Cross Reference to Related Applications

[0001] The present application claims filing benefit of United States

Provisional Patent Application Serial No. 61/844,652 having a filing date of July 10, 2013, and which is incorporated herein by reference in its entirety.

Background of the Invention

[0002] Composite tapes and rods formed from fibers embedded in a polymer resin have been employed in a wide variety of applications. For example, such tapes, and more specifically rods formed from the tapes, may be utilized as lightweight structural reinforcements. One specific application of such rods is in the oil and gas industry, such as in subsea applications as well as in on-shore oil and gas production fields. In on-shore or subsea applications, for, example, multilayer pipes may be utilized in risers, transfer lines, umbilicals and/or other suitable pipe assemblies. In production field applications, multi-layer pipes may be utilized in risers, infield flow lines, export pipelines and/or other suitable pipe assemblies. Power umbilicals, for example, are often used in the transmission of fluids and/or electric signals between the sea surface and equipment located on the sea bed. To help strengthen such umbilicals, attempts have been made to use pultruded carbon fiber rods as separate load carrying elements. Other applications of such rods may include, for example, use in high-voltage cables, tethers, etc.

Applications of tapes may include, for example, use in high-pressure vessels to provide reinforcement thereof. In general, composite tapes and rods may be utilized in any suitable applications that may require, for example, high strength-to- weight elements, high corrosion resistance, and/or low thermal expansion properties.

[0003] There are many significant problems, however, with currently known methods and apparatus for producing composite tapes and rods. For example, composite tapes and rods are typically formed by impregnating fiber rovings with a polymer resin. Many rovings rely upon thermoset resins (e.g., vinyl esters) to help achieve desired strength properties. Thermoset resins are difficult to use during manufacturing and do not possess good bonding characteristics for forming layers with other materials. Further, attempts have been made to form impregnated rovings from thermoplastic polymers in other types of applications. U.S. Patent Publication No. 2005/0186410 to Bryant, et al., for instance, describes attempts that were made to embed carbon fibers into a thermoplastic resin to form a composite core of an electrical transmission cable. Unfortunately, Bryant, et al. notes that these cores exhibited flaws and dry spots due to inadequate wetting of the fibers, which resulted in poor durability and strength. Another problem with such cores is that the thermoplastic resins could not operate at a high temperature.

[0004] More recently, methods and apparatus have been developed that allow for the use of thermoplastic resins with fiber rovings to form composite tapes and rods. However, use of these presently known methods and apparatus has in some cases resulted in composite rods having undesirably high void levels.

Additionally, presently known methods and apparatus are typically expensive and produce high levels of excess scrap.

[0005] Still further, capping layers have been developed as outer sheaths of composite rods that protect the composite rods. However, in many cases, currently known capping layers may not provide the desired wear resistance and surface energy required by particular applications. Further, currently known capping layers in some instances may undesirably adhere to, for example, materials extruded over the rods for use in particular applications, such as oil and gas industry applications.

[0006] Accordingly, improved rods, as well as improved systems and methods for forming such composites, are desired in the art. Specifically, a need currently exists for a rod which provides improved wear resistance. Further, adjustments to the surface energy of such rods as well as the prevention of adherence to other materials in particular applications would be advantageous. Still further, a need currently exists for a rod which exhibits these characteristics while providing the desired strength, durability, temperature performance and dimensional requirements demanded by a particular application.

Summary of the Invention

[0007] In accordance with one embodiment of the present disclosure, a composite rod is disclosed. The composite rod includes a core that includes a thermoplastic material and a plurality of continuous fibers embedded in the thermoplastic material, the plurality of continuous fibers having a generally unidirectional orientation within the thermoplastic material. The composite rod also includes a capping layer. The capping layer generally surrounds the core and includes a high performance polymer and a hydrophobic lubricant.

[0008] Other features and aspects of the present invention are set forth in greater detail below.

Brief Description of the Drawings

[0009] A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:

[0010] Fig. 1 is a perspective view of a composite rod formed according to one embodiment of the present disclosure.

[0011] Fig. 2 is a perspective view of a cable, in this embodiment an umbilical, according to one embodiment of the present disclosure;

[0012] Fig. 3 is a perspective view of a cable, in this embodiment an electrical cable, according to one embodiment of the present disclosure;

[0013] Fig. 4 is a schematic illustration of an impregnation system in accordance with one embodiment of the present disclosure;

[0014] Fig. 5 is a perspective view of a die in accordance with one embodiment of the present disclosure;

[0015] Fig. 6 is a cross-sectional view of the die shown in Fig. 5;

[0016] Fig. 7 is an exploded view of a manifold assembly and gate passage for a die in accordance with one embodiment of the present disclosure;

[0017] Fig. 8 is a perspective view of one embodiment of a second impregnation plate at least partially defining an impregnation zone in accordance with one embodiment of the present disclosure;

[0018] Fig. 9 is a close-up cross-sectional view of a portion of an

impregnation zone in accordance with one embodiment of the present disclosure;

[0019] Fig. 10 is a close-up cross-sectional view of a downstream end portion of an impregnation zone in accordance with one embodiment of the present disclosure; [0020] Fig. 1 1 is a perspective view of a land zone in accordance with one embodiment of the present disclosure;

[0021] Fig. 12 is a perspective view of a land zone in accordance with one embodiment of the present disclosure;

[0022] Fig. 13 is a schematic illustration of one embodiment of a pultrusion system that may be employed in the present invention;

[0023] Fig. 14 is a top cross-sectional view of one embodiment of various calibration dies that may be employed in accordance with the present invention;

[0024] Fig. 15 is a side cross-sectional view of one embodiment of a calibration die that may be employed in accordance with the present invention;

[0025] Fig. 16 is a front view of a portion of one embodiment of a calibration die that may be employed in accordance with the present invention;

[0026] Fig. 17 is a front view of one embodiment of forming rollers that may be employed in accordance with the present invention;

[0027] Fig. 18 is a perspective view of a tape in accordance with one embodiment of the present disclosure;

[0028] Fig. 19 is a cross-sectional view of a tape in accordance with one embodiment of the present disclosure; and

[0029] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

Detailed Description of Representative Embodiments

[0030] It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention.

[0031] Generally speaking, the present disclosure is directed to composite rods that include cores and capping layers surrounding the cores. A capping layer may surround and be bonded to a core, and may beneficially provide improved wear resistance to the rod. More specifically, the capping layer can include a high performance polymer and a hydrophobic lubricant. As utilized herein, the term "high performance polymer" generally refers to polymers that exhibit exceptional thermal, mechanical, electrical, optical, surface, and/or rheological properties. For example, high performance polymers can generally exhibit thermal stability and have a melting temperature of about 200°C or greater. [0032] In addition to improving wear resistance, the capping layer may include components that can advantageously modify the surface energy of the capping layer as desired for particular applications. For example, through selective addition of the type and amount of the hydrophobic fluoropolymer, the surface energy of the capping layer may be altered. The surface energy can affect the interaction of the rod to other materials. For instance, the capping layer may be designed to exhibit a surface energy that may prevent adherence of the rod to other materials, such as to polymers extruded over the rod in the formation of a rope or umbilical. However, in another embodiment, the capping layer may be designed to exhibit a surface energy that may encourage adherence of the rod to other materials.

[0033] Referring to Fig. 1 , one embodiment of a rod 750 is presented. As can be seen, the rod 750 includes a core 760 formed from a continuous fiber reinforced thermoplastic ("CFRT") material and a capping layer 800 that generally surrounds and is bonded to the core 760.

[0034] As illustrated, the rod 750 has a generally circular shape and includes a core 760 formed from one or more consolidated rovings 142. By "generally circular", it is generally meant that the aspect ratio of the rod (height divided by the width) is typically from about 1 .0 to about 1 .5, and in some embodiments, about 1 .0. Due to the selective control over the process used to impregnate the rovings and form tapes 152, 156, as well the process for compressing and shaping the tape(s) into a preform and finally into a core 760, as discussed further herein, the rod 750 and core 760 thereof may possess a relatively even distribution of resin 214 across along its entire length. This also means that the continuous fibers are distributed in a generally uniform manner about a longitudinal central axis "L" of the core 760. As shown in Fig. 1 , for example, the core 760 includes continuous fibers 400 embedded within a thermoplastic matrix 214. The fibers 400 are distributed generally uniformly about the longitudinal axis "L." It should be understood that only a few fibers are shown in Fig. 1 , and that the core 760 will typically contain a substantially greater number of uniformly distributed fibers.

