Fiber-reinforced thermoplastic unidirectional tape, method of manufacture and use thereof and reinforced thermoplastic pipe

Abstract

A fiber-reinforced thermoplastic unidirectional (UD) tape comprises a thermoplastic matrix material and unidirectionally arranged reinforcing fibers dispersed within the thermoplastic matrix material, wherein the thermoplastic matrix material comprises one or more aliphatic polyketones (POKs) and / or one or more aromatic polyetherketones (PEKs). A method for manufacturing the fiber-reinforced thermoplastic UD tape, the use of the fiber-reinforced thermoplastic UD tape in reinforced thermoplastic tubes (RTPs), and a reinforced thermoplastic tube (RTP) comprising, from its center to its outer periphery, a thermoplastic inner liner, a reinforcing layer comprising the fiber-reinforced thermoplastic UD tape, and a thermoplastic outer sheath.

Description

Technical Field

[0001] This invention relates to a fiber-reinforced thermoplastic unidirectional (UD) tape, a method for preparing the fiber-reinforced thermoplastic UD tape, and the use of the fiber-reinforced thermoplastic UD tape. The invention also relates to reinforced thermoplastic tubes (RTPs) comprising the fiber-reinforced thermoplastic UD tape. Background Technology

[0002] Introduced more than half a century ago, fiber-reinforced polymer compositions are widely used composite materials in industry, such as the automotive industry. The term "composite material" can be applied to any combination of individual materials, such as thermoplastic polymers (matrix) with fibers (reinforcing fillers) dispersed within them. The reinforced plastics industry uses different forms of glass fiber to reinforce the polymer matrix to produce a variety of products.

[0003] One example of product diversity is fiber-reinforced thermoplastic unidirectional (UD) tape. Fiber-reinforced thermoplastic UD tape is an endless tape reinforced with continuous fibers, in which fibers such as glass, basalt, or carbon fibers are unidirectionally arranged and embedded (dispersed) within a thermoplastic matrix material. The matrix material comprises one or more thermoplastic materials. Typical examples of thermoplastic materials used are polyetheretherketone (PEEK) or polyetherketoneketone (PEKK). These thermoplastic aromatic polyetherketone materials have relatively high melting points, making them suitable for use in reinforced thermoplastic tubes (RTP).

[0004] Due to its fiber reinforcement, RTP possesses high strength, making it suitable as a replacement for metal pipes in a wide range of applications currently using metal tubing. The disadvantages of metal-based pipes are their high susceptibility to corrosion and their weight and inflexibility. RTP is an excellent alternative to these metal pipes because it is corrosion-resistant and, when based on thermoplastic materials such as PEEK or PEKK, exhibits excellent high-temperature and chemical resistance. This makes RTP suitable for transporting (hot) hydrocarbon fluids. Another advantage is that RTP is flexible and can therefore be wound onto reels, enabling easy transport, easy installation, and very low maintenance requirements. Another advantage is that these materials are lighter than metals, allowing for easy and cheaper transportation. The disadvantages of thermoplastic materials such as PEEK or PEKK (aromatic polyketones) are the need for relatively high processing temperatures. Another disadvantage is their relatively high cost.

[0005] Polyvinylidene fluoride (PVDF), polyamide (PA), and polyester are also used as thermoplastic materials in RTP. However, most of these types of thermoplastic materials have lower chemical and / or hydrolytic resistance and / or are relatively expensive.

[0006] Other thermoplastic materials used in RTP UD tapes as alternatives to PEEK, PEKK, PVDF, polyamide, and polyester are polyolefins, such as polyethylene (PE) and polypropylene (PP). These types of thermoplastic polymers are very attractive because they are relatively inexpensive. However, a major drawback is that PE and PP have relatively low melting points, making them less suitable for applications requiring high-temperature resistant materials, such as in the transport of hot hydrocarbon fluids. Furthermore, polyolefin materials swell at temperatures above approximately 80°C when exposed to aliphatic and aromatic hydrocarbon liquids.

[0007] Therefore, there is a need for thermoplastic materials for UD tapes that have relatively low life cycle costs, high temperature resistance, and improved chemical / hydrolysis resistance.

[0008] Purpose

[0009] Therefore, the object of the present invention is to provide fiber-reinforced thermoplastic UD tapes that have high temperature resistance and improved chemical and hydrolytic resistance, as well as improved cost efficiency, making these UD tapes suitable for all types of applications.

[0010] For some applications, UD tape must be flame-retardant. For example, UD tape for RTP must be flame-retardant to allow for the safe transport of chemicals, such as hydrocarbon fluids, and for use in the aerospace and transportation sectors.

[0011] Therefore, the specific object of the present invention is to provide a fiber-reinforced thermoplastic UD tape that has high temperature resistance, improved chemical and hydrolytic resistance, and improved flame retardancy, and has improved cost efficiency. Summary of the Invention

[0012] In a first aspect, the present invention relates to a fiber-reinforced thermoplastic unidirectional (UD) tape comprising a thermoplastic matrix material and unidirectionally arranged reinforcing fibers dispersed within the thermoplastic matrix material, wherein the thermoplastic matrix material comprises one or more aliphatic polyketides (POKs).

[0013] This type of fiber-reinforced thermoplastic UD tape can be easily manufactured at a relatively low cost, is heat-resistant, and has improved resistance to hydrolysis and chemical degradation by gases and liquids. For example, it is resistant to swelling and degradation by typical components found in oil fluids (i.e., liquid hydrocarbons, water, CH4, CO2, and H2S). This makes this type of thermoplastic matrix material very suitable for UD tapes.

[0014] Furthermore, the thermoplastic matrix material itself can withstand temperatures above 85°C, preferably above 90°C, and more preferably above 100°C, for 30 years or longer with respect to the fluid. In addition, the thermoplastic matrix material must exhibit low permeability to water and the gas. This is particularly important when the reinforcing material is glass fiber, whose strength can be reduced by water and acid.

[0015] Therefore, this material, due to its cost efficiency, will fill the gap in the high-heat application market below high-end versions of thermoplastic matrix materials such as PEEK and PEKK.

[0016] POK is a natural flame retardant and coking polymer, making it an excellent choice for the thermoplastic matrix material used in the manufacture of flame-retardant UD tapes.

[0017] The UD tape according to the first aspect of the invention is well suited for applications such as tubes (e.g., reinforced thermoplastic tubes (RTP)), pressure vessels, automotive parts, electrical and electronic products, consumer appliances, and other high-heat applications.

[0018] Furthermore, the UD tape according to the first aspect of the invention is melt- and powder-impregnable, which enables the use of melt impregnation and powder dispersion in the manufacture of fiber-reinforced thermoplastic UD tapes.

[0019] In a second aspect, the present invention relates to a method for manufacturing a fiber-reinforced thermoplastic UD tape according to a first aspect of the present invention, the method comprising:

[0020] - Melt impregnation is achieved by contacting unidirectionally aligned reinforcing fibers with a molten thermoplastic matrix material; or

[0021] - Powder dispersion is achieved by applying a thermoplastic matrix material in powder form onto unidirectionally arranged reinforcing fibers.

