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: 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 fiber-reinforced polymer composition that comprises a polymer matrix that contains a propylene polymer is provided. The polymer matrix constitutes from about 30 wt. % to about 80 wt. % of the composition, and a plurality of long reinforcing fibers that are distributed within the polymer matrix. The fibers constitute from about 20 wt. % to about 70 wt. % of the composition. The polymer composition exhibits a spiral flow length of about 450 millimeters or more as determined in accordance with ASTM D3121-09, and after aging at a temperature of 150° C. for 1,000 hours, a Charpy unnotched impact strength greater than about 15 kJ/m2 as determined at a temperature of 23° C. in accordance with ISO Test No. 179-1:2010.

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 propylene polymer and constitutes from about 30 wt. % to about 90 wt. % of the composition. The fibers constitute from about 10 wt. % to about 70 wt. % of the composition. Further, the polymer composition exhibits a spiral flow length of about 450 millimeters or more as determined in accordance with ASTM D3123-09 and a volatile organic content of about 100 micrograms per gram or less as determined by VDA 277.

Abstract: A fiber-reinforced polymer composition that comprises a polymer matrix that contains a propylene polymer is provided. The polymer matrix constitutes from about 30 wt. % to about 80 wt. % of the composition, and a plurality of long reinforcing fibers that are distributed within the polymer matrix. The fibers constitute from about 20 wt. % to about 70 wt. % of the composition. The polymer composition exhibits a spiral flow length of about 450 millimeters or more as determined in accordance with ASTM D3123-09, and after aging at a temperature of 150° C. for 1,000 hours, a Charpy unnotched impact strength greater than about 15 kJ/m2 as determined at a temperature of 23° C. in accordance with ISO Test No. 179-1:2010.

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 propylene polymer and constitutes from about 30 wt. % to about 90 wt. % of the composition. The fibers constitute from about 10 wt. % to about 70 wt. % of the composition. Further, the polymer composition exhibits a spiral flow length of about 450 millimeters or more as determined in accordance with ASTM D3123-09 and a volatile organic content of about 100 micrograms per gram or less as determined by VDA 277.

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 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 propylene polymer and constitutes from about 30 wt. % to about 90 wt. % of the composition. The fibers constitute from about 10 wt. % to about 70 wt. % of the composition. Further, the polymer composition exhibits a spiral flow length of about 450 millimeters or more as determined in accordance with ASTM D3121-09 and a volatile organic content of about 100 micrograms per gram or less as determined by VDA 277.

Abstract: A fiber-reinforced polymer composition that comprises a polymer matrix that contains a propylene polymer is provided. The polymer matrix constitutes from about 30 wt. % to about 80 wt. % of the composition, and a plurality of long reinforcing fibers that are distributed within the polymer matrix. The fibers constitute from about 20 wt. % to about 70 wt. % of the composition. The polymer composition exhibits a spiral flow length of about 450 millimeters or more as determined in accordance with ASTM D3121-09, and after aging at a temperature of 150° C. for 1,000 hours, a Charpy unnotched impact strength greater than about 15 kJ/m2 as determined at a temperature of 23° C. in accordance with ISO Test No. 179-1:2010.

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: A die and a method for impregnating fiber rovings with a polymer resin are disclosed. The die includes a manifold assembly (220), an impregnation zone (250), and a gate passage (270). The manifold assembly (220) flows the resin therethrough, and includes a channel (222). The impregnation zone (250) is in fluid communication with the manifold assembly (220), and is configured to impregnate the roving with the resin. The gate passage (270) is between the manifold assembly (220) and the impregnation zone (250), and flows the resin from the manifold assembly (220) such that the resin coats the roving. The gate passage (270) includes a projection (300). The projection (300) is configured to diffuse resin flowing through the gate passage (270).

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 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 300 Newtons within the impregnation zone.

Abstract: A die and a method for impregnating at least one fiber roving with a polymer resin are disclosed. The die includes an impregnation section comprising an impregnation zone configured to impregnate the roving with the resin. The die further includes a passage at least partially defined in the impregnation section and in fluid communication with the impregnation zone, and a pump in fluid communication with the passage. The method includes coating at least one fiber roving with a polymer resin, traversing the coated roving through an impregnation zone of an impregnation section to impregnate the roving with the resin, and applying an external pressure to the impregnation zone.

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: 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: 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 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.