Methods and systems for making reinforced thermoplastic composites, and the products

A method of making an interim product for making a reinforced thermoplastic composite product, or for making a reinforced thermoplastic product comprising;

• a) preparing a mixture containing one or more thermoplastic precursor monomers preheated to a temperature above its melting point and one or more catalyst compounds, the catalyst compound(s) causing polymerization of the monomer(s) when brought into contact with an inorganic fiber reinforcing material having one or more activator compounds on the surfaces of the reinforcement material, the activator being a material that will react with the monomer mixture to cause polymerization of the monomer in the temperature range of about 140 to about 200 degrees C. to produce a thermoplastic matrix around the reinforcement material,
• b) feeding one or more layers of the monomer(s) mixture of step (a) onto a moving belt, the monomer(s) mixture having a temperature of at least about 100 degrees C., but below 140 degrees C.,
• c) feeding one or more layers of inorganic fibrous reinforcement products selected from a group consisting of woven roving or yarn fabric and/or scrim, chopped strand mat, continuous strand mat, nonwoven mat, chopped roving, chopped strands of fibers, chopped filaments and veil mat in any desired combination onto the one or more layers of the monomer mixture, and
• d) impregnating said reinforcing product(s) and coating fibers in said reinforcing product(s) with the monomer mixture to form an interim product comprising coated reinforcement and a matrix of the mixture of step (a).

A method of making a reinforced thermoplastic composite product comprising;

• a) preparing a mixture containing one or more thermoplastic precursor monomers and one or more catalyst compounds, the catalyst compound(s) causing polymerization of the monomer(s) when brought into contact with an inorganic fiber reinforcing material having one or more activator compounds on the surfaces of the reinforcement material, the activator being a material that will react with the monomer mixture to cause polymerization of the monomer in the temperature range of about 140 to about 200 degrees C. to produce a thermoplastic matrix around the reinforcement material,
• b) heating the reinforcing material to a temperature of at least about 100 degrees C., and/or
• c) heating the mixture comprising the monomer(s) and the catalyst compound(s) to a temperature of at least about 100 degrees C., and/or
• d) optionally heating a mold element to a temperature in the range of about 130 to about 200 degrees C.
• e) coating surfaces of the reinforcement of step (a) with the mixture of step (a) prior to or following contacting the optionally heated mold element followed by bringing the coated reinforcement into contact with the heated mold element, or alternatively coating the reinforcement with the mixture of step (a) while the mixture of step (a) is in or on the optionally heated mold element, to form a desired shape of coated reinforcement and a matrix of the mixture of step (a), and
• f) heating or maintaining the temperature of the desired shape in a range of about 140 to about 190 degrees C. until at least about 90 percent of the monomer(s) have polymerized to one or more a thermoplastic polymers.