System for producing a fully impregnated thermoplastic prepreg

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;
• a moisture purge mechanism that is configured to remove moisture from the fabric or mat as the fabric or mat is moved past the moisture purge mechanism;
• a resin application mechanism that is positioned atop the fabric or mat and that is configured to apply liquid monomers or oligomers to the fabric or mat, wherein the liquid monomers or oligomers are polymerizable to form a thermoplastic polymer;
• a press mechanism that is configured to press the fabric or mat as the fabric or mat is moved past or through the press mechanism so that the liquid monomers or oligomers fully saturate the fabric or mat;
• and
• a curing oven that is configured to effect polymerization of the liquid monomers or oligomers 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 resin application mechanism is positioned above a bottom belt of the press mechanism so that the liquid monomers or oligomers are applied to the fabric or mat as the fabric or mat is moved atop the bottom belt, wherein the bottom belt of the press mechanism extends from the curing oven;
• and
• wherein the resin application mechanism is positioned adjacent an inlet of the curing oven so that the fabric or mat is passed directly into the curing oven after the liquid monomers or oligomers are applied by the resin application mechanism.