[0022] In a third aspect, the present invention relates to the use of fiber-reinforced thermoplastic UD tape according to the first aspect of the present invention or fiber-reinforced thermoplastic UD tape prepared according to the second aspect of the present invention for reinforced thermoplastic tubes (RTP).

[0023] In a fourth aspect, the present invention relates to a reinforced thermoplastic tube (RTP) comprising, from its center to its outer periphery, a thermoplastic inner liner, a reinforcing layer, and a thermoplastic outer sheath, wherein the reinforcing layer comprises a fiber-reinforced thermoplastic UD tape according to a first aspect of the invention or a fiber-reinforced thermoplastic UD tape prepared according to a second aspect of the invention. The outer sheath protects the reinforcing layer comprising the fiber-reinforced thermoplastic UD.

[0024] Unless otherwise stated, the corresponding embodiments disclosed herein with respect to the first aspect are also applicable to the method of preparing fiber-reinforced thermoplastic UD tape (second aspect) and the use of fiber-reinforced thermoplastic UD tape (third aspect), as well as the RTP comprising fiber-reinforced thermoplastic UD tape according to the invention (fourth aspect). Attached Figure Description

[0025] The invention is described below with reference to the accompanying drawings, which illustrate embodiments of the invention, and wherein similar reference numerals denote the same or similar elements. The invention is by no means limited to the disclosed embodiments.

[0026] Figure 1 A schematic cross-section of a reinforced thermoplastic tube (RTP) including the UD strip according to the invention is shown;

[0027] Figure 2a A method for manufacturing a fiber-reinforced UD tape according to the present invention is shown;

[0028] Figure 2b Another method for manufacturing the fiber-reinforced UD tape according to the present invention is shown. Detailed Implementation

[0029] The present invention will now be described in detail.

[0030] thermoplastic matrix materials

[0031] Aliphatic polyketones (POK)

[0032] In this specification, "aliphatic polyketone" refers to a polyketone containing aliphatic comonomers (POKs) such as carbon monoxide, ethylene, and propylene monomers, according to the following structure:

[0033]

[0034] In this specification, "POK" refers to a polyketide polymer composed of aliphatic comonomers. POK is a class of thermoplastic polymers containing polar ketone groups in the polymer backbone. They are prepared by copolymerizing carbon monoxide with an olefin (e.g., ethylene) as a comonomer. POK has different types, depending on 1) the number of comonomers and 2) the type of comonomer. When using one olefin comonomer, the term copolymer is generally used, while when using two olefin comonomers, the term terpolymer is generally used.

[0035] The two most common aliphatic POK types are copolymers constructed from the monomers carbon monoxide and ethylene (where R is hydrogen), and terpolymers constructed from the monomers carbon monoxide, ethylene, and a second olefin comonomer, which can be propylene, butene (e.g., 1-butene), hexene, octene, or dodecene (where R is methyl, butyl, hexyl, octyl, or dodecyl in the comonomer).

[0036] POK has polar ketone groups in the polymer backbone, and the presence of these ketone groups provides a strong attraction between polymer chains, which increases the melting point of the material: about 260°C for copolymers (with carbon monoxide and ethylene monomers) and about 220°C for terpolymers (with carbon monoxide, ethylene and propylene monomers).

[0037] In this specification, "thermoplastic matrix material" refers to the thermoplastic polymer material that forms the matrix of fiber-reinforced thermoplastic composites.

[0038] In an embodiment of the first aspect of the invention, the thermoplastic matrix material comprises one or more POKs and optionally one or more PEKs. The POKs are selected from: copolymers of monomers comprising carbon monoxide and ethylene, and terpolymers of monomers comprising carbon monoxide, ethylene, and a second hydrocarbon comprising at least three carbon atoms, particularly an α-olefin such as propylene, butene (e.g., 1-butene), hexene, octene, or dodecene. The PEKs are selected from polyaryletherketones (PAEKs), such as polyetheretherketone (PEEK) and polyetherketoneketone (PEKK) – discussed below in the section on aromatic polyetherketones. These POKs improve the high-temperature rigidity, melt flow rate (MFR), and viscosity of the thermoplastic matrix material. Another advantage is that they improve the chemical resistance of fiber-reinforced thermoplastic UD tapes to hydrocarbons, water / hydrolysis, acids, and gases.

[0039] In yet another embodiment, the thermoplastic matrix material comprises 20 to 100% by weight, preferably 25 to 90% by weight, more preferably at least 60% by weight, and most preferably at least 70% by weight of one or more POK, based on the total weight of the thermoplastic matrix material. Thermoplastic matrix materials containing such a high amount of POK significantly reduce material costs.

[0040] One or more POKs used in this invention may have:

[0041] - A melt mass flow rate (MFR) of at least 60 g / 10 min, preferably at least 100 g / 10 min, more preferably at least 150 g / 10 min, and most preferably 60-200 g / 10 min, as determined by ASTM D1238-23 at 240 °C with a 2.16 kg load; and / or

[0042] A viscosity of up to 100 Pa·s, preferably up to 70 Pa·s, measured at 240°C according to ISO 6721.

[0043] Polymers with these properties are extremely suitable for use in UD tape applications.

[0044] Aromatic polyetherketone (PEK)

[0045] In this specification, "aromatic polyetherketone" refers to polyetherketone (PEK) containing comonomers with aromatic groups. PEK is a polymer whose main chain contains alternating ketone (R-CO-R) and ether (ROR) functional groups. PAEK is the most common type.

[0046] In this specification, "PAEK" refers to polyaryletherketone. This is a type of PEK whose molecular backbone contains alternating ketone (Aryl-CO-Aryl) and ether groups (Aryl-O-Aryl), where Aryl is a 1,4-substituted aryl group. These polymers are semi-crystalline thermoplastics with high-temperature stability and high mechanical strength.

[0047] In this specification, "PEEK" refers to polyetheretherketone according to the following structure:

[0048]

[0049] PEEK is PEK, more specifically the PAEK family. PEEK is a semi-crystalline thermoplastic with excellent mechanical properties and chemical resistance, which are maintained up to high temperatures. The processing conditions used to mold PEEK affect its crystallinity, and therefore its mechanical properties.

[0050] In this specification, "PEKK" refers to polyetherketone ketone according to the following structure:

[0051]

[0052] PEKK is also PEK, more specifically the PAEK family. PEKK is a semi-crystalline thermoplastic with excellent mechanical properties and chemical resistance, which are maintained up to high temperatures.

[0053] In an embodiment of the first aspect of the invention, the thermoplastic matrix material comprises one or more aromatic polyketides (PEKs), such as PEEK and PEKK. Due to the properties of these PEKs, they are suitable for use in reinforced thermoplastic pipes (RTPs).

[0054] Other thermoplastic polymers

[0055] Thermoplastic matrix materials may also include one or more other polymers selected from polyamides, polyolefins, polyphenylene sulfide (PPS), polyethersulfone (PES), and polyetherimide (PEI).

[0056] In this specification, "polyamide" refers to a polymer containing amide bonds. Several types of polyamides exist, such as aliphatic polyamides, aromatic polyamides, or polyphthalamides.

