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.

Abstract: Pipe sections and methods for forming pipe sections are disclosed. A pipe section includes a hollow body, 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 the hollow body, the barrier layer having an inner surface and an outer surface. The barrier layer is formed from a polyarylene sulfide composition. The polyarylene sulfide composition includes a polyarylene sulfide and a crosslinked impact modifier. Such pipe sections exhibit high strength characteristics and flexibility as well as resistance to degradation, even in extreme temperature environments, while maintaining desirable processing characteristics.

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 hollow lineal profile formed from a continuous fiber reinforced ribbon (“CFRT”) that contains a plurality of continuous fibers embedded within a first thermoplastic polymer matrix. 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”). The long fibers may be incorporated into the continuous fiber ribbon or formed as a separate layer of the profile. Regardless, at least at 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: An umbilical (600) for the transfer of fluids and/or electric current/signals, particularly between the sea surface and equipment deployed on the sea bed (e.g., in deep waters), is provided. The umbilical contains a plurality of elongated umbilical elements (e.g., two or more), such as a channel element (603), fluid pipe (604), electric conductor/wire (606) (e.g., optic fiber cable), armoring wire, etc., enclosed within an outer sheath (e.g., plastic sheath). The umbilical also contains at least one reinforcing rod (607) formed from a plurality of unidirectionally aligned fiber rovings embedded within a thermoplastic polymer matrix.

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: 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: An impregnation section of a die (150) and a method for impregnating at least one fiber roving with a polymer resin are disclosed. The impregnation section includes an impregnation zone (250) configured to impregnate the roving with the resin. The impregnation zone (250) includes a plurality of contact surfaces (252). The impregnation section further includes a device (300) positioned upstream of the impregnation zone (250) in a run direction of the roving. The device (300) is configured to reduce tension in the roving. The method includes tensioning a fiber roving, reducing the tension in the roving, coating the roving with a polymer resin, and traversing the coated roving through an impregnation zone (250) to impregnate the roving with the resin.

Abstract: Systems and methods for forming fiber reinforced polymer tapes are disclosed. A method may include, for example, traversing a polymer impregnated roving through a system comprising an inlet and an outlet, applying a consolidation pressure within the system to the polymer impregnated roving, and applying a smoothing pressure within the system to the polymer impregnated roving. The method may further include adjusting a temperature of the polymer impregnated roving with a heat transfer device between the inlet and the outlet, the heat transfer device having a temperature different from a temperature of the polymer impregnated roving at the inlet.

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: 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.

Abstract: An impregnation section of a die (150) and a method for impregnating at least one fiber roving with a polymer resin are disclosed. The impregnation section includes an impregnation zone (250) configured to impregnate the roving with the resin. The impregnation zone (250) includes a plurality of contact surfaces (252). The impregnation section further includes a roller (300) configured to impregnate the roving with the resin. The roller (300) is rotatable about a central axis. The method includes coating a fiber roving with a polymer resin. The method additionally includes traversing the coated roving through a impregnation zone (250) to impregnate the roving with the resin. The impregnation zone (250) includes a plurality of contact surfaces (252). The method further includes traversing the coated roving past a roller (300) to impregnate the roving with the resin.

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: An umbilical (600) for the transfer of fluids and/or electric current/signals, particularly between the sea surface and equipment deployed on the sea bed (e.g., in deep waters), is provided. The umbilical contains a plurality of elongated umbilical elements (e.g., two or more), such as a channel element (603), fluid pipe (604), electric conductor/wire (606) (e.g., optic fiber cable), armoring wire, etc., enclosed within an outer sheath (e.g., plastic sheath). The umbilical also contains at least one reinforcing rod (607) formed from a plurality of unidirectionally aligned fiber rovings embedded within a thermoplastic polymer matrix.

Abstract: Pipe sections and methods for forming pipe sections are disclosed. A pipe section includes a hollow body, 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 the hollow body, the barrier layer having an inner surface and an outer surface. The barrier layer is formed from a polyarylene sulfide composition. The polyarylene sulfide composition includes a polyarylene sulfide and a crosslinked impact modifier. Such pipe sections exhibit high strength characteristics and flexibility as well as resistance to degradation, even in extreme temperature environments, while maintaining desirable processing characteristics.

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 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 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 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.