibers, ionic liquid, etc.) and a plurality of mineral fibers distributed within a liquid crystalline polymer matrix is provided. Through careful selection of the conductive filler and mineral fibers, as well as the manner in which they are dispersed within the polymer matrix, the present inventors have discovered that a composition can be formed that has a reduced tendency to create a static electric charge during a molding operation, but yet also has good surface characteristics and mechanical properties.

Abstract: A polymer composition that contains a polyaryletherketone and a liquid crystalline polymer that includes repeating units derived from naphthenic hydroxycarboxylic acids, naphthenic dicarboxylic acids, or a combination thereof in an amount of more than about 15 mol. % of the polymer is provided.

Abstract: Polyarylene sulfide compositions are described that exhibit high strength and flexibility. Methods for forming the polyarylene sulfide compositions 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 crosslinking agent reacts with the impact modifier to form crosslinks within and among the polymer chains of the impact modifier. The compositions can exhibit excellent physical characteristics at extreme temperatures and can be used to form, e.g., tubular member such as pipes and hoses and fibers.

Abstract: A fuel line comprising a thermoplastic composition is described. The thermoplastic compositions exhibit high strength and flexibility and can be used to form one or more layers of single layer or multi-layer fuel lines. Methods for forming the thermoplastic compositions are also described. Formation methods include dynamic vulcanization of a composition that includes an impact modifier dispersed throughout a polyarylene sulfide. A crosslinking agent is combined with the other components of the composition following dispersal of the impact modifier. The crosslinking agent reacts with the impact modifier to form crosslinks within and among the polymer chains of the impact modifier. The compositions can exhibit excellent physical characteristics at extreme temperatures.

Abstract: Components formed of blow molded thermoplastic compositions are described. The blow molded thermoplastic compositions exhibit high strength and flexibility. Methods for forming the thermoplastic compositions are also described. Formation methods include dynamic vulcanization of a composition that includes an impact modifier dispersed throughout a polyarylene sulfide. A crosslinking agent is combined with the other components of the composition following dispersal of the impact modifier. The crosslinking agent reacts with the impact modifier to form crosslinks within and among the polymer chains of the impact modifier. The compositions can exhibit excellent physical characteristics at extreme temperatures and can be used to form, e.g., tubular member such as pipes and hoses and fibers.

Abstract: Polymer compositions are described containing a thermoplastic polymer in combination with one or more components, such as a white pigment and optionally one or more reinforcing fillers. In one embodiment, the polymer composition can be formulated to have high reflective properties. In other embodiments, the polymer composition can be formulated so as to have desired melt flow characteristics. In still another embodiment, the polymer composition can be formulated so as to have desired mechanical properties, such as impact resistance.

Abstract: An oil resistant polymer composition is disclosed that contains a thermoplastic elastomer combined with an olefin and vinyl acetate copolymer on an oleophobic agent. In one embodiment, the composition contains a thermoplastic polyester elastomer combined with an ethylene and vinyl acetate copolymer. In order to render the polymer composition oil resistant, the polymer composition can further contain an UHMW silicone, a fluoropolymer, and optionally a crosslinking agent and/or an antiplasticizer.

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 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.

Abstract: Subsea pipe sections and methods for forming subsea pipe sections are disclosed. A subsea pipe section includes a hollow body formed from a polymer material, the hollow body having an inner surface and an outer surface, the inner surface defining an interior. The subsea pipe section further includes a reinforcement layer surrounding and bonded to the hollow body, the reinforcement layer having an inner surface and an outer surface. The reinforcement layer is formed from a fiber reinforced thermoplastic material and has a resin rich portion and a fiber rich portion. The resin rich portion includes the inner surface of the reinforcement layer and is in contact with the hollow body. The fiber rich portion is spaced from the inner surface of the reinforcement layer.

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 continuous fiber composite is described and methods for forming the continuous fiber composite. The continuous fiber composite includes a plurality of unidirectionally aligned continuous fibers embedded within a polyarylene sulfide polymer. The continuous fiber composite includes a very high loading of continuous fibers, for instance greater than about 40% by weight of the continuous fiber composite. The continuous fiber composite is formed by reacting a starting polyarylene sulfide with a reactively functionalized disulfide compound in a melt processing unit. Reaction between the starting polyarylene sulfide and the reactively functionalized disulfide compound leads to formation of a reactively functionalized polyarylene sulfide. Upon embedding of the continuous fibers into the reactively functionalized polyarylene sulfide, the reactivity of the polyarylene sulfide can enhance adhesion between the polyarylene sulfide polymer and the fibers.