In-line compounding/extrusion deposition and molding apparatus and method of using the same

A process for in-line compounding of a reinforcing fiber bundle with extrusion compression molding using an in-line compounding/extrusion deposition and molding apparatus, the process comprising:

• providing a first material to a first inlet formed in the apparatus, the first inlet being in fluid communication with ail internal cavity of the apparatus, the internal cavity having a single rotatable extruder screw, the first material being fed into a first zone of the internal cavity;
• providing at least one reinforcing fiber bundle to a second inlet formed in the apparatus, the at least one reinforcing fiber bundle being fed into a second zone of the internal cavity under a predetermined constant tension to prevent slack in the at least one reinforcing fiber bundle;
• rotating the single rotatable extruder screw so as to melt the first material in the first zone prior to advancing the melted first material to the second zone, the rotation of the single rotatable extruder screw causing the at least one reinforcing fiber bundle to be fed into the second zone under the predetermined constant tension;
• shearing the at least one reinforcing fiber bundle in the second zone;
• mixing the sheared at least one reinforcing fiber bundle and the melted first material in a third zone to produce a fiber bundle filled melt;
• retracting the single rotatable extruder screw to permit expansion of a fourth zone, wherein the fiber filled melt accumulates in the fourth zone thereby forming a shot;
• and
• directing the fiber bundle filled melt through an outlet formed in the apparatus by movement of the single rotatable extruder screw in a direction toward the outlet.