System for producing a fully impregnated thermoplastic prepreg

A system for manufacturing a fully impregnated thermoplastic polyurethane prepreg, 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 and the fabric or mat being in substantially constant movement between the starting point and ending point;
• a resin applicator that is configured to apply a pre-polymer to the fabric or mat as the fabric or mat is moved past the resin applicator, the pre-polymer being in contact with a curative upon application of the pre-polymer to the fabric or mat, the curative facilitating in polymerizing the pre-polymer to form thermoplastic polyurethane (TPU);
• a press mechanism that is configured to press the pre-polymer through the fabric or mat as the fabric or mat is moved past or through the press mechanism such that the pre-polymer fully saturates the fabric or mat during polymerization of the pre-polymer;
• and
• a curing oven that is configured to effect polymerization of the pre-polymer and thereby form TPU as the fabric or mat is moved through the curing oven such that the fabric or mat is fully impregnated with TPU upon exiting the curing oven;
• wherein the resin applicator is positioned above a lower belt of the press mechanism so that the pre-polymer is applied to the fabric or mat as the fabric or mat is passed under the resin applicator and atop the lower belt.