[0035] A capping layer 800 may also extend around the perimeter of the rod 750 and define an external surface of the rod 750. [0036] The cross-sectional thickness ("T") of the rod 750 may be

strategically selected to help achieve a particular strength. For example, the rod 750 may have a thickness (e.g., diameter) of from about 0.1 to about 40 millimeters, in some embodiments from about 0.5 to about 30 millimeters, and in some embodiments, from about 1 to about 10 millimeters. The thickness of the capping layer 800 depends on the intended function of the part, but is typically from about 0.01 to about 10 millimeters, and in some embodiments, from about 0.02 to about 5 millimeters. Regardless, the total cross-sectional thickness or height of the rod typically ranges from about of from about 0.1 to about 50 millimeters, in some embodiments from about 0.5 to about 40 millimeters, and in some embodiments, from about 1 to about 20 millimeters. While the rod 750 may be substantially continuous in length, the length of the rod is often practically limited by the spool onto which it will be wound and stored or the length of the continuous fibers. For example, the length often ranges from about 1000 to about 5000 meters, although even greater lengths are certainly possible.

[0037] The capping layer includes a high performance polymer and a hydrophobic lubricant. For example, the capping layer can include about 98% or less, about 95% or less, about 90% or less, or about 85% or less high performance polymer by weight of the capping layer. For instance, the capping layer can include from about 50% to about 98% by weight high performance polymer or about 60% to about 95% by weight high performance polymer. High performance polymers as may be utilized in forming the capping layer can include both semi- crystalline and amorphous high performance polymers as well as high

performance thermoplastic fluoropolymers. As previously mentioned, high performance polymers are generally considered those polymers having a melting temperature greater of about 200°C or greater.

[0038] Suitable high performance polymers can include, without limitation, fluorinated ethylene propylene, perfluoroalkoxy, polyvinylidene fluoride, ethylene tetrafluoroethylene, chlorotrifluoroethylene, polyetherether ketone,

polyphthalamide, polyarylene sulfide (e.g., polyphenylene sulfide), liquid crystal polymer, polybutylene terephthalate, polyethylene terephthalate,

polyoxymethylene, polyphenylsulfone, polysulfone, polyetherimide, Polyamide- imide, and mixtures of high performance polymers. According to one embodiment, a suitable high dielectric strength capping layer materials may include polyetherether ketone (e.g., polyetherether ketone ("PEEK")), either alone or in a blend with another high performance polymer, such as a polyarylene sulfide.

[0039] The capping layer can also include a hydrophobic lubricant. As utilized herein, the term "hydrophobic lubricant" generally refers to a polymer that can reduce the internal friction of the capping layer and can reduce the surface energy of the capping layer and that can resist water. By way of example, the hydrophobic lubricant can include a fluoropolymer or an organosilane. In general, the capping layer can include about 30% or less, about 25% or less, about 20% or less, or about 10% or less hydrophobic lubricant by weight of the capping layer. For instance, the capping layer can include from about 1 % to about 30% by weight, or about 2% to about 20% by weight of the hydrophobic lubricant.

[0040] Fluoropolymers are polymers including a hydrocarbon backbone in which some or all of the hydrogen atoms are substituted with fluorine atoms. The backbone polymer is usually polyolefinic and formed from fluorine-substituted, unsaturated olefin monomers. The fluoropolymer can be a homopolymer of such fluorine-substituted monomers or a copolymer of fluorine-substituted monomers or mixtures of fluorine-substituted monomers and non-fluorine-substituted monomers. Along with fluorine atoms, the fluoropolymer can also be substituted with other halogen atoms, such as chlorine and bromine atoms. Representative monomers suitable for forming fluoropolymers include, without limitation, tetrafluoroethylene ("TFE"), vinylidene fluoride ("VF2"), hexafluoropropylene ("HFP"),

chlorotrifluoroethylene ("CTFE"), perfluoroethylvinyl ether ("PEVE"),

perfluoromethylvinyl ether ("PMVE"), perfluoropropylvinyl ether ("PPVE"), etc., as well as mixtures thereof. Specific examples of suitable fluoropolymers include polytetrafluoroethylene ("PTFE"), perfluoroalkylvinyl ether ("PVE"),

poly(tetrafluoroethylene-co-perfluoroalkyvinyl ether) ("PFA"), fluorinated ethylene- propylene copolymer ("FEP"), ethylene-tetrafluoroethylene copolymer ("ETFE"), polyvinyl idene fluoride ("PVDF"), polychlorotrifluoroethylene ("PCTFE"), and TFE copolymers with VF2 and/or HFP, etc., as well as mixtures thereof. A particularly suitable fluoropolymer is polytetrafluoroethylene ("PTFE").

[0041] Organosilane lubricants as may be incorporated in the capping layer can include alkoxy silane lubricants including monoalkoxy silanes, dialkoxysilanes, chorlor silanes, and the like. The alkoxysilane lubricant may be a silane compound selected from, and without limitation to, vinlyalkoxysilanes, epoxyalkoxysilanes, aminoalkoxysilanes, mercaptoalkoxysilanes, and combinations thereof. Examples of the vinylalkoxysilane that may be utilized include vinyltriethoxysilane,

vinyltrimethoxysilane and vinyltris( -methoxyethoxy)silane. Examples of the epoxyalkoxysilanes that may be used include γ-glycidoxypropyltrimethoxysilane, β- (3,4-epoxycyclohexyl) ethyltrimethoxysilane and γ-glycidoxypropyltriethoxysilane. Examples of the mercaptoalkoxysilanes that may be employed include γ- mercaptopropyltrimethoxysilane and γ-mercaptopropyltriethoxysilane.

[0042] Aminosilane lubricants that may be included in the capping layer are typically of the formula: R ³ -Si-(R ⁴ )3, wherein R ³ is selected from the group consisting of an amino group such as NH ₂ ; an aminoalkyl of from about 1 to about 10 carbon atoms, or from about 2 to about 5 carbon atoms, such as aminomethyl, aminoethyl, aminopropyl, aminobutyl, and so forth; an alkene of from about 2 to about 10 carbon atoms, or from about 2 to about 5 carbon atoms, such as ethylene, propylene, butylene, and so forth; and an alkyne of from about 2 to about 10 carbon atoms, or from about 2 to about 5 carbon atoms, such as ethyne, propyne, butyne and so forth; and wherein R ⁴ is an alkoxy group of from about 1 to about 10 atoms, or from about 2 to about 5 carbon atoms, such as methoxy, ethoxy, propoxy, and so forth.

[0043] In one embodiment, R ³ is selected from the group consisting of aminomethyl, aminoethyl, aminopropyl, ethylene, ethyne, propylene and propyne, and R ⁴ is selected from the group consisting of methoxy groups, ethoxy groups, and propoxy groups. In another embodiment, R ³ is selected from the group consisting of an alkene of from about 2 to about 10 carbon atoms such as ethylene, propylene, butylene, and so forth, and an alkyne of from about 2 to about 10 carbon atoms such as ethyne, propyne, butyne and so forth, and R ⁴ is an alkoxy group of from about 1 to about 10 atoms, such as methoxy group, ethoxy group, propoxy group, and so forth. A combination of various aminosilanes may also be included in the capping layer.

[0044] Some representative examples of amino silane coupling agents that may be included in the thermoplastic composition include aminopropyl triethoxy silane, aminoethyl triethoxy silane, aminopropyl trimethoxy silane, aminoethyl trimethoxy silane, ethylene trimethoxy silane, ethylene triethoxy silane, ethyne trimethoxy silane, ethyne triethoxy silane, aminoethylaminopropyltrimethoxy silane, 3-aminopropyl triethoxy silane, 3-aminopropyl trimethoxy silane, 3-aminopropyl methyl dimethoxysilane or 3-aminopropyl methyl diethoxy silane, N-(2-aminoethyl)- 3-aminopropyl trimethoxy silane, N-methyl-3-aminopropyl trimethoxy silane, N- phenyl-3-aminopropyl trimethoxy silane, bis(3-aminopropyl) tetramethoxy silane, bis(3-aminopropyl) tetraethoxy disiloxane, and combinations thereof. The amino silane may also be an aminoalkoxysilane, such as γ-aminopropyltrimethoxysilane, γ-aminopropyltriethoxysilane, γ-aminopropylmethyldimethoxysilane, γ- aminopropylmethyldiethoxysilane, N-( -aminoethyl)-y- aminopropyltrimethoxysilane, N-phenyl-y-aminopropyltrimethoxysilane, γ- diallylaminopropyltrimethoxysilane and γ-diallylaminopropyltrimethoxysilane. One suitable amino silane is 3-aminopropyltriethoxysilane which is available from Degussa, Sigma Chemical Company, and Aldrich Chemical Company.

[0045] The capping layer is generally free of continuous fibers. That is, the capping layer contains less than about 10 wt.% of continuous fibers, in some embodiments about 5 wt.% or less of continuous fibers, and in some

embodiments, about 1 wt.% or less of continuous fibers (e.g., 0 wt.%).

Nevertheless, the capping layer may contain other additives for improving the final properties of the rod. Additive materials employed at this stage may include those that are not suitable for incorporating into the continuous fiber material. For instance, it may be desirable to add pigments to reduce finishing labor, or it may be desirable to add flame retardant agents to enhance the flame retarding features of the rod. Because many additive materials are heat sensitive, an excessive amount of heat may cause them to decompose and produce volatile gases.

