Ticona Gmbh

Southwire Company, LLC

Sherri M Nelson

David W Eastep

Michael L Wesley

Timothy A Regan

Allan W Daniel

Mark Lancaster

Timothy L Tibor

Yuhsin Hawig

Paul Springer

Tim Tibor

Tim Regan

Richard Stiehm

Richard Steihm

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 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') () 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. The discontinuous fibers are also embedded within a thermoplastic matrix, in such a way as to assist in bonding of the layers to achieve the desired strength. At least a portion of the fibers are oriented in the transverse direction to provide increased transverse strength.

Method for forming reinforced pultruded profiles

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 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 a portion of the long fibers are oriented at an angle (e.g., 90&#xb0;) to the longitudinal direction to provide increased transverse strength to the profile.

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Winona, MN, United States of America

Sherri M Nelson