[0057] In this specification, "polyolefin" refers to a polymer of olefin monomers with the general formula (CH2CHR). n , where R is an alkyl group. Examples are polypropylene and polyethylene or copolymers thereof.

[0058] In this specification, "PPS" refers to polyphenylene sulfide. It is a thermoplastic polymer composed of aromatic rings linked by thioether bonds.

[0059] In this specification, "PES" refers to polyethersulfone according to the following structure. This is a thermoplastic polymer whose backbone contains ether bonds, aromatic rings, and sulfone bonds:

[0060]

[0061] In this specification, "PEI" refers to polyetherimide. This is a high-temperature thermoplastic polymer, similar to PEEK. Compared to PEEK, it has lower impact strength. PEI contains phthalimide and bisphenol A subunits. It has the following structure:

[0062]

[0063] In this specification, "PVDF" refers to polyvinylidene fluoride, a fluorinated type of polyolefin. It has the following structure:

[0064]

[0065] Unidirectional (UD) band

[0066] Preferably, the fiber-reinforced thermoplastic UD tape has a width of at least 2 cm and / or a thickness of 0.10-0.80 mm, preferably 0.15-0.50 mm, more preferably 0.25-0.35 mm. These dimensions of UD tape provide an optimal balance between flexibility and suitability with strength. This makes them particularly suitable for producing complex part shapes. Furthermore, the low thickness of the UD tape allows the reinforced thermoplastic tube to have only a very small increase in thickness.

[0067] In this specification, "unidirectional (UD) tape" refers to a continuous fiber-reinforced tape containing reinforcing fibers of varying widths arranged in a unidirectional direction. In UD tape, fibers such as glass fiber or carbon fiber are ideally embedded in a thermoplastic matrix, creating entirely new possibilities in part production. Despite their low thickness, UD tapes exhibit a high level of stability and are exceptionally lightweight. Furthermore, UD tapes are readily processable and, depending on the combination and additives present, are flame-retardant. Additionally, UD tapes are collected and stored in rolls, allowing them to be cut to length and width according to the application. Another important characteristic of thermoplastic UD tapes is their recyclability.

[0068] additive

[0069] In addition to one or more POK and / or one or more PEK and / or one or more other thermoplastic polymers, the thermoplastic matrix material used in this invention may contain one or more additives. The one or more additives are selected from compatibilizers, stabilizers, impregnating agents, lubricants, antioxidants, and flame retardants.

[0070] In this specification, "additive" refers to an additive used in thermoplastic polymers that may be present in thermoplastic matrix materials. Additives are generally used to improve the properties of thermoplastic polymers. Examples include compatibilizers and stabilizers.

[0071] In this specification, "compatibility agent" refers to an additive that improves the compatibility between two different thermoplastic polymers. Examples include block or graft copolymers. Suitable compatibility agents may be added to improve the compatibility of POK with other polymers.

[0072] Block copolymers comprise two or more homopolymer subunits linked by covalent bonds. They consist of blocks of different polymeric monomers. Examples include diblock copolymers, which have two distinct blocks (e.g., ~AAAAABBBBB~), and triblock copolymers, which have three distinct blocks (e.g., ~AAAABBBBCCCC~).

[0073] Graft copolymers are segmented copolymers having a linear backbone with one segment and randomly distributed branched segments with another segment. The branched segments are structurally different from the precursor segments that form the linear backbone.

[0074] In this specification, "stabilizer" refers to an additive that helps prevent thermal, oxidative, and chemical degradation of fiber-reinforced thermoplastic composites. Examples include phenolic olefin dicarboxylic acid esters, which provide degradation-resistant stabilization over extended periods and have a reduced tendency to yellowing and improved melt processing properties; aluminum phosphate or aluminum silicate treated with polyethylene glycol, which improves the color stability of the material; and zinc oxide or lead stabilizers, which also improve color stability and the thermal stability and processing temperature range of POK.

[0075] In this specification, "impregnating agent" refers to a material that is compatible with and even soluble in the thermoplastic polymer to be reinforced. Those skilled in the art can select suitable combinations based on general knowledge, and such combinations can also be found in the art.

[0076] Suitable examples of impregnating agents include low molecular weight compounds, such as low molecular weight or oligomeric polyurethanes, polyesters such as unsaturated polyesters, polycaprolactone, polyethylene terephthalate, poly(α-olefins) such as highly branched polyethylene and polypropylene, polyamides such as nylon, and other hydrocarbon resins.

[0077] Preferably, the impregnating agent is non-volatile and / or substantially solvent-free. In the context of this invention, non-volatile means that the impregnating agent has a boiling point or range higher than the temperature at which POK is melt-impregnated onto the reinforcing fiber (about 230-240°C). In the context of this invention, "substantially solvent-free" means that the impregnating agent contains less than 10% by weight of solvent, preferably less than 5% by weight, based on the amount of impregnating agent. In a preferred embodiment, the impregnating agent does not contain any organic solvents.

[0078] In this specification, "lubricant" refers to a material that helps reduce friction between surfaces in contact with each other, which ultimately reduces the heat generated when the surfaces move. Examples are stearamides and stearates, such as EBS, calcium stearate, or magnesium stearate.

[0079] In this specification, "antioxidant" refers to a compound that inhibits oxidation (a chemical reaction capable of generating free radicals). Antioxidant additives may contain one, two, or more phenolic hydroxyl groups. These phenolic antioxidant additives may be sterically hindered phenolic additives. Examples include tris(2,4-di-tert-butylphenyl) phosphite, commercially available as Irgafos 168, and octadecyl-3-[3,5-di-tert-butyl-4-hydroxyphenyl]propionate, available as Irganox 1076 from BASF.

[0080] In this specification, "flame retardant" refers to a material that is activated by the presence of an ignition source and is intended to prevent or slow the further development of ignition through a variety of different physical and chemical methods. They may be added as copolymers during polymerization, or later to the polymer in molding or extrusion processes, or applied as a surface finish. Examples include minerals such as aluminum hydroxide (ATH), magnesium hydroxide (MDH), calcium magnesium carbonate, and magnesia; organohalogen compounds such as organochlorine compounds, organobromine compounds, and polybrominated compounds; organophosphorus compounds such as organophosphates, phosphonates, and hypophosphonates; and organic compounds such as carboxylic acids and dicarboxylic acids.

[0081] Reinforcing fibers

[0082] Reinforcing fibers are dispersed in a thermoplastic material such that they are unidirectionally aligned within the thermoplastic material to obtain a fiber-reinforced thermoplastic UD tape according to a first aspect of the invention. The unidirectionally aligned reinforcing fibers may be selected from glass fibers, carbon fibers, basalt fibers, ceramic fibers, aramid fibers, hemp fibers, flax fibers, sisal fibers, and one or more combinations thereof, preferably glass fibers, carbon fibers, and / or basalt fibers, more preferably glass fibers and / or basalt fibers. This wide range of fiber types that can be used to reinforce thermoplastic matrix materials provides additional flexibility in the manufacturing process and makes it less reliant on one or a few types of fibers.

[0083] The advantage of embodiments comprising at least 20% by weight, preferably at least 40% by weight, and more preferably at least 50% by weight of one or more POK based on a thermoplastic matrix material is that they improve the flame retardancy of the UD tape, thereby enabling the UD tape to be used in applications requiring high flame retardancy.