Therefore, if a heat sensitive additive material is extruded with an impregnation resin under high heating conditions, the result may be a complete degradation of the additive material. Additive materials may include, for instance, mineral reinforcing agents, flame retardants, blowing agents, foaming agents, ultraviolet light resistant agents, thermal stabilizers, pigments, and combinations thereof. Suitable mineral reinforcing agents may include, for instance, calcium carbonate, silica, mica, clays, talc, calcium silicate, graphite, calcium silicate, alumina trihydrate, barium ferrite, and combinations thereof.

[0046] In one embodiment, and to help prevent a galvanic response, it is typically desired that the composition forming the capping layer has a dielectric strength of at least about 1 kilovolt per millimeter (kV/mm), in some embodiments at least about 2 kV/mm, in some embodiments from about 3 kV/mm to about 50 kV/mm, and in some embodiments, from about 4 kV/mm to about 30 kV/mm, such as determined in accordance with ASTM D149-09.

[0047] Referring again to Fig. 1 , the CFRT material of the core 760 includes a thermoplastic material and a plurality of continuous fibers embedded therein. Suitable thermoplastic materials for use in rods include, for instance, polyolefins (e.g., polypropylene, propylene-ethylene copolymers, etc.), polyesters (e.g., polybutylene terephalate ("PBT")), polycarbonates, polyamides (e.g., PA12, Nylon™), polyether ketones (e.g., polyether ether ketone ("PEEK")),

polyetherimides, polyarylene ketones (e.g., polyphenylene diketone ("PPDK")), liquid crystal polymers, polyarylene sulfides (e.g., polyphenylene sulfide ("PPS"), poly(biphenylene sulfide ketone), poly(phenylene sulfide diketone),

poly(biphenylene sulfide), etc.), fluoropolymers (e.g., polytetrafluoroethylene- perfluoromethylvinylether polymer, perfluoro-alkoxyalkane polymer,

petrafluoroethylene polymer, ethylene-tetrafluoroethylene polymer, etc.), polyacetals, polyurethanes, polycarbonates, styrenic polymers (e.g., acrylonitrile butadiene styrene ("ABS")), and so forth.

[0048] In one embodiment, the thermoplastic material of the core may include the high performance polymer of the capping layer. For instance, both the core 760 and the capping layer 800 can include PEEK.

[0049] The thermoplastic material of the core 760 may further include a plurality of fibers embedded therein to reinforce the thermoplastic material. In exemplary embodiments, the CFRT material includes continuous fibers, although it should be understood that long fibers may additionally be included therein. The fibers may be dispersed in the thermoplastic material to form the CFRT material. As used therein, the term "long fibers" generally refers to fibers, filaments, yarns, or rovings that are not continuous, and as opposed to "continuous fibers" which generally refer to fibers, filaments, yarns, or rovings having a length that is generally limited only by the length of a part. The fibers dispersed in the polymer material may be formed from any conventional material known in the art, such as metal fibers, glass fibers (e.g., E-glass, A-glass, C-glass, D-glass, AR-glass, R- glass, S-glass such as S1 -glass or S2-glass), carbon fibers (e.g., graphite), boron fibers, ceramic fibers (e.g., alumina or silica), aramid fibers (e.g., Kevlar® marketed by E. I. duPont de Nemours, Wilmington, Del.), synthetic organic fibers (e.g., polyamide, polyethylene, paraphenylene, terephthalamide, polyethylene terephthalate and polyphenylene sulfide), and various other natural or synthetic inorganic or organic fibrous materials known for reinforcing polymer compositions. Glass fibers, carbon fibers, and aramid fibers are particularly desirable. In exemplary embodiments, the continuous fibers may be generally unidirectional.

[0050] One embodiment of an application utilizing a rod 750 according to the present disclosure is shown in Fig. 2. In this embodiment, a cable 20, which in this case is an umbilical, is provided. This particular embodiment contains a central portion 22, which may be formed from a steel pipe, rubber sheath, metallic strand, metallic strand over-sheathed with a thermoplastic material, etc. One or more inner channel elements 24 (e.g., polyvinylchloride), electric conductors/wires 26 (e.g., optic fiber cables), and/or fluid pipes 28 (e.g., steel) may be concentrically disposed about the central portion 22. For example, such umbilical elements may be wound helically around the central portion 22 using a helix machine as is known in the art. The cable 20 may also contain conventional strength elements 30, such as those made from steel rope or armoring wires. A filler 32 (e.g., foam or thermoplastic material) may be arranged at least partly around and between two or more of the umbilical elements. An outer sheath 34 (e.g., polyethylene) also typically encloses the umbilical elements.

[0051] Rods 750 as described herein may be incorporated into the cable 20 in any desired manner, such as individually or in the form of bundles. In the embodiment illustrated in Fig. 2, a bundle of reinforcing rods is disposed within the central portion 22 to provide enhanced strength to the umbilical 20. At least one, but preferably all of the rods are rods 750 formed from a CFRT material and capping layer in accordance with the present disclosure. Of course, the rods need not be contained within the central portion of the umbilical, and rather may have any suitable positioning within the cable 20 as shown or any other suitable cable. For example, bundles of rods 750 and/or individual rods 750 may be positioned about the periphery of the umbilical 20.

[0052] In alternative embodiments, rods 750 may be employed in electrical cables (e.g., high voltage transmission wires). Generally speaking, such transmission cables contain a core surrounded by a plurality of conductive elements. The core may contain only a single rod or it may contain multiple rods. In certain embodiments, for example, the core may contain two or more layers of concentrically arranged rods, which may be stranded together in a variety of different patterns (e.g., helical). In one particular embodiment, for example, the core contains a center rod, a second layer of rods (e.g., 6 rods) concentrically disposed about the center rod, and a third layer of rods (e.g., 12 rods)

concentrically disposed about the second layer. The conductive elements can be made from any suitable conductive material, such as a metal (e.g., copper, aluminum, or alloys thereof), carbon, etc. The manner in which the conductive elements may vary as is known in the art. If desired, the conductive elements may also be formed from materials such as described above.

[0053] Referring to Fig. 3, one embodiment of a transmission line generally 50 is shown. As illustrated, the transmission line 50 includes a plurality of conductive elements 52 (e.g., aluminum) radially disposed about a bundle of generally cylindrical composite rods 750, which may be formed in accordance with the present disclosure. Fig. 3 illustrates six core rods 750 surrounding a single core rod 750, although any suitable number of rods 750 in any suitable

arrangement is within the scope and spirit of the present disclosure. A capping layer 800 also extends around the perimeter of and defines an external surface of each core 760 of each rod 750. The conductive elements may be arranged in a single layer or in multiple layers. In the illustrated embodiment, for example, the conductive elements 52 are arranged to form a first concentric layer 56 and a second concentric layer 58. Of course, any number of concentric layers may be employed. The shape of the conductive elements 52 may also be varied to optimize the number of elements that can be disposed about the composite rods 750. In the illustrated embodiment, for example, the conductive elements 52 have a trapezoidal cross sectional shape. Of course, other shapes may also be employed, such as circular, elliptical, rectangular, square, etc. The conductive elements 52 may also be twisted or wrapped around the bundle of core rods 750 in any desired geometrical configuration, such as in a helical manner.

[0054] It should further be understood that the present disclosure is not limited to the above disclosed applications, and rather that rods 750 formed according to the present disclosure may be utilized in any suitable applications. For example, a rod 750 formed according to the present disclosure may be utilized in oil and gas industry applications, such as to transport tools, etc. to downhole locations, etc.

[0055] A rod 750 may be formed using any suitable process or apparatus. Exemplary embodiments of suitable processes and apparatus, such as pultrusion processes and apparatus, for forming a tape and rod according to the present disclosure are discussed in detail below.

[0056] Referring to Fig. 4, one embodiment of such an extrusion device is shown. More particularly, the apparatus includes an extruder 130 containing a screw shaft 134 mounted inside a barrel 132. A heater 136 (e.g., electrical resistance heater) is mounted outside the barrel 132. During use, a feedstock 137 is supplied to the extruder 130 through a hopper 138. The feedstock is formed from a thermoplastic material as discussed above. The feedstock 137 is conveyed inside the barrel 132 by the screw shaft 134 and heated by frictional forces inside the barrel 132 and by the heater 136. Upon being heated, the feedstock 137 exits the barrel 132 through a barrel flange 138 and enters a die flange 139 of an impregnation die 150.

[0057] A continuous fiber roving 142 or a plurality of continuous fiber rovings 142 are supplied from a reel or reels 144 to die 150. The rovings 142 are generally positioned side-by-side, with minimal to no distance between neighboring rovings, before impregnation. The feedstock 137 may further be heated inside the die by heaters 146 mounted in or around the die 150. The die is generally operated at temperatures that are sufficient to cause and/or maintain the proper melt temperature for the thermoplastic material, thus allowing for the desired level of impregnation of the rovings by the thermoplastic material. Typically, the operation temperature of the die is higher than the melt temperature of the thermoplastic material, such as at temperatures from about 200°C to about 450°C. When processed in this manner, the continuous fiber rovings 142 become embedded in the thermoplastic material, which may be a resin 214 processed from the feedstock 137. The mixture may then exit the impregnation die 150 as wetted composite, extrudate, or tape 152.

