Controlled geometry composite micro pellets for use in compression molding

Composite pellets produced by a method comprising:

• extruding a blended mixture comprising molten thermoplastic resin and reinforcing fibers through a die orifice with a cross-sectional shape having a rectangular envelope with an aspect ratio of about 1.5:1 to 5:1, wherein the reinforcing fibers have a largest dimension which is no more than about 90% of a width of the die orifice;
• and cutting the extruded mixture to form pellets having an axial length to cross-sectional width ratio of about 0.25:1 to 5:1;
• wherein the pellet has at least three substantially planar faces;
• and
• the thermoplastic polymeric resin comprises polyetheretherketone, polyetherketoneetherketoneketone, polyetherimide, polyethersulfone, polyphthalamide or a combination thereof.

Composite pellets produced by a method comprising:

• extruding a blended mixture comprising molten thermoplastic polymeric resin and reinforcing fibers through a die orifice with a cross-sectional shape having a rectangular envelope with an aspect ratio of about 1.5:1 to 5:1, wherein the reinforcing fibers have a largest dimension which is no more than about 90% of a width of the die orifice;
• and
• cutting the extruded mixture to form pellets having an axial length to cross-sectional width ratio of about 0.25:1 to 5:1;
• wherein the thermoplastic polymeric resin comprises oxyphenoxyphenoxybenzoyl polyetheretherketone;
• and the reinforcing particulates comprise milled and/or chopped carbon fibers.

Composite pellets produced by a method comprising:

• extruding a blended mixture comprising molten thermoplastic resin and reinforcing fibers through a die orifice with a cross-sectional shape having a rectangular envelope with an aspect ratio of about 1.5:1 to 5:1, wherein the reinforcing fibers have a largest dimension which is no more than about 90% of a width of the die orifice;
• and
• cutting the extruded mixture to form pellets having an axial length to cross-sectional width ratio of about 0.25:1 to 5:1;
• wherein the reinforcing fibers comprise milled and/or chopped glass fibers, milled and/or chopped carbon fibers, or a combination thereof;
• the thermoplastic polymeric resin comprises polyarylether/arylketone.

Composite pellets produced by a method comprising:

• (a) extruding a blended mixture comprising molten thermoplastic polymeric resin and reinforcing fibers through a die orifice with a cross-sectional shape having a rectangular envelope with an aspect ratio of about 1.5:1 to 5:1, wherein the reinforcing fibers have a largest dimension which is no more than about 90% of a width of the die orifice;
• and (b) cutting the extruded mixture to form pellets having an axial length to cross-sectional width ratio of about 0.25:1 to 5:1;
• wherein the composite pellets comprise about 30 to 90 wt. % of the thermoplastic polymeric resin;
• and about 10 to 70 wt. % of the reinforcing fibers dispersed in the thermoplastic polymeric resin;
• and
• the thermoplastic polymeric resin comprises polyarylether/arylketone.

A method of producing composite pellets comprising:

• blending a mixture comprising reinforcing fibers and molten thermoplastic polymeric resin;
• extruding the blended mixture through a die orifice with a cross sectional shape having a rectangular envelope with an aspect ratio of about 1.5:1 to 5:1, wherein the reinforcing fibers have a largest dimension which is no more than about 90% of a largest dimension of the die orifice;
• and
• cutting the extruded mixture to form pellets, each pellet having an axial length to cross sectional width ratio of about 0.25:1 to 5:1;
• wherein the reinforcing fibers comprise milled and/or chopped glass fibers, milled and/or chopped carbon fibers, or a combination thereof;
• and
• the thermoplastic polymeric resin comprises polyarylether/arylketone.