Abstract: An impregnation section (150) and a method for impregnating fiber rovings (142) with a polymer resin (214) are disclosed. The impregnation section (150) includes an impregnation zone (250) and a gate passage (270). The impregnation zone (250) is configured to impregnate the plurality of rovings (142) with the resin (214). The gate passage (270) is in fluid communication with the impregnation zone (250) for flowing the resin therethrough such that the resin impinges on a surface (216) of each of the plurality of rovings (142) facing the gate passage (270) and substantially uniformly coats the plurality of rovings. The method includes impinging a polymer resin (214) onto a surface of a plurality of fiber rovings (142), 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 (250).

Abstract: A die and a method for impregnating fiber rovings (142) with a polymer resin (214) are disclosed. The die includes a manifold assembly (220), an impregnation zone, and a gate passage (270). The manifold assembly flows the resin (214) therethrough, and includes a plurality of branched runners (222). The impregnation zone is in fluid communication with the manifold assembly, and is configured to impregnate the roving with the resin. The gate passage (270) is between the manifold assembly and the impregnation zone (250), 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.

Abstract: The invention provides an insulated pipe-in-pipe assembly comprising (a) at least one inner pipe, (b) an outer pipe disposed around the at least one inner pipe so as to create an annular space between the outer and inner pipes, (c) porous, resilient, compressible material disposed in the annular space, and (d) a remnant of a container that previously was positioned in the annular space and previously held the compressible material in a volume less than the volume of the compressible material in the annular space. The invention also provides a method for making such an insulated pipe-in-pipe assembly.

Abstract: Pipe sections and methods for forming pipe sections are disclosed. A pipe section includes a hollow body formed from a metal material, the hollow body having an inner surface and an outer surface, the inner surface defining an interior. The pipe section further includes a barrier layer surrounding and bonded to the hollow body, the barrier layer having an inner surface and an outer surface. The barrier layer is formed from a continuous fiber reinforced thermoplastic material. Such pipe sections may be lightweight and flexible while exhibiting improved strength characteristics.

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 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: 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: Insulated pipe systems or assemblies include a particulate, composite or monolithic insulating aerogel material. Techniques for installing or manufacturing such systems or assemblies are described, as are components useful in the installation or manufacture processes.

Abstract: The invention provides an insulated pipe-in-pipe assembly comprising (a) at least one inner pipe, (b) an outer pipe disposed around the at least one inner pipe so as to create an annular space between the outer and inner pipes, (c) porous, resilient, compressible material disposed in the annular space, and (d) a remnant of a container that previously was positioned in the annular space and previously held the compressible material in a volume less than the volume of the compressible material in the annular space. The invention also provides a method for making such an insulated pipe-in-pipe assembly.

Abstract: A lineal product includes a substrate having an outer surface, a thermoplastic base layer applied to the outer surface, and a second thermoplastic layer applied over at least a portion of the base layer, the second layer having a hardness of at least 1H pencil hardness.

Abstract: A plastic component includes a fiber-reinforced pultruded profile having an outer surface and a phosphorescent coating located on at least a portion of the surface.