System for producing chopped roving thermoplastic composite sheets

A system for manufacturing a chopped roving thermoplastic composite sheet, 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 to compress a chopped roving 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 fiber applicator positioned above the lower belt so that the fiber applicator disperses chopped rovings directly onto the lower belt as the lower belt is moved under and past the fiber applicator, the chopped rovings being dispersed onto the lower belt prior to application of any thermoplastic resin to form the chopped roving web or mesh;
• a resin applicator that is positioned atop the lower belt, the resin applicator being configured to apply a thermoplastic resin to the chopped roving web or mesh;
• and
• an oven that is configured to melt the thermoplastic resin as the chopped roving web or mesh and the thermoplastic resin are moved through the oven;
• wherein:
• the double belt mechanism compresses the chopped roving web or mesh and the melted thermoplastic resin as the chopped roving web or mesh is passed through the oven such that the melted thermoplastic resin is dispersed within the chopped roving web or mesh and saturates the chopped roving web or mesh;
• the system does not include an entangling device that entangles the chopped rovings of the chopped roving web or mesh and does not include a binder application device that applies a binder to the chopped rovings such that the chopped roving web or mesh is not mechanically bonded and does not include a binder other than the thermoplastic resin;
• and
• the chopped roving thermoplastic composite sheet is substantially free of unpolymerized resin materials;
• wherein the chopped roving web or mesh includes glass fibers, carbon fibers, basalt fibers, metal fibers, ceramic fiber, cellulosic fibers, natural fibers, aramid fibers, inorganic fibers, polymer fibers, or a combination thereof.