[0084] In one embodiment, the UD tape consists of unidirectionally arranged reinforcing fibers and a thermoplastic matrix material.

[0085] In one embodiment, the unidirectional reinforcing fibers are basalt fibers. In a specific embodiment, the unidirectional reinforcing fibers are basalt fibers, and the thermoplastic matrix material consists of 100% by weight of one or more POKs, based on the total weight of the thermoplastic matrix material.

[0086] In this specification, "unidirectionally arranged reinforcing fibers" means substantially all fibers, preferably all fibers arranged in a single direction. In this specification, "single direction" refers to the longitudinal direction of the UD belt, i.e., the processing direction in which the UD belt is manufactured.

[0087] In this specification, "parallel-arranged continuous multi-filament strands" refers to a continuous strand of reinforcing fibers that are positioned parallel to each other in the longitudinal direction of the UD tape. The fibers in fiber-reinforced thermoplastic UD tapes are typically supplied in the form of multiple continuous, very long filaments, and can be in the form of strands, rovings, or yarns.

[0088] A filament is a single fiber that reinforces a material. A strand is a bundle of filaments. Yarn is a collection of strands, such as strands twisted together. Roving refers to a package of strands wound into a ball.

[0089] In this specification, "reinforcing fiber" refers to fibers added to a thermoplastic matrix material to improve the strength of the matrix material. In other words, fibers that reinforce the matrix material.

[0090] In this specification, "glass fiber" refers to a material composed of many extremely fine glass fibers. Fine strands of silica-based or other formulated glass are extruded into many fibers with a small diameter suitable for textile processing.

[0091] The most common type of glass fiber is E-glass, which is aluminoborosilicate glass. E-glass contains less than 1% wt% alkali metal oxides and is primarily used for glass-reinforced plastics. Other types of glass used include A-glass (soda lime glass with little or no boron oxide), E-CR-glass (electrochemically resistant; alumino lime silicate with less than 1% wt% alkali metal oxides, exhibiting high acid resistance), C-glass (soda lime glass with high boron oxide content, used for short glass fibers and insulation), D-glass (borosilicate glass, named for its low dielectric constant), R-glass (aluminosilicate glass without MgO and CaO, meeting high mechanical requirements as a reinforcing material), and S-glass (aluminosilicate glass without CaO but with high MgO content, exhibiting high tensile strength).

[0092] In this specification, "carbon fiber" refers to carbon fibers (or alternatively, CF or graphite fibers) that primarily consist of carbon atoms arranged in a graphite structure and have a diameter of approximately 5 to 10 micrometers. Specifically, the graphene planes are oriented parallel to the axis of the carbon fibers. Carbon fibers possess numerous advantages: high stiffness, high tensile strength, high strength-to-weight ratio, high chemical resistance, high temperature resistance, and low thermal expansion. However, they are relatively expensive compared to similar fibers such as glass fibers and basalt fibers.

[0093] In this specification, "basalt fiber" refers to fiber produced by melting basalt and converting its melt into fibers. Basalt fiber, or more specifically, continuous basalt fiber, can be used to produce reinforcing materials and composite products. Basalt fiber is made from pulverized basalt from a single material sourced from carefully selected quarries. Basalt with high acidity (over 46% silica content) and low iron content is considered suitable for fiber production. Unlike other composites, virtually no materials are added during its production: the basalt is simply washed and then melted. Basalt fiber is fire-resistant and non-combustible, making it ideal for use as a reinforcing material in fiber-reinforced thermoplastic UD tapes requiring good flame retardancy.

[0094] Furthermore, when basalt fibers are used to reinforce polymers, the resulting composites exhibit good strength, a wide operating temperature range, good chemical resistance, excellent thermal and sound insulation properties, and low water absorption. Additionally, basalt fibers are easy to process, environmentally friendly, and relatively inexpensive.

[0095] In this specification, "ceramic fiber" refers to fine filaments or threads containing ceramic materials (typically alumina and silicon dioxide) used in lightweight units for electrical, thermal, and sound insulation. Primarily, there are two types of ceramic fibers: oxide ceramic fibers and non-oxide ceramic fibers.

[0096] Oxide ceramic fibers are primarily composed of alumina (Al₂O₃) and alumina-silica (Al₂O₃-SiO₂) mixtures, and are commonly used in high-temperature applications due to their high melting point. Oxide ceramic fibers serve as both insulating and reinforcing materials. The most well-known examples of oxide ceramic fibers include oxides with different properties, such as silica (SiO₂), mullite (3Al₂O₃·2SiO₂), alumina (Al₂O₃), and zirconium oxide (ZrO₂).

[0097] Non-oxide fibers are difficult to produce due to their high melting point and resistance to densification. Oxidation resistance is often their main drawback. An example is silicon carbide-based fibers. Silicon carbide (SiC) fibers possess an excellent combination of high strength, modulus, and thermal stability, including good oxidation resistance at high temperatures and mechanical properties (compressive-tensile strength). Silicon carbide-based fibers are commonly used as continuous fibers in ceramic matrices. This type of ceramic matrix composite (CMC) is used in the hot sections of engines for power applications, etc.

[0098] In this specification, "aramid fiber" refers to aromatic polyamide fiber, a type of heat-resistant and strong synthetic fiber. The chain molecules in the fiber are highly oriented along the fiber axis. Therefore, compared to many other synthetic fibers, a higher proportion of chemical bonds contributes more to the fiber strength. Aramids have very high melting points (>500°C). The "aramid" in the name refers to the aromatic ring containing a six-membered carbon atom. In aramids, these rings are connected via amide bonds, each containing a CO group attached to an NH group. Based on the position of the connecting bonds attached to the ring, aramids are divided into two main types: para-aramids and meta-aramids. The carbon atoms are numbered sequentially around the ring; para-aramids have connecting bonds at positions 1 and 4, while meta-aramids have connecting bonds at positions 1 and 3. That is, in para-aramids, the connecting points are radially opposite each other, while in meta-aramids, the connecting points are two atoms apart.

[0099] In this specification, "fiber hemp" refers to plant fiber that is typically based on the arrangement of cellulose from hemp plants of the genus *Hylocereus* and usually contains lignin.

[0100] In this specification, "flax fiber" refers to plant fiber extracted from the bast or outer skin of the stem of the flax plant (Linum usitatissimum L.).

[0101] In this specification, "sisal fiber" refers to plant fiber derived from the sisal plant, a species of Agave genus.

[0102] Regardless of the reinforcing fiber chosen, the fiber should have a suitable sizing agent applied to it. The sizing agent is selected to protect the fiber during processing, but also to provide good adhesion to the thermoplastic matrix polymer, thereby increasing the strength of the UD tape. The sizing agent on the glass fiber must be selected based on the thermoplastic matrix material. Therefore, for POK matrix materials, using the knowledge of those skilled in the art, the sizing agent for the reinforcing fiber (e.g., glass fiber or carbon fiber) is selected to maximize the strength of the UD tape.

