A hollow lineal profile (16) formed from a continuous fiber reinforced ribbon (“CFRT”) that contains a plurality of continuous fibers embedded within a first thermoplastic polymer matrix (6). To enhance the tensile strength of the profile, the continuous fibers are aligned within the ribbon in a sub
A hollow lineal profile (16) formed from a continuous fiber reinforced ribbon (“CFRT”) that contains a plurality of continuous fibers embedded within a first thermoplastic polymer matrix (6). To enhance the tensile strength of the profile, the continuous fibers are aligned within the ribbon in a substantially longitudinal direction (e.g., the direction of pultrusion). In addition to continuous fibers, the hollow profile of the present invention also contains a plurality of long fibers that may be optionally embedded within a second thermoplastic matrix to form a long fiber reinforced thermoplastic (“LFRT”) (4). The long fibers may be incorporated into the continuous fiber ribbon or formed as a separate layer of the profile. Regardless, at least a portion of the long fibers are oriented at an angle (e.g., 90°) to the longitudinal direction to provide increased transverse strength to the profile.
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1. A hollow lineal profile comprising: a consolidated ribbon that contains a plurality of continuous fibers embedded within a first thermoplastic matrix and substantially oriented in a longitudinal direction;a plurality of long fibers, at least a portion of which are oriented at an angle relative to
1. A hollow lineal profile comprising: a consolidated ribbon that contains a plurality of continuous fibers embedded within a first thermoplastic matrix and substantially oriented in a longitudinal direction;a plurality of long fibers, at least a portion of which are oriented at an angle relative to the longitudinal direction, wherein the ratio of the weight of the continuous fibers to the ratio of the weight of the long fibers is from about 0.2 to about 10;wherein the long fibers are included within a first layer of the profile and the ribbon is included within a second layer of the profile, the first layer being positioned adjacent to the second layer; andwherein the profile exhibits a flexural modulus and maximum flexural strength in the transverse direction, wherein the ratio of the flexural modulus to the maximum flexural strength is from about 50 to about 2200. 2. The hollow lineal profile of claim 1, wherein the ratio of the weight of the continuous fibers to the ratio of the weight of the long fibers is from about 0.5 to about 4. 3. The hollow lineal profile of claim 1, wherein the ratio is from about 200 to about 800. 4. The hollow lineal profile of claim 1, wherein the profile exhibits a flexural modulus of about 2 Gigapascals or more. 5. The hollow lineal profile of claim 1, wherein the profile exhibits a flexural modulus of from about 4 to about 20 Gigapascals. 6. The hollow lineal profile of claim 1, wherein the profile exhibits a maximum flexural strength of about 12 Megapascals or more. 7. The hollow lineal profile of claim 1, wherein the profile exhibits a maximum flexural strength of from about 15 to about 50 Megapascals. 8. The hollow lineal profile of claim 1, wherein the continuous fibers, the long fibers, or both, include glass fibers, carbon fibers, or a combination of glass and carbon fibers. 9. The hollow lineal profile of claim 1, wherein the first thermoplastic polymer matrix includes a polyolefin, polyether ketone, polyetherimide, polyarylene ketone, liquid crystal polymer, polyarylene sulfide, fluoropolymer, polyacetal, polyurethane, polycarbonate, styrenic polymer, polyester, polyamide, or a combination thereof. 10. The hollow lineal profile of claim 1, wherein the long fibers are embedded within a second thermoplastic matrix. 11. The hollow lineal profile of claim 10, wherein the second thermoplastic polymer matrix includes a polyolefin, polyether ketone, polyetherimide, polyarylene ketone, liquid crystal polymer, polyarylene sulfide, fluoropolymer, polyacetal, polyurethane, polycarbonate, styrenic polymer, polyester, polyamide, or a combination thereof. 12. The hollow lineal profile of claim 1, wherein the ribbon has a void fraction of about 2% or less. 13. The hollow lineal profile of claim 1, wherein about 10% or more of the long fibers are oriented at an angle relative to the longitudinal direction. 14. The hollow lineal profile of claim 1, wherein the profile has a generally rectangular shape. 15. The hollow lineal profile of claim 1, wherein the first layer forms an inner layer of the hollow profile. 16. The hollow lineal profile of claim 15, wherein the second layer extends substantially around the periphery of the first layer. 17. The hollow lineal profile of claim 15, wherein the second layer is located in one or more discrete regions adjacent to the first layer. 18. The hollow lineal profile of claim 1, wherein the second layer forms an inner layer of the hollow profile. 19. The hollow lineal profile of claim 18, wherein the first layer extends substantially around the periphery of the second layer. 20. The hollow lineal profile of claim 18, wherein the first layer is located in one or more discrete regions adjacent to the second layer. 21. The hollow lineal profile of claim 1, wherein the cross-section shape of the profile is substantially the same along the entire length of the profile. 22. The hollow lineal profile of claim 1, further comprising a capping layer that defines an external surface of the profile. 23. A hollow lineal profile comprising: a consolidated ribbon that contains a plurality of continuous fibers embedded within a first thermoplastic matrix and substantially oriented in a longitudinal direction;a plurality of long fibers incorporated into the consolidated ribbon, at least a portion of which are oriented at an angle relative to the longitudinal direction, wherein the ratio of the weight of the continuous fibers to the ratio of the weight of the long fibers is from about 0.2 to about 10; andwherein the profile exhibits a flexural modulus and maximum flexural strength in the transverse direction, wherein the ratio of the flexural modulus to the maximum flexural strength is from about 50 to about 2200. 24. The hollow lineal profile of claim 23, wherein the ratio of the weight of the continuous fibers to the ratio of the weight of the long fibers is from about 0.5 to about 4. 25. The hollow lineal profile of claim 23, wherein the ratio is from about 200 to about 800. 26. The hollow lineal profile of claim 23, wherein the profile exhibits a flexural modulus of about 2 Gigapascals or more. 27. The hollow lineal profile of claim 23, wherein the profile exhibits a maximum flexural strength of about 12 Megapascals or more. 28. The hollow lineal profile of claim 23, wherein the long fibers are embedded within a second thermoplastic matrix. 29. The hollow lineal profile of claim 23, wherein the ribbon has a void fraction of about 2% or less. 30. The hollow lineal profile of claim 23, wherein about 10% or more of the long fibers are oriented at an angle relative to the longitudinal direction. 31. The hollow lineal profile of claim 23, further comprising a capping layer that defines an external surface of the profile.
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