POLYETHYLENE COMPOSITE MEMBERS AND METHODS FOR FORMING THE SAME

1 . A composite member, comprising:

a base member, the base member formed from a polyethylene; and

a tape bonded to the base member, the tape formed from a fiber reinforced thermoplastic material, the fiber reinforced thermoplastic material comprising a plurality of fibers dispersed in a polyethylene resin.

2 . The composite member of claim 1 , wherein the polyethylene forming the base member is one of a high molecular weight polyethylene, a very-high molecular weight polyethylene, or an ultra-high molecular weight polyethylene.

3 . The composite member of claim 1 , wherein the polyethylene resin is a high density polyethylene.

4 . The composite member of claim 1 , wherein the fibers are one of glass fibers, carbon fibers or aramid fibers.

5 . The composite member of claim 1 , wherein the fibers are continuous fibers.

6 . The composite member of claim 5 , wherein the continuous fibers are generally unidirectional.

7 . The composite member of claim 1 , wherein the tape is bonded to an outer surface of the base member.

8 . The composite member of claim 1 , wherein the tape is disposed within the base member.

9 . The composite member of claim 1 , wherein the tape provides local reinforcement to the base member.

10 . The composite member of claim 1 , wherein the base member is a semi-finished good.

11 . The composite member of claim 1 , wherein the tape is a plurality of tapes.

12 . The composite member of claim 11 , wherein at least a portion of the plurality of tapes are arranged as a plurality of tape layers.

13 . A method for forming a composite member, the method comprising:

forming a base member from a polyethylene material; and

bonding a tape to the base member, the tape formed from a fiber reinforced thermoplastic material, the fiber reinforced thermoplastic material comprising a plurality of fibers dispersed in a thermoplastic resin.

14 . The method of claim 13 , wherein the bonding step comprises:

positioning the tape on an outer surface of the base member; and

heating the tape and base member.

15 . The method of claim 13 , wherein the bonding step comprises:

positioning the tape on an outer surface of the base member; and

applying a generally constant pressure to the tape and base member.

16 . The method of claim 13 , wherein the forming step and the bonding step occur simultaneously, and further comprising the steps of:

positioning the tape in a mold; and

introducing the polyethylene material into the mold.

17 . The method of claim 16 , wherein the polyethylene material is a polyethylene powder.

18 . The method of claim 13 , wherein the bonding step comprises welding the tape to the base member.

19 . The method of claim 18 , wherein the welding step comprises applying ultrasonic vibrations to the tape and the base member.

20 . The method of claim 13 , further comprising the step of forming the tape from the fiber reinforced thermoplastic material, wherein the forming step comprises:

flowing the polyethylene resin through a manifold assembly of a die, the manifold assembly comprising a plurality of branched runners;

coating at least one fiber roving with the resin, the at least one fiber roving comprising the plurality of fibers; and

traversing the coated roving through an impregnation zone of the die to impregnate the roving with the resin.

21 . The method of claim 13 , wherein the polyethylene forming the base member is one of a high molecular weight polyethylene, a very-high molecular weight polyethylene, or an ultra-high molecular weight polyethylene.

22 . The method of claim 13 , wherein the thermoplastic resin is a polyethylene resin.

23 . The method of claim 22 , wherein the polyethylene resin is a high density polyethylene.

24 . The method of claim 13 , wherein the fibers are one of glass fibers, carbon fibers or aramid fibers.