[0103] In this specification, "fiber distribution throughout the tape" refers to the distribution of fibers relative to the longitudinal direction (i.e., the processing direction) across the width of the fiber-reinforced thermoplastic UD tape. A relatively non-uniform distribution may result in undesirable and / or unpredictable structural properties in the UD tape. A relatively uniform distribution means that continuous, unidirectionally aligned fibers are evenly distributed throughout the UD tape, providing a UD tape with desired and / or predictable structural properties. Preferably, the fiber distribution is relatively uniform.

[0104] In this specification, "near the surface" means that the average distance between the top or bottom surface of the fiber-reinforced thermoplastic UD tape and the fibers embedded in the fiber-reinforced thermoplastic UD tape is 5% to 20% of the thickness of the fiber-reinforced thermoplastic UD tape.

[0105] Preferably, the unidirectionally aligned reinforcing fibers have a diameter of 4 to 20 μm and / or a length of at least 100 mm, preferably at least 1000 mm. This specific diameter and / or length of fiber provides sufficient strength for the UD tape along its entire length (in the longitudinal direction). Furthermore, it allows for the fabrication of fiber-reinforced thermoplastic UD tapes with relatively low thickness.

[0106] In another embodiment, the unidirectionally aligned reinforcing fibers are aligned parallel to each other in the longitudinal direction. This increases the strength of the UD tape along its entire length (in the longitudinal direction) while maintaining the flexibility of the UD tape. In this specification, "longitudinal" refers to the processing direction in which the UD tape is manufactured.

[0107] In another embodiment, the UD tape comprises 10 to 74 wt% unidirectionally aligned reinforcing fibers, 25 to 89 wt% thermoplastic matrix material, and 1 to 10 wt% additives, based on the total weight of the UD tape. Higher fiber content in the UD tape results in better performance. However, excessively high fiber content may cause insufficient impregnation and / or mechanical strength problems in the UD tape, such as reduced integrity, leading to tape decomposition.

[0108] Transformation from thermoplastic to thermosetting

[0109] For some applications, it is desirable to convert thermoplastic materials into thermosetting materials. This can be accomplished, for example, through heat-induced crosslinking. Crosslinking of the thermoplastic matrix material is performed after the production (molding or molding) of articles containing fiber-reinforced thermoplastic UD tapes. POK is more suitable for this conversion compared to other thermoplastic polymers such as PEEK and PA-12.

[0110] In one embodiment, the thermoplastic matrix material comprises one or more cross-linked POKs. This is advantageous because the UD tape is resistant to creep, and this allows for use above the melting point of the POK for short periods of time.

[0111] Method for manufacturing fiber-reinforced thermoplastic UD tape

[0112] Various methods exist for preparing fiber-reinforced UD tapes containing POK and / or PEK. Two potential manufacturing methods are melt impregnation and powder dispersion.

[0113] In a method according to an embodiment of the second aspect of the present invention, wherein melt impregnation is used, the method includes the following steps:

[0114] a1) Provides unidirectionally aligned reinforcing fibers such that they are aligned parallel to each other in the longitudinal direction;

[0115] b1) Heating the thermoplastic matrix material to melt it;

[0116] c1) Applying a molten thermoplastic matrix material to the unidirectionally aligned reinforcing fibers; and

[0117] d1) Cooling to obtain fiber-reinforced thermoplastic UD tape.

[0118] Step c1), which involves applying a molten polymer to the fiber, is also known as the impregnation step in a melt impregnation method. The fiber is impregnated with a molten polymer such that it is substantially completely covered by one or more of the polymers. Fiber-reinforced thermoplastic UD tapes can be manufactured by melt extrusion onto unidirectionally aligned reinforcing fibers using a screw extruder.

[0119] In another embodiment of the method according to a second aspect of the invention, wherein powder dispersion is used, the method includes the following steps:

[0120] a2) Provide unidirectional aligned reinforcing fibers such that they are aligned parallel to each other in the longitudinal direction;

[0121] b2) Distribute the thermoplastic matrix material in powder form onto the unidirectionally aligned reinforcing fibers;

[0122] c2) Heating the thermoplastic matrix material to melt it; and

[0123] d2) Cooling to obtain fiber-reinforced thermoplastic UD tape.

[0124] In yet another embodiment of the second aspect of the invention, a multilayer fiber-reinforced thermoplastic UD tape (or: UD tape laminate) is manufactured, comprising two or more layers of UD tape. The method includes the following additional steps:

[0125] e) Stack at least two layers of fiber-reinforced thermoplastic UD tape together;

[0126] f) Heating the at least two layers to bring the thermoplastic matrix material into a molten state; and

[0127] g) Cooling to obtain a multi-layer fiber-reinforced thermoplastic UD tape.

[0128] In this specification, "multilayer fiber-reinforced thermoplastic UD tape" or "UD tape laminate" refers to a final UD tape containing two or more layers of fiber-reinforced thermoplastic UD tape. This allows for the fabrication of thicker reinforcing layers when needed.

[0129] use

[0130] In an embodiment of the third aspect of the invention, the fiber-reinforced thermoplastic UD tape prepared according to the first aspect or according to the second aspect is used to transport fluids (e.g., hydrocarbon fluids). In this specification, "fluid" refers to liquids (e.g., water) and gases (e.g., butane).

[0131] application

[0132] In this specification, "Reinforced Thermoplastic Pipe (RTP)" refers to a multi-layered pipe made of reinforced thermoplastic material. Other names used are flexible composite pipe, thermoplastic composite pipe, flexible flow line, flexible pipeline pipe, windable reinforced plastic pipeline pipe, flexible reinforced pipe, reinforced pipeline pipe, or windable composite material. For marine applications, other names include marine flexible pipe or flexible umbilical riser. According to the invention, the RTP comprises at least the following layers from its center to its periphery: a thermoplastic inner liner, a reinforcing layer, and a thermoplastic outer sheath. The outer sheath provides protection for the reinforcing UD tape winding against external mechanical damage.

[0133] In this specification, "UD tape winding" refers to a fiber-reinforced thermoplastic UD tape disposed on (around) a thermoplastic liner. "Fiber-reinforced thermoplastic UD tape" refers to a thermoplastic UD tape provided with fibers that reinforce the thermoplastic UD tape.

[0134] In this specification, "thermoplastic liner" refers to the inner layer of an RTP made of thermoplastic materials (e.g., PVDF, PPS, POK, PA-11, PA-12, PE, and PP). To prevent damage to the RTP, the thermoplastic liner must be made of a material resistant to chemicals (e.g., gaseous or liquid hydrocarbons transported through the RTP). Preferably, the thermoplastic liner is also heat-resistant. "Heat" refers to the temperature of the fluid flowing through the RTP, which is above 85°C, preferably above 90°C, and more preferably above 100°C.

[0135] In this specification, "reinforcing layer" refers to the layer formed by fiber-reinforced thermoplastic UD tape between the thermoplastic inner liner and the thermoplastic outer sheath. The reinforcing layer provides additional strength to the pipe, hence the name "Reinforced Thermoplastic Pipe (RTP)".

