System for producing a fully impregnated thermoplastic prepreg

A method of forming a fully impregnated polymethyl methacrylate prepreg comprising:

• unwinding a fabric or mat from a roller so that the fabric or mat is positioned atop a lower belt of a double belt compression press that is configured to move the fabric or mat between a starting point to an ending point, wherein the fabric or mat is subjected to a plurality of processes and is in substantially constant movement atop the lower belt;
• mixing a methyl methacrylate (MMA) resin with an initiator to form an MMA resin mixture, the initiator facilitating in polymerizing the MMA resin to form polymethyl methacrylate (PMMA);
• applying the MMA resin mixture to the fabric or mat as the fabric or mat is moved under a resin application die that is positioned above the fabric or mat, the MMA resin mixture having a viscosity of 10 poises or less, wherein the fabric or mat remains in contact with the lower belt as the resin application die applies the MMA resin mixture to the fabric or mat;
• sandwiching the fabric or mat between the lower belt and an upper belt of the double belt compression press to press the MMA resin mixture entirely through the fabric or mat such that the MMA resin mixture fully saturates the fabric or mat;
• and
• passing the MMA resin mixture coated fabric or mat through a curing oven having a temperature that is maintained at between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA, wherein the fabric or mat is in constant movement through the curing oven between the upper belt and the lower belt;
• wherein upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.