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 system for manufacturing a fully impregnated thermoplastic prepreg in a continuous process, the system comprising:
a mechanism for moving a fabric or mat from a starting point to an ending point, the fabric or mat being subjected to a plurality of processes between the starting point and the ending point and the fabric or mat being in substantially constant movement between the starting point and ending point; a fabric or mat drying mechanism that is configured to remove residual moisture from at least one surface of the fabric or mat as the fabric or mat is moved past the drying mechanism; a resin application mechanism that is configured to apply a monomer or oligomer to the fabric or mat as the fabric or mat is moved past the resin application mechanism, the monomer or oligomer being in contact with a catalyst and an activator upon application of the monomer or oligomer onto the fabric or mat, the catalyst and activator facilitating in polymerizing the monomer or oligomer to form a thermoplastic polymer; a press mechanism that is configured to press the monomer or oligomer through the fabric or mat as the fabric or mat is moved past or through the press mechanism such that the monomer or oligomer fully saturates the fabric or mat; and a curing oven having a temperature of greater than 120 degrees Celsius, the curing oven being configured to effect polymerization of the monomer or oligomer to form the thermoplastic polymer as the fabric or mat is moved through the curing oven such that the fabric or mat is fully impregnated with the thermoplastic polymer; wherein the system is configured to maintain a temperature of the monomer or oligomer to between 70 and 120 degrees Celsius prior to passing the coated fabric or mat through the curing oven; and wherein the system is further configured to maintain an environment in the vicinity of the coated fabric or mat to a humidity of substantially zero prior to subjecting the coated fabric or mat to the curing oven.