[0136] In this specification, "thermoplastic outer sheath" refers to the outer sheath, layer, or cover of the RTP made of thermoplastic materials (e.g., PDVF, PPS, POK, PA-11, PA-12, PE, and PP). To prevent damage to the RTP, the thermoplastic outer sheath must be made of an impact-resistant material that is resistant to one or more of the following: ultraviolet light, high temperature, and water. "High temperature" refers to the temperature of the fluid flowing through the RTP, which is above 85°C, preferably above 90°C, and more preferably above 100°C.

[0137] In addition, the thermoplastic outer sheath must be made of a sufficiently strong material to prevent damage from the surrounding environment.

[0138] Detailed description of the attached figures

[0139] Figure 1 A cross-sectional view is shown of a reinforced thermoplastic tube (RTP) 1 comprising a thermoplastic inner liner 5, a reinforcing layer 7, and a thermoplastic outer sheath 9, from the center 3 (i.e., the interior of the RTP) to the periphery. The reinforcing layer 7 comprises a fiber-reinforced thermoplastic UD tape according to a first aspect of the invention or a fiber-reinforced thermoplastic UD tape prepared according to a second aspect of the invention. Figure 1 The RTP shown can be used to transport hydrocarbon fluids.

[0140] Figure 2a A method 101 for manufacturing a fiber-reinforced thermoplastic UD tape according to the present invention is shown. The method includes the steps of:

[0141] Step a1) or a2) In method 101, unidirectionally aligned reinforcing fibers are provided by taking individual fiber strands 103 from one or more spools and spreading them out 105 using a fiber diffuser, such that the unidirectionally aligned fibers are aligned parallel to each other in the longitudinal direction.

[0142] Steps b1) and c1) In the case of melt impregnation, the thermoplastic matrix material is first heated to 107a to melt it, and then applied to unidirectionally aligned fibers in the molten state to obtain a hot fiber-reinforced thermoplastic UD strip. In step c1), the hot fiber-reinforced thermoplastic UD strip is extruded and pulled by hot rollers, so that lateral pressure is applied to the UD strip;

[0143] Steps b2) and c2) In the case of powder dispersion, the thermoplastic matrix material is first dispersed in powder form 109b onto unidirectionally aligned fibers, and then the powder-dispersed unidirectionally aligned fibers are heated 107b to melt the thermoplastic matrix material, thereby obtaining a hot fiber-reinforced thermoplastic UD tape. In step c2), the hot fiber-reinforced thermoplastic UD tape is extruded and pulled by hot rollers, so that lateral pressure is applied to the UD tape;

[0144] Step d1) or d2) After the steps of heating 107a and applying 109a or spreading 109b and heating 107b, the hot fiber-reinforced thermoplastic UD tape obtained by pulling the hot fiber-reinforced thermoplastic UD tape through / through the roller is cooled by 111 to obtain the fiber-reinforced thermoplastic UD tape according to the invention and wound 113 on a reel.

[0145] Figure 2bThe above method is shown (and in Figure 2a The method steps (shown in the diagram) include additional steps:

[0146] Step e) After the cooling step 111, two fiber-reinforced thermoplastic UD tapes are stacked together 115.

[0147] Step f) After stacking 115, the stacked fiber-reinforced thermoplastic UD strips are heated 117 to bring the thermoplastic matrix material into a molten state. In step f), the heated stacked fiber-reinforced thermoplastic UD strips are extruded and pulled by hot rollers, so that lateral pressure is applied to the stack of UD strips;

[0148] Step g) After heating step 117, the hot fiber-reinforced thermoplastic UD tape stack obtained in step 119 is cooled by pulling the hot fiber-reinforced thermoplastic UD tape stack through / through rollers to obtain a multilayer fiber-reinforced thermoplastic UD tape.

[0149] Example

[0150] The invention is further illustrated by the following embodiments, which are merely illustrative and not intended to limit the invention. Those skilled in the art will readily recognize that various non-critical parameters can be changed or modified to produce substantially the same results.

[0151] Example 1

[0152] Fiber-reinforced thermoplastic UD tapes are manufactured by melt impregnation.

[0153] First, a glass fiber tow (CPIC 4303) is provided, wherein the fiber has a fiber diameter between 10 and 20 μm (nominal diameter of 13 μm) and a tow diameter between 3 and 10 mm, or has a g / m² of 1200 g / m². 2 The fiber count is determined. The tow is spread into a spread fiber layer such that the glass fibers are unidirectionally aligned parallel in the longitudinal direction, i.e., the processing direction. Simultaneously, a molten thermoplastic matrix material is prepared by heating a polymer resin to a molten state. The polymer resin (HyosungPOK_M930F) has a melt mass flow rate (MFR) of 220 g / 10 min, determined according to ASTM D1238-23 at 240°C with a 2.16 kg load. The molten resin (by extrusion) is applied to the unidirectionally aligned reinforcing fibers at a temperature of 280°C, such that the fibers are completely covered by the molten thermoplastic matrix material, in other words, impregnated. The unidirectionally aligned reinforcing fibers covered with molten resin are then extruded and pulled through rollers, thereby applying transverse pressure to the reinforcing fibers to obtain a hot, fiber-reinforced thermoplastic UD tape.

[0154] Third, the hot fiber-reinforced thermoplastic UD tape is cooled at 40°C using cold rollers to obtain fiber-reinforced thermoplastic UD tape. Finally, the fiber-reinforced thermoplastic UD tape is wound onto a reel for easy transport.

[0155] Analysis of UD band

[0156] The fiber-reinforced thermoplastic UD tape obtained in Example 1 has a fiber weight content of 59.59%, which corresponds to a fiber volume content of 41% based on the total weight of the fiber-reinforced thermoplastic UD tape. The properties of the fiber-reinforced thermoplastic UD tape are given in Table 1.

[0157] Table 1. Comparison of the UD bands of the present invention

[0158]

[0159] There is no official testing standard for tensile testing of composite tapes. This test is based on ASTM D3039, which is used for tensile testing of laminates. Sample size: 250 mm × 15 mm; Test speed: 2 mm / min.

[0160] Lamination conditions: Temperature: 230℃; Pressure: 0.75MPa; Preheating time: 10 minutes; Heating time: 10 minutes; Cooling time: 20 minutes.

[0161] As can be seen from Table 1, Example 1 exhibits tensile strength, flexural strength, flexural modulus, and ILSS comparable to UD tapes made using thermoplastic matrix materials based on conventional polymers such as PEEK or PEKK. However, the relatively high melting point of POK (MFR of 220 g / 10 min) makes it suitable for use in RTPs transporting hot fluids such as hydrocarbons. In contrast, PE and PP have excessively low melting points, making these materials less suitable for use in RTPs transporting hot fluids. Furthermore, the presented data are found to be substantially similar to those of fiber-reinforced thermoplastic UD tapes known in the art, such as PEK-based UD tapes.

[0162] The inventors have observed that the impregnation quality, fiber spreading, tensile strength, and other mechanical properties are sufficiently good. Furthermore, the inventors have observed that when using the matrix material of the present invention compared to polyolefins, the mechanical properties of the thermoplastic matrix material are better maintained in the final product.

[0163] Furthermore, the results presented above demonstrate that fiber-reinforced thermoplastic UD tapes using POK as the thermoplastic matrix material can be manufactured by melt impregnation, and it also strongly suggests that UD tapes can also be prepared by powder dispersion.