[0058] As used herein, the term "roving" generally refers to a bundle of individual fibers 400. The fibers 400 contained within the roving can be twisted or can be straight. The rovings may contain a single fiber type or different types of fibers 400. Different fibers may also be contained in individual rovings or, alternatively, each roving may contain a different fiber type. The continuous fibers employed in the rovings possess a high degree of tensile strength relative to their mass. For example, the ultimate tensile strength of the fibers is typically from about 1 ,000 to about 15,000 Megapascals ("MPa"), in some embodiments from about 2,000 MPa to about 10,000 MPa, and in some embodiments, from about 3,000 MPa to about 6,000 MPa. Such tensile strengths may be achieved even though the fibers are of a relatively light weight, such as a mass per unit length of from about 0.05 to about 2 grams per meter, in some embodiments from about 0.4 to about 1 .5 grams per meter. The ratio of tensile strength to mass per unit length may thus be about 1 ,000 Megapascals per gram per meter ("MPa/g/m") or greater, in some embodiments about 4,000 MPa/g/m or greater, and in some

embodiments, from about 5,500 to about 20,000 MPa/g/m. Carbon fibers are particularly suitable for use as the continuous fibers, which typically have a tensile strength to mass ratio in the range of from about 5,000 to about 7,000 MPa/g/m. The continuous fibers often have a nominal diameter of about 4 to about 35 micrometers, and in some embodiments, from about 9 to about 35 micrometers. The number of fibers contained in each roving can be constant or vary from roving to roving. Typically, a roving contains from about 1 ,000 fibers to about 50,000 individual fibers, and in some embodiments, from about 5,000 to about 30,000 fibers.

[0059] A pressure sensor 147 may sense the pressure near the

impregnation die 150 to allow control to be exerted over the rate of extrusion by controlling the rotational speed of the screw shaft 134, or the feed rate of the feeder. That is, the pressure sensor 147 is positioned near the impregnation die 150, such as upstream of the manifold assembly 220, so that the extruder 130 can be operated to deliver a correct amount of resin 214 for interaction with the fiber rovings 142. After leaving the impregnation die 150, impregnated rovings 142 or the extrudate or tape 152, which may comprises the CFRT material, may enter an optional pre-shaping or guiding section (not shown) and/or a preheating device to control the temperature of the extrudate before entering a nip formed between two adjacent rollers 190. Although optional, the rollers 190 can help to consolidate the impregnated rovings 142 into a tape 156 or consolidate the tape 152 into a final tape 156, as well as enhance fiber impregnation and squeeze out any excess voids. In addition to the rollers 190, other shaping devices may also be employed, such as a die system. Regardless, the resulting consolidated tape 156 is pulled by tracks 162 and 164 mounted on rollers. The tracks 162 and 164 also pull the impregnated rovings 142 or tape 152 from the impregnation die 150 and through the rollers 190. If desired, the consolidated tape 156 may be wound up at a section 171 . Generally speaking, the resulting tapes are relatively thin and typically have a thickness of from about 0.05 to about 1 millimeter, in some embodiments from about 0.1 to about 0.8 millimeters, and in some embodiments, from about 0.1 to about 0.4 millimeters.

[0060] Perspective views of one embodiment of a die 150 according to the present disclosure are further shown in Figs. 4 and 5. As shown, resin 214 is flowed into the die 150 as indicated by resin flow direction 244. The resin 214 is distributed within the die 150 and then interacted with the rovings 142. The rovings 142 are traversed through the die 150 in roving run direction 282, and are coated with resin 214. The rovings 142 are then impregnated with the resin 214, and these impregnated rovings 142 exit the die 150. In some embodiments, as shown in Fig. 4, the impregnated rovings 142 are connected by the resin 214 and thus exit as tape 152. In other embodiments, as shown in Figs. 5 and 6, the impregnated rovings 142 exit the die separately, each impregnated within resin 214.

[0061] Within the impregnation die, it is generally desired that the rovings 142 are traversed through an impregnation zone 250 to impregnate the rovings with the polymer resin 214. In the impregnation zone 250, the polymer resin may be forced generally transversely through the rovings by shear and pressure created in the impregnation zone 250, which significantly enhances the degree of impregnation. This is particularly useful when forming a composite from tapes of high fiber content, such as about 35% weight fraction ("Wf ) or more, and in some embodiments, from about 40% Wf or more. Typically, the die 150 will include a plurality of contact surfaces 252, such as for example at least 2, at least 3, from 4 to 7, from 2 to 20, from 2 to 30, from 2 to 40, from 2 to 50, or more contact surfaces 252, to create a sufficient degree of penetration and pressure on the rovings 142. Although their particular form may vary, the contact surfaces 252 typically possess a curvilinear surface, such as a curved lobe, pin, etc. The contact surfaces 252 are also typically made of a metal material. [0062] Fig. 6 shows a cross-sectional view of an impregnation die 150. As shown, the impregnation die 150 includes a manifold assembly 220 and an impregnation section. The impregnation section includes an impregnation zone 250. In some embodiments, the impregnation section additionally includes a gate passage 270. The manifold assembly 220 is provided for flowing the polymer resin 214 therethrough. For example, the manifold assembly 220 may include a channel 222 or a plurality of channels 222. The resin 214 provided to the impregnation die 150 may flow through the channels 222.

[0063] As shown in Fig. 7, in exemplary embodiments, at least a portion of each of the channels 222 may be curvilinear. The curvilinear portions may allow for relatively smooth redirection of the resin 214 in various directions to distribute the resin 214 through the manifold assembly 220, and may allow for relatively smooth flow of the resin 214 through the channels 222. Alternatively, the channels 222 may be linear, and redirection of the resin 214 may be through relatively sharp transition areas between linear portions of the channels 222. It should further be understood that the channels 222 may have any suitable shape, size, and/or contour.

[0064] The plurality of channels 222 may, in exemplary embodiments as shown in Fig. 7, be a plurality of branched runners 222. The runners 222 may include a first branched runner group 232. The first branched runner group 232 includes a plurality of runners 222 branching off from an initial channel or channels 222 that provide the resin 214 to the manifold assembly 220. The first branched runner group 232 may include 2, 3, 4 or more runners 222 branching off from the initial channels 222.

[0065] If desired, the runners 222 may include a second branched runner group 234 diverging from the first branched runner group 232, as shown. For example, a plurality of runners 222 from the second branched runner group 234 may branch off from one or more of the runners 222 in the first branched runner group 232. The second branched runner group 234 may include 2, 3, 4 or more runners 222 branching off from runners 222 in the first branched runner group 232.

[0066] If desired, the runners 222 may include a third branched runner group 236 diverging from the second branched runner group 234, as shown. For example, a plurality of runners 222 from the third branched runner group 236 may branch off from one or more of the runners 222 in the second branched runner group 234. The third branched runner group 236 may include 2, 3, 4 or more runners 222 branching off from runners 222 in the second branched runner group 234.

[0067] In some exemplary embodiments, as shown, the plurality of branched runners 222 has a symmetrical orientation along a central axis 224. The branched runners 222 and the symmetrical orientation thereof generally evenly distribute the resin 214, such that the flow of resin 214 exiting the manifold assembly 220 and coating the rovings 142 is substantially uniformly distributed on the rovings 142. This desirably allows for generally uniform impregnation of the rovings 142.

[0068] Further, the manifold assembly 220 may in some embodiments define an outlet region 242. The outlet region 242 is that portion of the manifold assembly 220 wherein resin 214 exits the manifold assembly 220. Thus, the outlet region 242 generally encompasses at least a downstream portion of the channels or runners 222 from which the resin 214 exits. In some embodiments, as shown, at least a portion of the channels or runners 222 disposed in the outlet region 242 have an increasing area in a flow direction 244 of the resin 214. The increasing area allows for diffusion and further distribution of the resin 214 as the resin 214 flows through the manifold assembly 220, which further allows for substantially uniform distribution of the resin 214 on the rovings 142. Additionally or

alternatively, various channels or runners 222 disposed in the outlet region 242 may have constant areas in the flow direction 244 of the resin 214, or may have decreasing areas in the flow direction 244 of the resin 214.

[0069] In some embodiments, as shown, each of the channels or runners 222 disposed in the outlet region 242 is positioned such that resin 214 flowing therefrom is combined with resin 214 from other channels or runners 222 disposed in the outlet region 242. This combination of the resin 214 from the various channels or runners 222 disposed in the outlet region 242 produces a generally singular and uniformly distributed flow of resin 214 from the manifold assembly 220 to substantially uniformly coat the rovings 142. Alternatively, some of the channels or runners 222 disposed in the outlet region 242 may be positioned such that resin 214 flowing therefrom is discrete from the resin 214 from other channels or runners 222 disposed in the outlet region 242. In these embodiments, a plurality of discrete but generally evenly distributed resin flows 214 may be produced by the manifold assembly 220 for substantially uniformly coating the rovings 142.

