System for producing a fully impregnated thermoplastic prepreg

A system for manufacturing a thermoplastic prepreg, the system comprising:

• a double belt mechanism that includes an upper belt and a lower belt, the upper belt being positioned atop the lower belt so as to compress a fiber mat, web, or mesh that is passed through the double belt mechanism and the lower belt having a longitudinal length that is substantially longer than the upper belt;
• a resin applicator that is positioned atop the lower belt and that is configured to apply liquid monomers or oligomers to the fiber mat, web, or mesh as the fiber mat, web, or mesh is moved past the resin applicator and atop the lower belt, wherein the liquid monomers or oligomers are polymerizable to form a thermoplastic polymer;
• and
• a curing oven that is configured to effect polymerization of the liquid monomers or oligomers and thereby form the thermoplastic polymer as the coated fiber mat, web, or mesh is moved through the curing oven;
• wherein the double belt mechanism compresses the fiber mat, web, or mesh and the applied liquid monomers or oligomers as the fiber mat, web, or mesh is passed through the curing oven such that the liquid monomers or oligomers fully saturate the fiber mat, web, or mesh and the fiber mat, web, or mesh is fully impregnated with the thermoplastic polymer upon polymerization of the monomers or oligomers;
• wherein the resin applicator is positioned immediately adjacent to an inlet of the curing oven so that the fiber mat, web, or mesh is passed directly into the curing oven after the liquid monomers or oligomers are applied by the resin applicator.