Ticona Gmbh

Southwire Company, LLC

Ticona Celstran, Inc.

Michael L Wesley

David W Eastep

Sherri M Nelson

Timothy A Regan

Allan W Daniel

Mark Lancaster

Timothy L Tibor

Yuhsin Hawig

Paul Springer

Tim Tibor

Richard Stiehm

Tim Regan

Richard Steihm

Stephen T Bowen

Eric V Lee

Subodh K Sharma

Randy J Skarlupka

Jeffrey N Compton

Dale K Roland

Allan Daniel

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.

Continuous fiber reinforced thermoplastic rod and pultrusion method for its manufacture

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.

Structural member formed from a solid lineal profile

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.

Electrical transmission cables with composite cores

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.

Composite core for electrical transmission cables

A structural member that contains a solid lineal profile () that is formed from a plurality of consolidated ribbons (). 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.

An umbilical () 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 (), fluid pipe (), electric conductor/wire () (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 () 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 ravings 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 ravings 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 for reinforcing the umbilical elements.

Umbilical for use in subsea applications

A process for the continuous preparation of a coated, long fiber reinforcing composite structure suitable for the preparation of shaped articles. The process is characterized by impregnating a plurality of continuous lengths of reinforcing fiber strands with a first thermoplastic resin material while continuously drawing the fiber strands to produce a long fiber reinforcing composite structure followed by coating a second thermoplastic resin material containing additives onto the long fiber reinforcing composite structure to produce a coated, long fiber reinforcing composite structure. The coating additives may be selected from mineral reinforcing agents, lubricants, flame retardants, blowing agents, foaming agents, ultraviolet light resistant agents, heat sensitive pigments, etc. The coated, long fiber reinforcing composite structure prepared according to the process is suitable for the preparation of shaped articles exhibiting good physical and chemical properties.

Coated, long fiber reinforcing composite structure and process of

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Dover, MN, United States of America

Michael L Wesley