[0070] As shown in Fig. 6, at least a portion of the channels or runners 222 disposed in the outlet region 242 have curvilinear cross-sectional profiles. These curvilinear profiles allow for the resin 214 to be gradually directed from the channels or runners 222 generally downward towards the rovings 142.

Alternatively, however, these channels or runners 222 may have any suitable cross-sectional profiles.

[0071] As further illustrated in Figs. 6 and 7, after flowing through the manifold assembly 220, the resin 214 may flow through gate passage 270. Gate passage 270 is positioned between the manifold assembly 220 and the

impregnation zone 250, and is provided for flowing the resin 214 from the manifold assembly 220 such that the resin 214 coats the rovings 142. Thus, resin 214 exiting the manifold assembly 220, such as through outlet region 242, may enter gate passage 270 and flow therethrough.

[0072] In some embodiments, as shown in Fig. 6, the gate passage 270 extends vertically between the manifold assembly 220 and the impregnation zone 250. Alternatively, however, the gate passage 270 may extend at any suitable angle between vertical and horizontal such that resin 214 is allowed to flow therethrough.

[0073] Further, as shown in Fig. 6, in some embodiments at least a portion of the gate passage 270 has a decreasing cross-sectional profile in the flow direction 244 of the resin 214. This taper of at least a portion of the gate passage 270 may increase the flow rate of the resin 214 flowing therethrough before it contacts the rovings 142, which may allow the resin 214 to impinge on the rovings 142. Initial impingement of the rovings 142 by the resin 214 provides for further impregnation of the rovings, as discussed below. Further, tapering of at least a portion of the gate passage 270 may increase backpressure in the gate passage 270 and the manifold assembly 220, which may further provide more even, uniform distribution of the resin 214 to coat the rovings 142. Alternatively, the gate passage 270 may have an increasing or generally constant cross-sectional profile, as desired or required.

[0074] Upon exiting the manifold assembly 220 and the gate passage 270 of the die 150 as shown in Fig. 6, the resin 214 contacts the rovings 142 being traversed through the die 150. As discussed above, the resin 214 may

substantially uniformly coat the rovings 142, due to distribution of the resin 214 in the manifold assembly 220 and the gate passage 270. Further, in some embodiments, the resin 214 may impinge on an upper surface of each of the rovings 142, or on a lower surface of each of the rovings 142, or on both an upper and lower surface of each of the rovings 142. Initial impingement on the rovings 142 provides for further impregnation of the rovings 142 with the resin 214.

Impingement on the rovings 142 may be facilitated by the velocity of the resin 214 when it impacts the rovings 142, the proximity of the rovings 142 to the resin 214 when the resin exits the manifold assembly 220 or gate passage 270, or other various variables.

[0075] As shown in Fig. 6, the coated rovings 142 are traversed in run direction 282 through impregnation zone 250. The impregnation zone 250 is in fluid communication with the manifold assembly 220, such as through the gate passage 270 disposed therebetween. The impregnation zone 250 is configured to impregnate the rovings 142 with the resin 214.

[0076] For example, as discussed above, in exemplary embodiments as shown in Figs. 6 and 8 through 10, the impregnation zone 250 includes a plurality of contact surfaces 252. The rovings 142 are traversed over the contact surfaces 252 in the impregnation zone. Impingement of the rovings 142 on the contact surface 252 creates shear and pressure sufficient to impregnate the rovings 142 with the resin 214 coating the rovings 142.

[0077] In some embodiments, as shown in Figs. 6, 9 and 10, the

impregnation zone 250 is defined between two spaced apart opposing

impregnation plates 256 and 258, which may be included in the impregnation section. First plate 256 defines a first inner surface 257, while second plate 258 defines a second inner surface 259. The impregnation zone 250 is defined between the first plate 256 and the second plate 258. The contact surfaces 252 may be defined on or extend from both the first and second inner surfaces 257 and 259, or only one of the first and second inner surfaces 257 and 259.

[0078] In exemplary embodiments, as shown in Figs. 6, 9 and 10, the contact surfaces 252 may be defined alternately on the first and second surfaces 257 and 259 such that the rovings alternately impinge on contact surfaces 252 on the first and second surfaces 257 and 259. Thus, the rovings 142 may pass contact surfaces 252 in a waveform, tortuous or sinusoidal-type pathway, which enhances shear.

[0079] Angle 254 at which the ravings 142 traverse the contact surfaces 252 may be generally high enough to enhance shear and pressure, but not so high to cause excessive forces that will break the fibers. Thus, for example, the angle 254 may be in the range between approximately 1 ° and approximately 30°, and in some embodiments, between approximately 5° and approximately 25°.

[0080] As stated above, contact surfaces 252 typically possess a curvilinear surface, such as a curved lobe, pin, etc. In exemplary embodiments as shown, a plurality of peaks, which may form contact surfaces 252, and valleys are thus defined. Further, in many exemplary embodiments, the impregnation zone 250 has a waveform cross-sectional profile. In one exemplary embodiment as shown in Figs. 6 and 8 through 10, the contact surfaces 252 are lobes that form portions of the waveform surfaces of both the first and second plates 256 and 258 and define the waveform cross-sectional profile. Fig. 8 illustrates the second plate 258 and the various contact surfaces thereon that form at least a portion of the impregnation zone 250 according to some of these embodiments.

[0081] In other embodiments, the contact surfaces 252 are lobes that form portions of a waveform surface of only one of the first or second plate 256 or 258. In these embodiments, impingement occurs only on the contact surfaces 252 on the surface of the one plate. The other plate may generally be flat or otherwise shaped such that no interaction with the coated ravings occurs.

[0082] In other alternative embodiments, the impregnation zone 250 may include a plurality of pins (or rods), each pin having a contact surface 252. The pins may be static, freely rotational (not shown), or rotationally driven. Further, the pins may be mounted directly to the surface of the plates defining the impingement zone, or may be spaced from the surface. It should be noted that the pins may be heated by heaters 143, or may be heated individually or otherwise as desired or required. Further, the pins may be contained within the die 150, or may extend outwardly from the die 150 and not be fully encased therein.

[0083] In further alternative embodiments, the contact surfaces 252 and impregnation zone 250 may comprise any suitable shapes and/or structures for impregnating the ravings 142 with the resin 214 as desired or required. [0084] As discussed, a roving 142 traversed through an impregnation zone 250 according to the present disclosure may become impregnated by resin 214, thus resulting in an impregnated roving 142, and optionally a tape 152 comprising at least one roving 142, exiting the impregnation zone 250, such as downstream of the contact surfaces 252 in the run direction 282. The impregnated ravings 142 and optional tape 152 exiting the impregnation zone 250 are thus formed from a fiber impregnated polymer material, as discussed above.

[0085] As further shown in Figs. 5 and 6, in some embodiments, a faceplate 290 may adjoin or be adjacent to the impregnation zone 250. The faceplate 290 may be positioned downstream of the impregnation zone 250 and, if included, the land zone 280, in the run direction 282. The faceplate 290 may contact other components of the die 150, such as the impregnation zone 250 or land zone 280, or may be spaced therefrom. Faceplate 290 is generally configured to meter excess resin 214 from the ravings 142. Thus, apertures in the faceplate 290, through which the ravings 142 traverse, may be sized such that when the ravings 142 are traversed therethrough, the size of the apertures causes excess resin 214 to be removed from the ravings 142.

[0086] As shown in Fig. 4, in alternative embodiments, the die 150 may lack a faceplate 290. Further, in some embodiments, the formation and maintenance of a tape 152 within and exited from a die 150 of the present disclosure may be facilitated through the lack of or removal of a faceplate from the die 150. Removal of the faceplate 290 allows for a plurality of ravings 142 exiting a die 150 to exit as a single sheet or tape 152, rather than as separated ravings 142 due to metering through the faceplate. This could potentially eliminate the need to later form these ravings 142 into such a sheet or tape 156. Removal of the faceplate 290 may have additional advantages. For example, removal may prevent clogging of the faceplate with resin 214, which can disrupt the traversal of ravings 142

therethrough. Additionally, removal may allow for easier access to the

impregnation zone 250, and may thus make it easier to introduce and reintroduce ravings 142 to the impregnation zone 250 during start-up, after temporary disruptions such as due to breakage of a roving 142, or during any other suitable time period.

[0087] It should be understood that a tape 152, 156 according to the present disclosure may have any suitable cross-sectional shape and/or size. For example, such tape 152, 156 may have a generally rectangular shape, or a generally oval or circular or other suitable polygonal or otherwise shape. Further, it should be understood that one or more impregnated ravings 142 having been traversed through the impregnation zone 250 may together form the tape 152, 156, with the resin 214 of the various ravings 142 connected to form such tape 152, 156. The various above amounts, ranges, and/or ratios may thus in exemplary embodiments be determined for a tape 152 having any suitable number of impregnated ravings 142 embedded and generally dispersed within resin 214.

