SYSTEM FOR PRODUCING A FULLY IMPREGNATED THERMOPLASTIC PREPREG

摘要

According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.

主权项

1. A method of forming a fully impregnated thermoplastic prepreg product comprising:
moving a fabric or mat from a starting point to an ending point, wherein the fabric or mat is subjected to a plurality of processes and wherein the fabric or mat is in substantially constant movement between the starting point and ending point; drying the fabric or mat to remove residual moisture from one or more surfaces of the fabric or mat; mixing a monomer or oligomer with a catalyst and an activator to form a reactive resin mixture, the catalyst and activator facilitating in polymerizing the monomer or oligomer to form a thermoplastic polymer; applying the reactive resin mixture to the fabric or mat, the reactive resin mixture having a viscosity of 10 centipoises or less; passing the reactive resin mixture coated fabric or mat through a calendar or press to press the reactive resin mixture entirely through the fabric or mat such that the reactive resin mixture fully saturates the fabric or mat; and passing the reactive resin mixture coated fabric or mat through a curing oven to polymerize the reactive resin mixture and thereby form the thermoplastic polymer; wherein an environment in the vicinity of the coated fabric or mat is controlled to maintain a humidity in the air to substantially zero prior to passing the coated fabric or mat through the curing oven.