Abstract: A fiber-reinforced polymer composition that contains a polymer matrix and a plurality of long reinforcing fibers distributed within the polymer matrix is provided. The polymer matrix contains a propylene impact copolymer having a first melt flow rate of from about 10 to about 100 grams per 10 minutes and a metallocene-catalyzed propylene homopolymer having a second melt flow rate of from about 10 to about 100 grams per 10 minutes, wherein the ratio of the second melt flow rate to the first melt flow rate is from about 0.1 to about 2. The composition exhibits a toluene equivalent volatile organic content of about 50 ?gC/g or less as determined in accordance with VDA 278:2002.

Abstract: A fiber-reinforced polymer composition a plurality of continuous fibers embedded and distributed within a thermoplastic polymer matrix is provided. The thermoplastic polymer matrix constitutes from about 20 wt. % to about 90 wt. % of the composition and the continuous fibers constitute from about 10 wt. % to about 80 wt. % of the composition. Further, the polymer composition has a deflection temperature under load of about 60° C. or more as determined in accordance with ISO 75:2013 at a load of 3.5 MPa.

Abstract: A long fiber-reinforced polymer composition is disclosed having excellent flame retardant properties, optionally in combination with long-term heat stability. The flame retardant composition can include a flame retardant system comprised of only two flame retardant components. The composition can display excellent flame resistant properties at extremely small thicknesses. The composition can also contain a stabilizer package that dramatically improves heat aging properties.

Abstract: An electronic module that comprises a housing that receives at least one electronic component is disclosed. The housing contains a fiber-reinforced polymer composition comprising a polymer matrix that contains a thermoplastic polymer and a plurality of long reinforcing fibers that are distributed within the polymer matrix. The polymer composition exhibits a dielectric constant of about 4 or less and dissipation factor of about 0.01 or less at a frequency of 2 GHz. Further, the polymer composition exhibits a Charpy unnotched impact strength of about 20 kJ/m2 or more as determined in accordance with ISO Test No. 179-1:2010 at a temperature of about 23° C.

Abstract: A fiber-reinforced polymer composition comprising from about 60 wt. % to about 90 wt. % of a polymer matrix that contains a propylene polymer and from about 10 wt. % to about 40 wt. % of a plurality of long reinforcing fibers that are distributed within the polymer matrix, is provided. The polymer composition exhibits a dielectric constant of about 4 or less and dissipation factor of about 0.01 or less at a frequency of 2 GHz. Further, the polymer composition exhibits a Charpy unnotched impact strength of about 20 kJ/m2 or more as determined in accordance with ISO Test No. 179-1:2010 at a temperature of about 23° C., and a Limiting Oxygen Index of about 25 or more as determined in accordance with ISO 4589:2017.

Abstract: An antenna module that comprises a housing that receives at least one antenna element configured to transmit and receive 5G radio frequency signals is disclosed. The housing contains a fiber-reinforced polymer composition comprising a polymer matrix that contains a thermoplastic polymer and a plurality of long reinforcing fibers that are distributed within the polymer matrix. The polymer composition exhibits a dielectric constant of about 3.5 or less and dissipation factor of about 0.009 or less at a frequency of 2 GHz.

Abstract: A fiber-reinforced polymer composition that contains a polymer matrix and a plurality of long reinforcing fibers that are distributed within the polymer matrix is provided. The polymer matrix contains a thermoplastic polymer and the polymer matrix constitutes from about 30 wt. % to about 90 wt. % of the composition. The fibers have a nominal diameter of from about 20 micrometers to about 40 micrometers and constitute from about 10 wt. % to about 70 wt. % of the composition. Furthermore, the polymer composition defines a surface that exhibits a ?E value of from about 0.6 to about 3 after being exposed to UV light at a total exposure level of 2,500 kJ/m2 according to SAE J2412_201508.

Abstract: A fiber-reinforced polymer composition a plurality of continuous fibers embedded and distributed within a thermoplastic polymer matrix is provided. The thermoplastic polymer matrix constitutes from about 20 wt. % to about 90 wt. % of the composition and the continuous fibers constitute from about 10 wt. % to about 80 wt. % of the composition. Further, the polymer composition has a deflection temperature under load of about 60° C. or more as determined in accordance with ISO 75:2013 at a load of 3.5 MPa.

Abstract: 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.

Abstract: A three-dimensional printing method is provided. The method comprises supplying a polymer composition to an extruder system and selectively dispensing the polymer composition through an extruder nozzle to form a three-dimensional structure. The polymer composition comprises a plurality of reinforcing fibers embedded and distributed within a thermoplastic polymer matrix, wherein the thermoplastic polymer matrix constitutes from about 20 wt. % to about 90 wt. % of the composition and the reinforcing fibers constitute from about 10 wt. % to about 80 wt. % of the composition.

Abstract: 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.

Abstract: 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.

Abstract: An extruder (1) and a method for producing high-fiber volume reinforced thermoplastic resin structures (50), as well as a tape (156) having opposing resin rich portions (302) and a fiber rich portion (304) disposed therebetween and a method for impregnating at least one fiber roving (142) with a polymer resin to form a tape (156. The extruder (1) includes an impregnation die (3) having a channel (4) that applies pressurized molten thermoplastic resin to a plurality of rovings (142) drawn through the channel (4), and a die (3) faceplate (5) facing the downstream side (34) of said die (3). The faceplate (5) has a plurality of sizing holes (42) or a slot (75) arranged along a line that the resin-impregnated rovings (142) are simultaneously drawn through that remove excess resin and pultrude the resin-impregnated rovings (142) into rod-shaped or sheet-shaped structures.

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: The present invention discloses electrical cables containing a cable core and a plurality of conductive elements surrounding the cable core. The cable core contains at least one composite core, and each composite core contains a rod which contains a plurality of unidirectionally aligned fiber rovings embedded within a thermoplastic polymer matrix, and surrounded by a capping layer.

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 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: The present invention discloses electrical cables containing a cable core and a plurality of conductive elements surrounding the cable core. The cable core contains at least one composite core, and each composite core contains a rod which contains a plurality of unidirectionally aligned fiber rovings embedded within a thermoplastic polymer matrix, and surrounded by a capping layer.

Abstract: The present invention discloses electrical cables containing a cable core and a plurality of conductive elements surrounding the cable core. The cable core contains at least one composite core, and each composite core contains a rod which contains a plurality of unidirectionally aligned fiber rovings embedded within a thermoplastic polymer matrix, and surrounded by a capping layer.

Abstract: 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.