[0088] To further facilitate impregnation of the ravings 142, they may also be kept under tension while present within the die 150, and specifically within the impregnation zone 250. The tension may, for example, range from about 5 to about 300 Newtons, in some embodiments from about 50 to about 250 Newtons, and in some embodiments, from about 100 to about 200 Newtons per roving 142 or tow of fibers.

[0089] As shown in Figs. 1 1 and 12, in some embodiments, a land zone 280 may be positioned downstream of the impregnation zone 250 in run direction 282 of the ravings 142. The ravings 142 may traverse through the land zone 280 before exiting the die 150. In some embodiments, as shown in Fig. 1 1 , at least a portion of the land zone 280 may have an increasing cross-sectional profile in run direction 282, such that the area of the land zone 280 increases. The increasing portion may be the downstream portion of the land zone 280 to facilitate the ravings 142 exiting the die 150. Alternatively, the cross-sectional profile or any portion thereof may decrease, or may remain constant as shown in Fig. 12.

[0090] Additionally, other components may be optionally employed to assist in the impregnation of the fibers. For example, a "gas jet" assembly may be employed in certain embodiments to help uniformly spread a roving of individual fibers, which may each contain up to as many as 24,000 fibers, across the entire width of the merged tow. This helps achieve uniform distribution of strength properties. Such an assembly may include a supply of compressed air or another gas that impinges in a generally perpendicular fashion on the moving ravings that pass across exit ports. The spread ravings may then be introduced into a die for impregnation, such as described above.

[0091] It should be understood that tapes 152, 156 and impregnated ravings 142 thereof according to the present disclosure need not be formed in the dies 150 and other apparatus as discussed above. Such dies 150 and apparatus are merely disclosed as examples of suitable equipment for forming tapes 152, 156. The use of any suitable equipment or process to form tapes 152, 156 is within the scope and spirit of the present disclosure.

[0092] A relatively high percentage of fibers may be employed in a tape, and CFRT material thereof, to provide enhanced strength properties. For instance, fibers typically constitute from about 25 wt.% to about 90 wt.%, in some embodiments from about 30 wt.% to about 75 wt.%, and in some embodiments, from about 35 wt.% to about 70 wt.% of the tape or material thereof. Likewise, polymer(s) typically constitute from about 20 wt.% to about 75 wt.%, in some embodiments from about 25 wt.% to about 70 wt.%, and in some embodiments, from about 30 wt.% to about 65 wt.% of the tape 152, 156. Such percentage of fibers may additionally or alternatively be measured as a volume fraction. For example, in some embodiments, the CFRT material may have a fiber volume fraction between approximately 25% and approximately 80%, in some

embodiments between approximately 30% and approximately 70%, in some embodiments between approximately 40% and approximately 60 %, and in some embodiments between approximately 45% and approximately 55%.

[0093] After formation of a tape 152, 156, the tape 152, 156 may be formed into a core 760 of a rod 750. Any suitable processes and apparatus may be utilized to form a tape 152, 156 into the core 760 of a rod 750. The specific manner in which rovings and tapes 152, 156, are shaped may be carefully controlled to ensure that rods 750 can be formed with an adequate degree of compression and strength properties. Referring to Fig. 13, for example, one particular embodiment of a system and method for forming a rod are shown. In this embodiment, two tapes 152, 156 are initially provided in a wound package on a creel 620. The creel 620 may be an unreeling creel that includes a frame provided with horizontal spindles 622, each supporting a package. A pay-out creel may also be employed, particularly if desired to induce a twist into the fibers. It should also be understood that the tape may also be formed in-line with the formation of the rod. In one embodiment, for example, the tape 152, 156 downstream of the guide assembly 510 may be directly supplied to the system used to form a rod. A tension-regulating device 640 may also be employed to help control the degree of tension in the tapes 152, 156. The device 640 may include inlet plate 630 that lies in a vertical plane parallel to the rotating spindles 622 of the creel 620 and/or perpendicular to the incoming ribbons. The tension-regulating device 640 may contain cylindrical bars 641 arranged in a staggered configuration so that the tape 152, 156 passes over and under these bars to define a wave pattern. The height of the bars can be adjusted to modify the amplitude of the wave pattern and control tension.

[0094] The tapes 152, 156 may be heated in an oven 645 before entering a consolidation die. Heating may be conducted using any known type of oven, as in an infrared oven, convection oven, etc. During heating, the fibers in the tapes are unidirectionally oriented to optimize the exposure to the heat and maintain even heat across the entire tape. The temperature to which the tapes 152, 156 are heated is generally high enough to soften the thermoplastic polymer to an extent that the tapes can bond together. However, the temperature is not so high as to destroy the integrity of the material. The temperature may, for example, range from about 100°C to about 500°C, in some embodiments from about 200°C to about 400°C, and in some embodiments, from about 250°C to about 350°C. In one particular embodiment, for example, polyphenylene sulfide ("PPS") is used as the polymer, and the tapes are heated to or above the melting point of PPS, which is about 285°C.

[0095] Upon being heated, the tapes 152, 156 are provided to a

consolidation die 650 that compresses them together into a preform 614, as well as aligns and forms the initial shape of the rod. As shown generally in Fig. 13, for example, the tapes 152, 156 are guided through a flow passage 651 of the die 650 in a direction "A" from an inlet 653 to an outlet 655. The passage 651 may have any of a variety of shapes and/or sizes to achieve the rod configuration. For example, the channel and rod configuration may be circular, elliptical, parabolic, etc. Within the die 650, the tapes are generally maintained at a temperature at or above the melting point of the thermoplastic matrix used in the ribbon to ensure adequate consolidation.

[0096] The desired heating, compression, and shaping of the tapes 152, 156 may be accomplished through the use of a die 650 having one or multiple sections. For instance, although not shown in detail in FIG. 13, the consolidation die 650 may possess multiple sections that function together to compress and shape the tapes 152, 156 into the desired configuration. For instance, a first section of the passage 651 may be a tapered zone that initially shapes the material as it flows from into the die 650. The tapered zone generally possesses a cross- sectional area that is larger at its inlet than at its outlet. For example, the cross- sectional area of the passage 651 at the inlet of the tapered zone may be about 2% or more, in some embodiments about 5% or more, and in some embodiments, from about 10% to about 20% greater than the cross-sectional area at the outlet of the tapered zone. Regardless, the cross-sectional of the flow passage typically changes gradually and smoothly within the tapered zone so that a balanced flow of the composite material through the die can be maintained. A shaping zone may also follow the tapered zone that compresses the material and provides a generally homogeneous flow therethrough. The shaping zone may also pre-shape the material into an intermediate shape that is similar to that of the rod, but typically of a larger cross-sectional area to allow for expansion of the thermoplastic polymer while heated so as to minimize the risk of backup within the die 650. The shaping zone could also include one or more surface features that impart a directional change to the preform. The directional change forces the material to be redistributed resulting in a more even distribution of the fiber/resin in the final shape. This also reduces the risk of dead spots in the die that can cause burning of the resin. For example, the cross-sectional area of the passage 651 at the shaping zone may be about 2% or more, in some embodiments about 5% or more, and in some embodiments, from about 10% to about 20% greater than the width of the preform 614. A die land may also follow the shaping zone to serve as an outlet for the passage 651 . The shaping zone, tapered zone, and/or die land may be heated to a temperature at or above that of the glass transition temperature or melting point of the thermoplastic matrix.

[0097] If desired, a second die 660 (e.g., calibration die) may also be employed that compresses the preform 614 into the final shape of the rod. When employed, it is sometimes desired that the preform 614 is allowed to cool briefly after exiting the consolidation die 650 and before entering the optional second die 660. This allows the consolidated preform 614 to retain its initial shape before progressing further through the system. Typically, cooling reduces the

temperature of the exterior of the rod below the melting point temperature of the thermoplastic matrix to minimize and substantially prevent the occurrence of melt fracture on the exterior surface of the rod. The internal section of the rod, however, may remain molten to ensure compression when the rod enters the calibration die body. Such cooling may be accomplished by simply exposing the preform 614 to the ambient atmosphere (e.g., room temperature) or through the use of active cooling techniques (e.g., water bath or air cooling) as is known in the art. In one embodiment, for example, air is blown onto the preform 614 (e.g., with an air ring). The cooling between these stages, however, generally occurs over a small period of time to ensure that the preform 614 is still soft enough to be further shaped. For example, after exiting the consolidation die 650, the preform 614 may be exposed to the ambient environment for only from about 1 to about 20 seconds, and in some embodiments, from about 2 to about 10 seconds, before entering the second die 660. Within the die 660, the preform is generally kept at a temperature below the melting point of the thermoplastic matrix used in the ribbon so that the shape of the rod can be maintained. Although referred to above as single dies, it should be understood that the dies 650 and 660 may in fact be formed from multiple individual dies (e.g., face plate dies).

[0098] Thus, in some embodiments, multiple individual dies 660 may be utilized to gradually shape the material into the desired configuration. The dies 660 are placed in series, and provide for gradual decreases in the dimensions of the material. Such gradual decreases allow for shrinkage during and between the various steps.