[0164] This suggests that the relatively inexpensive POK is a very suitable alternative to the more expensive PEK, such as PEEK.

[0165] Modifications and additions to the above methods and embodiments will be clearly visible to those skilled in the art and are covered by the scope of the appended claims. The embodiments and examples of the first aspect of the invention may also be applied to the second or other aspects of the invention.

[0166] Those skilled in the art will understand and implement other variations of the disclosed embodiments, and this will be achieved by studying the accompanying drawings, description, and appended claims. In the claims, the word "comprising / including" does not exclude other elements or steps, and the indefinite article "an" or "a" does not exclude multiple / a kind. The fact that certain measures are described in mutually different dependent claims does not mean that combinations of these measures cannot be advantageously used. Any reference signs in the claims should not be construed as limiting their scope. The scope of the invention is defined by the appended claims. One or more objects of the invention are achieved by the appended claims.

[0167] Terms and Conditions

[0168] 1. A fiber-reinforced thermoplastic unidirectional (UD) tape comprising a thermoplastic matrix material and unidirectionally arranged reinforcing fibers dispersed within the thermoplastic matrix material, wherein the thermoplastic matrix material comprises one or more aliphatic polyketides (POKs).

[0169] 2. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the thermoplastic matrix material further comprises one or more aromatic polyketides (PEKs).

[0170] 3. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the thermoplastic matrix material comprises POK and optionally one or more PEKs, wherein the POK is selected from copolymers of monomers comprising carbon monoxide and ethylene, and terpolymers of monomers comprising carbon monoxide, ethylene and a second hydrocarbon comprising at least three carbon atoms, the second hydrocarbon being particularly an α-olefin such as propylene, butene, hexene, octene or dodecene, and the PEK is selected from polyaryletherketones (PAEKs) such as polyetheretherketone (PEEK) and polyetherketoneketone (PEKK).

[0171] 4. The fiber-reinforced thermoplastic UD tape as described in Clause 1, having a width of at least 2 cm.

[0172] 5. The fiber-reinforced thermoplastic UD tape as described in Clause 1, having a thickness of 0.10 to 0.80 mm.

[0173] 6. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the thermoplastic matrix material comprises 20 to 100% by weight of one or more POK, based on the total weight of the thermoplastic matrix material.

[0174] 7. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the thermoplastic matrix material comprises 25 to 90% by weight of one or more POK, based on the weight of the thermoplastic matrix material.

[0175] 8. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the thermoplastic matrix material further comprises one or more other polymers selected from polyamides, polyolefins, polyphenylene sulfide (PPS), polyethersulfone (PES), and polyetherimide (PEI).

[0176] 9. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the thermoplastic matrix material further comprises one or more additives selected from compatibilizers, stabilizers, impregnating agents, lubricants, antioxidants and flame retardants.

[0177] 10. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the POK has:

[0178] - A melt mass flow rate (MFR) of at least 60 g / 10 min, determined according to ASTM D1238-23 at 240°C with a 2.16 kg load; and / or

[0179] - Viscosity of up to 100 Pa·s, measured at 240°C according to ISO 6721.

[0180] 11. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the POK has:

[0181] - A melt mass flow rate (MFR) of at least 100 g / 10 min, determined according to ASTM D1238-23 at 240°C with a 2.16 kg load; and / or

[0182] - Viscosity of up to 100 Pa·s, measured at 240°C according to ISO 6721.

[0183] 12. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the POK has:

[0184] - Melt mass flow rate (MFR) of 60-200 g / 10 min determined according to ASTM D1238-23 at 240°C with a 2.16 kg load; and / or

[0185] - Viscosity of up to 100 Pa·s, measured at 240°C according to ISO 6721.

[0186] 13. The fiber-reinforced thermoplastic UD tape as described in Clause 1, wherein the UD tape comprises 10-74% by weight of unidirectionally arranged reinforcing fibers, 25-89% by weight of thermoplastic matrix material and 1-10% by weight of additives, based on the total weight of the UD tape.

[0187] 14. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the unidirectionally arranged reinforcing fibers are selected from glass fibers, carbon fibers, basalt fibers, ceramic fibers, aramid fibers, hemp fibers, flax fibers, sisal fibers, and one or more combinations thereof.

[0188] 15. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the unidirectionally arranged reinforcing fibers are glass fibers, carbon fibers and / or basalt fibers.

[0189] 16. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the unidirectionally arranged reinforcing fibers are glass fibers and / or basalt fibers.

[0190] 17. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the unidirectionally arranged reinforcing fibers have a diameter of 4-20 μm.

[0191] 18. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the unidirectionally arranged reinforcing fibers have a length of at least 100 mm, preferably at least 1000 mm.

[0192] 19. The fiber-reinforced thermoplastic UD tape according to Clause 1, wherein the unidirectional reinforcing fibers are arranged parallel to each other in the longitudinal direction.

[0193] 20. The fiber-reinforced thermoplastic UD tape as described in Clause 1, wherein the UD tape comprises one or more cross-linked POKs.

[0194] 21. A method of manufacturing a fiber-reinforced thermoplastic UD tape according to Clause 1, the method comprising:

[0195] - Melt impregnation is achieved by contacting unidirectionally aligned reinforcing fibers with a molten thermoplastic matrix material; or

[0196] - Powder dispersion is achieved by applying a thermoplastic matrix material in powder form onto unidirectionally arranged reinforcing fibers.

[0197] 22. A reinforced thermoplastic tube (RTP) comprising, from its center to its outer periphery, a thermoplastic inner liner, a reinforcing layer, and a thermoplastic outer sheath, the reinforcing layer comprising a fiber-reinforced thermoplastic UD tape as described in Clause 1 or a fiber-reinforced thermoplastic UD tape prepared according to the method described in Clause 21.

[0198] 23. A fiber-reinforced thermoplastic unidirectional (UD) tape comprising a thermoplastic matrix material and unidirectionally arranged reinforcing fibers dispersed within the thermoplastic matrix material, wherein the thermoplastic matrix material comprises one or more aliphatic polyketides (POKs).

[0199] 24. The fiber-reinforced thermoplastic UD tape as described in Clause 23, wherein the thermoplastic matrix material further comprises one or more aromatic polyketides (PEKs).

[0200] 25. The fiber-reinforced thermoplastic UD tape according to Clause 23, wherein the thermoplastic matrix material comprises POK and optionally one or more PEKs, the POK being selected from copolymers of monomers comprising carbon monoxide and ethylene, and terpolymers of monomers comprising carbon monoxide, ethylene and a second hydrocarbon comprising at least three carbon atoms, the second hydrocarbon being particularly an α-olefin such as propylene, butene, hexene, octene or dodecene, the PEK being selected from polyaryletherketone (PAEK) such as polyetheretherketone (PEEK) and polyetherketoneketone (PEKK), and / or wherein the unidirectionally arranged reinforcing fibers are selected from glass fibers, carbon fibers, basalt fibers, ceramic fibers, aramid fibers, hemp fibers, flax fibers, sisal fibers and one or more combinations thereof, preferably glass fibers, carbon fibers and / or basalt fibers, more preferably glass fibers and / or basalt fibers.

