Bi-polymer thermoplastic

Abstract

A method for forming a thermoplastic prepreg is disclosed. The method includes supplying continuous fibers to a first extrusion device, supplying a first thermoplastic feedstock to the first extrusion device, wherein the feedstock comprises a first thermoplastic polymer, pre-heating, tensioning, and spreading the continuous fibers, extruding the continuous fibers and the first feedstock within an impregnation die to form a first extrudate in which the continuous fibers are embedded with a matrix of the first thermoplastic polymer, twisting the first extrudate, supplying a second thermoplastic polymer to a second extrusion device, extruding the first extrudate and the second thermoplastic feedstock within an impregnation die to form a second extrudate in which the second feedstock forms a layer around the first extrudate, while the first extrudate is twisted and under tension, and forming a sleeve of the second extrudate having the second feedstock forming a layer around the first extrudate.

Dependencies are inferred from the claim text.