[0099] For example, as shown in Figs. 14 through 16, a first die 660 may include one or more inlets 662 and corresponding outlets 664, as shown. Any number of inlets 662 and corresponding outlets 664 may be included in a die 660, such as four as shown, one, two, three, five, six, or more. An inlet 662 in some embodiments may be generally oval or circle shaped. In other embodiments, the inlet 662 may have a curved rectangular shape, i.e. a rectangular shape with curved corners or a rectangular shape with straight longer sidewalls and curved shorter sidewalls. Further, an outlet 664 may be generally oval or circle shaped, or may have a curved rectangular shape. In some embodiments wherein an oval shaped inlet is utilized, the inlet 662 may have a major axis length 666 to minor axis length 668 ratio in a range between approximately 3 to 1 and approximately 5 to 1 . In some embodiments wherein an oval or circular shaped inlet is utilized, the outlet 664 may have a major axis length 666 to minor axis length 668 ratio in a range between approximately 1 to 1 and approximately 3 to 1 . In embodiments wherein a curved rectangular shape is utilized, the inlet and outlet may have major axis length 666 to minor axis length 668 ratios (aspect ratios) between

approximately 2 to 1 and approximately 7 to 1 , with the outlet 664 ratio being less than the inlet 662 ratio.

[00100] In further embodiments, the cross-sectional area of an inlet 662 and the cross-sectional area of a corresponding outlet 664 of the first die 660 may have a ratio in a range between approximately 1 .5 to 1 and 6 to 1 .

[00101] The first die 660 thus provides a generally smooth transformation of polymer impregnated fiber material to a shape that is relatively similar to a final shape of the resulting rod, which in exemplary embodiments has a circular or oval shaped cross-section. Subsequent dies, such as a second die 660 and third die 660 as shown in Fig. 14, may provide for further gradual decreases and/or changes in the dimensions of the material, such that the shape of the material is converted to a final cross-sectional shape of the rod. These subsequent dies 660 may both shape and cool the material. For example, in some embodiments, each subsequent die 660 may be maintained at a lower temperature than the previous dies. In exemplary embodiments, all dies 660 are maintained at temperatures that are higher than a softening point temperature for the material.

[00102] In further exemplary embodiments, dies 660 having relatively long land lengths 669 may be desired, due to for example desires for proper cooling and solidification, which are critical in achieving a desired rod shape and size. Relatively long land lengths 669 reduce stresses and provide smooth

transformations to desired shapes and sizes, and with minimal void fraction and bow characteristics. In some embodiments, for example, a ratio of land length 669 at an outlet 664 to major axis length 666 at the outlet 664 for a die 660 may be in the range between approximately 0 and approximately 20, such as between approximately 2 and approximately 6.

[00103] The use of calibration dies 660 according to the present disclosure provides for gradual changes in material cross-section, as discussed. These gradual changes may in exemplary embodiments ensure that the resulting product, such as a rod or other suitable product has a generally uniform fiber distribution with relatively minimal void fraction. [00104] It should be understood that any suitable number of dies 660 may be utilized to gradually form the material into a profile having any suitable cross- sectional shape, as desired or required by various applications.

[00105] In addition to the use of one or more dies, other mechanisms may also be employed to help compress the preform 614 into the shape of a core 760 for a rod 750. For example, forming rollers 690, as shown in Fig. 17, may be employed between the consolidation die 650 and the calibration die 660, between the various calibration dies 660, and/or after the calibration dies 660 to further compress the preform 614 before it is converted into its final shape. The rollers may have any configuration, such as pinch rollers, overlapping rollers, etc., and may be vertical as shown or horizontal rollers. Depending on the roller 690 configuration, the surfaces of the rollers 690 may be machined to impart the dimensions of the final product, such as the rod, profile, or other suitable product, to the preform 614. In exemplary embodiment, the pressure of the rollers 690 should be adjustable to optimize the quality of the final product.

[00106] The rollers 690 in exemplary embodiments, such as at least the portions contacting the material, may have generally smooth surfaces. For example, relatively hard, polished surfaces are desired in many embodiments. For example, the surface of the rollers may be formed from a relatively smooth chrome or other suitable material. This allows the rollers 690 to manipulate the preform 614 without damaging or undesirably altering the preform 614. For example, such surfaces may prevent the material from sticking to the rollers, and the rollers may impart smooth surfaces onto the materials.

[00107] In some embodiments, the temperature of the rollers 690 is controlled. This may be accomplished by heating of the rollers 690 themselves, or by placing the rollers 690 in a temperature controlled environment.

[00108] Further, in some embodiments, surface features 692 may be provided on the rollers 690. The surface features 692 may guide and/or control the preform 614 in one or more directions as it is passed through the rollers. For example, surface features 692 may be provided to prevent the preform 614 from folding over on itself as it is passed through the rollers 690. Thus, the surface features 692 may guide and control deformation of the preform 614 in the cross- machine direction relative to the machine direction A as well as in the vertical direction relative to the machine direction A. The preform 614 may thus be pushed together in the cross-machine direction, rather than folded over on itself, as it is passed through the rollers 690 in the machine direction A.

[00109] In some embodiments, tension regulation devices may be provided in communication with the rollers. These devices may be utilized with the rollers to apply tension to the preform 614 in the machine direction, cross-machine direction, and/or vertical direction to further guide and/or control the preform.

[00110] While not shown in detail herein, the capping die 672 may include various features known in the art to help achieve the desired application of the capping layer. For instance, the capping die 672 may include an entrance guide that aligns the incoming rod. The capping die may also include a heating mechanism (e.g., heated plate) that pre-heats the rod before application of the capping layer to help ensure adequate bonding. Following capping, the shaped part 615, or rod 750, is then finally cooled using a cooling system 680 as is known in the art. The cooling system 680 may, for instance, be a sizing system that includes one or more blocks (e.g., aluminum blocks) that completely encapsulate the rod while a vacuum pulls the hot shape out against its walls as it cools. A cooling medium may be supplied to the sizer, such as air or water, to solidify the rod in the correct shape.

[00111] Even if a sizing system is not employed, it is generally desired to cool the rod 750 after it exits the capping die (or the consolidation or calibration die if capping is not applied). Cooling may occur using any technique known in the art, such a water tank, cool air stream or air jet, cooling jacket, an internal cooling channel, cooling fluid circulation channels, etc. Regardless, the temperature at which the material is cooled is usually controlled to achieve optimal mechanical properties, part dimensional tolerances, good processing, and an aesthetically pleasing composite. For instance, if the temperature of the cooling station is too high, the material might swell in the tool and interrupt the process. For semi- crystalline materials, too low of a temperature can likewise cause the material to cool down too rapidly and not allow complete crystallization, thereby jeopardizing the mechanical and chemical resistance properties of the composite. Multiple cooling die sections with independent temperature control can be utilized to impart the optimal balance of processing and performance attributes. In one particular embodiment, for example, a water tank is employed that is kept at a temperature of from about 0°C to about 30°C, in some embodiments from about 1 °C to about 20°C, and in some embodiments, from about 2°C to about 15°C.

[00112] If desired, one or more sizing blocks (not shown) may also be employed, such as after capping. Such blocks contain openings that are cut to the exact rod shape, graduated from oversized at first to the final rod shape. As the rod passes therethrough, any tendency for it to move or sag is counteracted, and it is pushed back (repeatedly) to its correct shape. Once sized, the rod may be cut to the desired length at a cutting station (not shown), such as with a cut-off saw capable of performing cross-sectional cuts or the rod can be wound on a reel in a continuous process. The length of rod will then be limited to the length of the fiber tow.

[00113] As will be appreciated, the temperature of the rod as it advances through any section of the system of the present invention may be controlled to yield optimal manufacturing and desired final composite properties. Any or all of the assembly sections may be temperature controlled utilizing electrical cartridge heaters, circulated fluid cooling, etc., or any other temperature controlling device known to those skilled in the art.

[00114] Referring again to Fig. 13, a pulling device 682 is positioned downstream from the cooling system 680 that pulls the finished 750 through the system for final sizing of the composite. The pulling device 682 may be any device capable of pulling the rod through the process system at a desired rate. Typical pulling devices include, for example, caterpillar pullers and reciprocating pullers.

[00115] The rods 750 that result from use of dies and methods according to the present disclosure may have a very low void fraction, which helps enhance their strength. For instance, the void fraction may be about 5% or less, in some embodiments about 4% or less, in some embodiments about 3% or less, in some embodiments about 2% or less, in some embodiments about 1 .5% or less, in some embodiments about 1 % or less, and in some embodiments, about 0.5% or less. The void fraction may be measured using techniques well known to those skilled in the art. For example, the void fraction may be measured using a "resin burn off' test in which samples are placed in an oven (e.g., at 600° C for 3 hours) to burn out the resin. The mass of the remaining fibers may then be measured to calculate the weight and volume fractions. Such "burn off' testing may be performed in accordance with ASTM D 2584-08 to determine the weights of the fibers and the polymer matrix, which may then be used to calculate the "void fraction" based on the following equations:

where,

V _f is the void fraction as a percentage;

c is the density of the composite as measured using known techniques, such as with a liquid or gas pycnometer (e.g., helium pycnometer);

p _t is the theoretical density of the composite as is determined by the following equation:

p _t = 1/[W _f /p _f + W _m /p _m ] p _m is the density of the polymer matrix (e.g., at the appropriate crystallinity); p _f is the density of the fibers;

W _f is the weight fraction of the fibers; and

W _m is the weight fraction of the polymer matrix.