[0201] 26. The fiber-reinforced thermoplastic UD tape according to Clause 23, wherein the thermoplastic matrix material comprises 20-100% by weight, preferably 25-90% by weight, more preferably at least 60% by weight, and most preferably at least 70% by weight of one or more POK, based on the total weight of the thermoplastic matrix material.

[0202] 27. The fiber-reinforced thermoplastic UD tape according to Clause 23, wherein the thermoplastic matrix material further comprises one or more other polymers selected from polyamides, polyolefins, polyphenylene sulfide (PPS), polyethersulfone (PES), and polyetherimide (PEI).

[0203] 28. The fiber-reinforced thermoplastic UD tape according to Clause 23, wherein the thermoplastic matrix material further comprises one or more additives selected from compatibilizers, stabilizers, impregnating agents, lubricants, flame retardants and fiber bonding reinforcing agents.

[0204] 29. The fiber-reinforced thermoplastic UD tape as described in Clause 23, wherein the UD tape comprises 10-74% by weight of unidirectionally arranged reinforcing fibers, 25-89% by weight of thermoplastic matrix material and 1-10% by weight of additives, based on the total weight of the UD tape.

[0205] 30. The fiber-reinforced thermoplastic UD tape according to Clause 23, wherein the unidirectional reinforcing fibers are arranged parallel to each other in the longitudinal direction.

[0206] 31. The fiber-reinforced thermoplastic UD tape as described in Clause 23, wherein the UD tape comprises one or more cross-linked POKs.

[0207] 32. A method of manufacturing a fiber-reinforced thermoplastic UD tape according to Clause 23, the method comprising:

[0208] - Melt impregnation is achieved by contacting unidirectionally aligned reinforcing fibers with a molten thermoplastic matrix material; or

[0209] - Powder dispersion is achieved by applying a thermoplastic matrix material in powder form onto unidirectionally arranged reinforcing fibers.

[0210] 33. A reinforced thermoplastic tube (RTP) comprising, from its center to its outer periphery, a thermoplastic inner liner, a reinforcing layer, and a thermoplastic outer sheath, the reinforcing layer comprising a fiber-reinforced thermoplastic UD tape as described in Clause 23 or a fiber-reinforced thermoplastic UD tape prepared according to the method described in Clause 32.

Claims

1. Fiber-reinforced thermoplastic unidirectional (UD) tape comprising a thermoplastic matrix material and unidirectionally arranged reinforcing fibers dispersed within the thermoplastic matrix material, wherein the thermoplastic matrix material comprises one or more aliphatic polyketones (POK).

2. The fiber-reinforced thermoplastic UD tape according to claim 1, wherein the thermoplastic matrix material further comprises one or more aromatic polyketones (PEK).

3. The fiber-reinforced thermoplastic UD tape according to claim 1 or 2, wherein the thermoplastic matrix material comprises one or more POK and optionally one or more PEK, the POK being selected from copolymers comprising monomers of carbon monoxide and ethylene, and terpolymers comprising monomers of carbon monoxide, ethylene and a second hydrocarbon of at least three carbon atoms, the second hydrocarbon being in particular an a-olefin such as propylene, butene, hexene, octene or dodecene, the PEK being selected from polyaryletherketone (PAEK) such as polyether ether ketone (PEEK) and polyether ketone ketone (PEKK).

4. The fiber-reinforced thermoplastic UD tape according to any one of the preceding claims, having a width of at least 2 cm and / or having a thickness of 0.10 to 0.80 mm, preferably 0.15 to 0.50 mm, more preferably 0.25 to 0.35 mm.

5. The fiber-reinforced thermoplastic UD tape according to any one of the preceding claims, wherein the thermoplastic matrix material comprises 20 to 100 wt.%, preferably 25 to 90 wt.%, more preferably at least 60 wt.%, most preferably at least 70 wt.% of the one or more POK, based on the total weight of the thermoplastic matrix material.

6. The fiber-reinforced thermoplastic UD tape according to any one of the preceding claims, wherein the thermoplastic matrix material further comprises one or more further polymers selected from polyamides, polyolefins, polyphenylene sulfide (PPS), polyether sulfone (PES) and polyetherimide (PEI).

7. The fiber-reinforced thermoplastic UD tape according to any one of the preceding claims, wherein the thermoplastic matrix material further comprises one or more additives selected from compatibilizers, stabilizers, impregnating agents, lubricants, antioxidants and flame retardants.

8. The fiber-reinforced thermoplastic UD tape according to any one of the preceding claims, wherein the one or more POK has: - a melt mass flow rate (MFR) of at least 60 g / 10 min, preferably at least 100 g / 10 min, more preferably at least 150 g / 10 min, most preferably 60-200 g / 10 min, determined according to ASTM D1238-23 at 240 °C with a 2.16 kg load; and / or - a viscosity of at most 100 Pa s, preferably at most 70 Pa s, determined according to ISO 6721 at 240 °C.

9. The fiber-reinforced thermoplastic UD tape according to any one of the preceding claims, wherein the UD tape comprises 10-74 wt.% of the unidirectionally arranged reinforcing fibers, 25-89 wt.% of the thermoplastic matrix material and 1-10 wt.% of the additives, based on the total weight of the UD tape.

10. The fiber-reinforced thermoplastic UD tape according to any one of the preceding claims, wherein the unidirectionally arranged reinforcing fibers are selected from the group consisting of glass fibers, carbon fibers, basalt fibers, ceramic fibers, aramid fibers, hemp fibers, flax fibers, sisal fibers, and one or more combinations thereof, preferably glass fibers, carbon fibers and / or basalt fibers, more preferably glass fibers and / or basalt fibers.

11. The fiber-reinforced thermoplastic UD tape according to any one of the preceding claims, wherein the unidirectionally arranged reinforcing fibers have a diameter of 4-20 pm and / or a length of at least 100 mm, preferably at least 1000 mm.

12. The fiber-reinforced thermoplastic UD tape according to any one of the preceding claims, wherein the unidirectionally arranged reinforcing fibers are arranged parallel to each other in the longitudinal direction.

13. The fiber-reinforced thermoplastic UD tape according to any one of the preceding claims, wherein the UD tape comprises one or more crosslinked POKs.

14. A method of manufacturing the fiber-reinforced thermoplastic UD tape according to any one of the preceding claims, the method comprising: - melt impregnation by contacting the unidirectionally arranged reinforcing fibers with a molten thermoplastic matrix material; or - powder spreading by applying the thermoplastic matrix material in powder form on the unidirectionally arranged reinforcing fibers.

15. Use of the fiber-reinforced thermoplastic UD tape according to any one of claims 1-13 or manufactured according to the method of claim 14 for a reinforced thermoplastic pipe (RTP), preferably for the transport of fluids.

16. A reinforced thermoplastic pipe (RTP) comprising from center to periphery a thermoplastic inner liner, a reinforcement layer and a thermoplastic outer jacket, the reinforcement layer comprising the fiber-reinforced thermoplastic UD tape according to any one of claims 1-13 or manufactured according to the method of claim 14.

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