Abstract: An article of manufacture comprises a pultruded thermoplastic composite body having at least two integral sections of different cross-sectional shapes. This is produced by a method and/or in an apparatus wherein an elongated body of reinforced thermoplastic material is pulled through a plurality of dies and the plurality of dies are operated independently of each other so that any combination of the dies can be selected to operate on the elongated body for imparting to at least a portion of the body the cross-sectional shape of the selected one or ones of the dies.

Abstract: Apparatus and methods are provided for simultaneously winding at least two filament reinforced thermoplastic strips onto a mandrel or similar form, comprising: a rotatable mandrel for receiving the strips; a winding assembly for rotating the mandrel and winding the strips onto the mandrel; a strip feeder, for feeding the strips to the mandrel as the mandrel rotates; and a joining assembly, located between the feeder and the mandrel, for ceaselessly urging the strips into generally parallel, contiguous juxtaposition. The joining assembly comprises an arcuate member having an inside radius positioned to deflectingly contact the strips between the strip feeder and the mandrel. Preferably, the joining assembly is connected to the exit of the strip feeder.

Abstract: Processes for preparing fiber reinforced thermoplastic articles are provided, for example, thermoplastic fibers and reinforcement fibers can be intermingled to produce a composite yarn, which is used to weave a fabric, then the fabric heated to produce a reinforced article. As another example, thermoplastic yarn and reinforcement yarn can be woven together to produce a composite fabric, which, upon heating, produces a reinforced article.

Abstract: An apparatus and process are provided for continuously consolidating and shaping a plurality of continuous prepreg structures into a unitary formed product structure. Each prepreg structure comprises a solidified thermoplastic resin matrix containing long reinforcing fibers. In operation, the respective prepregs of the plurality are continuously placed into interfacial contact with one another along their lengths, and passed through a heated die zone wherein consolidation and shaping are achieved to produce a desired unitary formed structure. The unitary formed product is then cooled.

Abstract: Processes for preparing fiber reinforced thermoplastic articles are provided, for example, thermoplastic fibers and reinforcement fibers can be intermingled to produce a composite yarn, which is used to weave a fabric. then the fabric heated to produce a reinforced article. As another example, thermoplastic yarn and reinforcement yarn can be woven together to produce a composite fabric, which, upon heating, produces a reinforced article.

Abstract: A process to form a fiber-reinforced prepreg and shaped objects having a continuous thermoplastic matrix of poly(arylene sulfide ketone) resins is provided. The prepreg is useful to form composites with high temperature resistance. The prepreg is prepared by pultrusion of resin-impregnated fiber reinforcement through a shaped die. The reinforcement can be impregnated from a liquid slurry or resin particles and a wetting agent.

Abstract: Methods and fasteners are provided for joining thermoplastic articles and for connecting a single thermoplastic article to a non-thermoplastic substrate. A first thermoplastic article and a second thermoplastic article can be placed against each other, and then localized adjacent portions of the articles are heated preferably with an ultrasonic heating device. A sharpened end of a thermoplastic fastener is driven through the heated areas of the first thermoplastic article and the second thermoplastic article. Upon cooling of the heated areas of the first thermoplastic article and the second thermoplastic article, those articles are looked to the thermoplastic fastener by fusion of the contacting surfaces of the articles and fastener.

Abstract: Compositions comprising a poly(arylene sulfide) which crystallizes to a fine-grained crystalline morphology are provided. A method is also provided for treating compositions comprising a poly(arylene sulfide) by incorporation of a crystalline morphology altering additive, heating the resulting mixture above the melting point of the poly(arylene sulfide) and cooling the mixture at a rate of less than 50.degree. C. per minute. Exemplary additives include a poly(arylene sulfide-ketone) and a polyaryl ketone.

Abstract: A process for preparing shaped objects of continuous fiber strand material in a poly(arylene sulfide) matrix and the shaped objects prepared thereby. The shaped objects are prepared by a pultrusion process requiring adaptation of polymer slurry contacting with fiber strands and specifically adapted die apparatus suitable for use with viscous poly(arylene sulfide).