[00116] Alternatively, the void fraction may be determined by chemically dissolving the resin in accordance with ASTM D 3171 -09. The "burn off' and "dissolution" methods are particularly suitable for glass fibers, which are generally resistant to melting and chemical dissolution. In other cases, however, the void fraction may be indirectly calculated based on the densities of the polymer, fibers, tape and/or rod in accordance with ASTM D 2734-09 (Method A), where the densities may be determined ASTM D792-08 Method A. Of course, the void fraction can also be estimated using conventional microscopy equipment.

[00117] As discussed above, after exiting an impregnation die 150, 412, the CFRT material may in some embodiments form a tape 152, 156. The number of rovings employed in each tape 152, 156 may vary. Typically, however, a tape 152, 156 will contain from 2 to 80 rovings, and in some embodiments from 10 to 60 rovings, and in some embodiments, from 20 to 50 rovings. In some embodiments, it may be desired that the rovings are spaced apart approximately the same distance from each other within the tape 152, 156. In other embodiments, however, it may be desired that the rovings are combined, such that the fibers of the rovings are generally evenly distributed throughout the tape 152, 156, such as throughout one or more resin rich portions and a fiber rich portion as discussed above. In these embodiments, the rovings may be generally indistinguishable from each other. Referring to Figs. 18 and 19, for example, embodiments of a tape 152, 156 are shown that contains ravings that are combined such that the fibers 400 are generally evenly distributed therein. As shown in Fig. 18, in exemplary

embodiments, the fibers extend generally unidirectionally, such as along a longitudinal axis of the tape 152, 156.

[00118] Through use of apparatus and methods according to the present disclosure and control over the various parameters mentioned above, tapes and rods having a very high strength may be formed. For example, the rods may exhibit a high maximum load. Maximum load may be determined according to ASTM D3039. The maximum load may be, for example, greater than about 290 pounds per square inch (psi), or for example greater than about 130 kilograms per square inch (130 ksi).

[00119] The rods may exhibit a relatively high flexural modulus. The term "flexural modulus" generally refers to the ratio of stress to strain in flexural deformation (units of force per area), or the tendency for a material to bend. It is determined from the slope of a stress-strain curve produced by a "three point flexural" test (such as ASTM D790-10, Procedure A), typically at room

temperature. For example, the rod of the present invention may exhibit a flexural modulus of from about 10 Gigapascals ("GPa") or more, in some embodiments from about 12 to about 400 GPa, in some embodiments from about 15 to about 200 GPa, and in some embodiments, from about 20 to about 150 GPa.

Furthermore, the ultimate tensile strength may be about 300 Megapascals ("MPa") or more, in some embodiments from about 400 MPa to about 5,000 MPa, and in some embodiments, from about 500 MPa to about 3,500 MPa. The term "ultimate tensile strength" generally refers to the maximum stress that a material can withstand while being stretched or pulled before necking and is the maximum stress reached on a stress-strain curve produced by a tensile test (such as ASTM D3916-08) at room temperature. The tensile modulus of elasticity may also be about 50 GPa or more, in some embodiments from about 70 GPa to about 500 GPa, and in some embodiments, from about 100 GPa to about 300 GPa. The term "tensile modulus of elasticity" generally refers to the ratio of tensile stress over tensile strain and is the slope of a stress-strain curve produced by a tensile test (such as ASTM 3916-08) at room temperature. Notably, the strength properties of the composite rod referenced above may also be maintained over a relatively wide temperature range, such as from about -40°C to about 300°C, and particularly from about 180°C to 200°C.

[00120] Rods made according to the present disclosure may further have relatively high flexural fatigue life, and may exhibit relatively high residual strength. Flexural fatigue life and residual flexural strength may be determined based on a "three point flexural fatigue" test (such as ASTM D790, typically at room

temperature. For example, the rods of the present invention may exhibit residual flexural strength after one million cycles at 160 Newtons ("N") or 180 N loads of from about 60 kilograms per square inch ("ksi")to about 1 15 ksi, in some

embodiments about 70 ksi to about 1 15 ksi, and in some embodiments about 95 ksi to about 1 15 ksi. Further, the rods may exhibit relatively minimal reductions in flexural strength. For example, rods having void fractions of about 4% or less, in some embodiments about 3% or less, may exhibit reductions in flexural strength after three point flexural fatigue testing of about 1 % (for example, from a maximum pristine flexural strength of about 106 ksi to a maximum residual flexural strength of about 105 ksi). Flexural strength may be tested before and after fatigue testing using, for example, a three point flexural test as discussed above.

[00121] The linear thermal expansion coefficient of the composite rod may be, on a ppm basis per °C, less than about 5, less than about 4, less than about 3, or less than about 2. For instance, the coefficient (ppm/°C) may be in a range from about -0.25 to about 5; alternatively, from about -0.17 to about 4; alternatively, from about -0.17 to about 3; alternatively, from about -0.17 to about 2; or alternatively, from about 0.29 to about 1 .18. The temperature range contemplated for this linear thermal expansion coefficient may be generally in the -50 °C to 200 °C range, the 0 °C to 200 °C range, the 0 °C to 175 °C range, or the 25 °C to 150 °C range. The linear thermal expansion coefficient is measured in the longitudinal direction, i.e., along the length of the fibers.

[00122] The composite rod may also exhibit a relatively small "bend radius", which is the minimum radius that the rod can be bent without breaking and is measured to the inside curvature of the rod. A smaller bend radius means that the rod is more flexible and can be spooled onto a smaller diameter bobbin. This property also makes the rod easier to implement in processes that currently use metal rods. Due to the improved process and resulting rod of the present invention, bend radiuses may be achieved that are less than about 40 times the outer diameter of the rod, in some embodiments from about 1 to about 30 times the outer diameter of the rod, and in some embodiments, from about 2 to about 25 times the outer diameter of the rod, determined at a temperature of about 25°C. For instance, the bend radius may be less than about 15 centimeters, in some embodiments from about 0.5 to about 10 centimeters, and in some embodiments, from about 1 to about 6 centimeters, determined at a temperature of about 25°C.

[00123] Embodiments of the present disclosure are illustrated by the following examples that are merely for the purpose of illustration of embodiments and are not to be regarded as limiting the scope of the invention or the manner in which it may be practiced. Unless specifically indicated otherwise, parts and percentages are given by weight.

Testing Methods

[00124] Maximum Load: Maximum load was determined according to ASTM D3039. Briefly, samples were placed in the grips of a Universal Test Machine at a specified grip separation and pulled until failure. Typically, the test speed was 2 mm/min (0.05 in/min). A strain gauge was used to determine the maximum load.

[00125] Modulus: Tensile modulus was tested according to ISO Test No. 527 (technically equivalent to ASTM D638). Modulus and strength measurements are made on the same test strip sample having a length of 80 mm, thickness of 10 mm, and width of 4 mm. The testing temperature is 23°C, and the testing speeds are 1 or 5 mm/min.

Example 1

[00126] Samples were formed including a core formed of polyphenylene sulfide with 50% by weight carbon fiber (CF50) rods each including 8 carbon fiber tows embedded in the polyphenylene sulfide (PPS). The capping layer included either polyphthalamide (PPA), polyetherether ketone (PEEK), or a combination of the two polymers with a Silicone additive (MB50-001 SILICONE MB from Dow Corning), with certain samples also include a polytetrafluoroethylene (PTFE) lubricant, as described in the table below.

4 PPS-CF50 94 - 6 -

5 PPS-CF50 - 90 - 10

6 PPS-CF50 - 80 - 20

7 PPS-CF50 - 100 - -

[00127] A wear test over a curved steel surface was completed on the PEEK capped samples (Sample no. 5, 6, and 7) and compared to a standard steel rod. During the wear test, the rods were tensioned at 100 lbs and drawn back and forth at a constant velocity over the curved steel surface. Results are shown in the table below.

Coefficient of Variation

[00128] As can be seen in the above table, both PEEK/PTFE rod samples (Sample no. 5 and 6) showed a significant improvement in wear performance compared to both the steel and standard PEEK capped rod (Sample no. 7), as well as lower abrasion imparted on the steel surface compared to the steel rod. Both the 10% and 20% PTFE/PEEK capped rods completed 1 1 ,000 cycles with minimal reduction in final rod diameter, whereas, the straight PEEK capped sample was fully abraded (no capping material left) after just 500 cycles.

[00129] These and other modifications and variations of the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the invention so further described in such appended claims.