Abstract: According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.

Abstract: Embodiments of the present technology may include a method of making a thermoplastic composite strand. The method may include melting a reactive thermoplastic resin to form a molten reactive resin. The method may also include fully impregnating a plurality of continuous fibers with the molten reactive resin in an impregnation device. The method may further include polymerizing the molten reactive resin to form a thermoplastic resin matrix. In addition, the method may include cooling the thermoplastic resin matrix to form a thermoplastic composite strand.

Abstract: This invention relates to a process of making a fiber-reinforced composite. Glass fibers may be provided. These glass fibers may be treated with a sizing composition that has a coupling-activator compound with the formula: S-X-(A)n, where S represents a silicon-containing coupling moiety capable of bonding to the surface of glass fibers, X represents a linking moiety, and (A)n, represents one or more polymerization activator moieties. The treated glass fibers may be combined with a resin to make a fiber-resin mixture. The resin may have a monomer, a catalyst, and an activator compound capable of initiating a polymerization of the monomer. The monomer may be a lactam or lactone having 3-12 carbon atoms in the main ring. The fiber-resin mixture may then be cured so that the monomer polymerizes to form a thermoplastic polymer matrix of the fiber-reinforced composite. The thermoplastic polymer matrix may be formed by in situ polymerization initiated from both the surface of the glass fibers and the resin.

Abstract: Methods of making fiber-resin compositions are described. The methods may include the providing of a thermoplastic resin to an extruder, where the thermoplastic resin may include at least one reactive moiety capable of forming a covalent bond with a coupling agent on a plurality of reactive fibers. The methods may further include combining the thermoplastic resin with the plurality of reactive fibers also supplied to the extruder. The reactive fibers are sized with the coupling agent that reacts with the thermoplastic resin to form the fiber-resin composition, which may be extruded from the extruder. Methods of making fiber-reinforced composite articles from the fiber-resin composition are also described.

Abstract: According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.

Abstract: Methods of making fiber reinforced composite articles are described. The methods may include the step of providing a pre-impregnated fiber-containing thermoplastic material to a mold for the article. The pre-impregnated fiber-containing thermoplastic material may include: (i) a plurality of fibers, and (ii) a first thermoplastic polymer made from a first reactive thermoplastic resin. Reactants of a second reactive thermoplastic resin may be introduced to fill open spaces in the mold that are left by the pre-impregnated fiber-containing thermoplastic material. The second reactive thermoplastic resin may then be polymerized to form a second thermoplastic polymer. The final fiber reinforced composite article includes at least two spatially distinct regions of thermoplastic polymer.

Abstract: Methods of making fiber reinforced composite articles are described. The methods may include the step of providing a pre-impregnated fiber-containing thermoplastic material to a mold for the article. The pre-impregnated fiber-containing thermoplastic material may include: (i) a plurality of fibers, and (ii) a first thermoplastic polymer made from a first reactive thermoplastic resin. Reactants of a second reactive thermoplastic resin may be introduced to fill open spaces in the mold that are left by the pre-impregnated fiber-containing thermoplastic material. The second reactive thermoplastic resin may then be polymerized to form a second thermoplastic polymer. The final fiber reinforced composite article includes at least two spatially distinct regions of thermoplastic polymer.

Abstract: Methods of making prepregs are described. The methods include the steps of forming a fiber-containing substrate, and contacting the fiber-containing substrate with a resin mixture. The resin mixture may include polymer particles mixed in a liquid medium, and the polymer particles may be coated on the fiber-containing substrate to form a coated substrate. The liquid medium may be removed from the coated substrate to form the prepreg. The prepregs may be used to make fiber-reinforced articles.

Abstract: Methods of making a fiber-reinforced thermoplastic polyurethane composite are described. The methods may include applying a sizing composition to a plurality of fibers to make sized fibers, where the sizing composition may include at least one curative for a thermoplastic polyurethane prepolymer. The sized fibers may be contacted with a thermoplastic polyurethane prepolymer composition to form a resin-fiber amalgam, where the thermoplastic polyurethane prepolymer composition includes 50 wt. % or less of a total amount of the curative that is also present on the sized fibers. The resin-fiber amalgam may then be cured to form the fiber-reinforced thermoplastic polyurethane composite.

Abstract: Methods of making prepregs are described. The methods include the steps of forming a fiber-containing substrate, and contacting the fiber-containing substrate with a resin mixture. The resin mixture may include polymer particles mixed in a liquid medium, and the polymer particles may be coated on the fiber-containing substrate to form a coated substrate. The liquid medium may be removed from the coated substrate to form the prepreg. The prepregs may be used to make fiber-reinforced articles.

Abstract: According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.

Abstract: According to one embodiment, a system for manufacturing a polymethyl methacrylate (PMMA) prepreg includes a mechanism for continuously moving a fabric or mat and a resin application component that applies a methyl methacrylate (MMA) resin to the fabric or mat. The system also includes a press mechanism that presses the fabric or mat during the continuous movement subsequent to the application of the MMA resin to ensure that the MMA resin fully saturates the fabric or mat. The system further includes a curing oven through which the fabric or mat is continuously moved. The curing oven is maintained at a temperature of between 40° C. and 100° C. to polymerize the MMA resin and thereby form PMMA so that upon exiting the curing oven, the fabric or mat is fully impregnated with PMMA.

Abstract: Methods of making a fiber-reinforced composite are described. The methods may include applying a sizing composition to a plurality of fibers to make sized fibers, where the sizing composition may include at least one of a curing agent or an accelerator for a resin composition. The sized fibers may be contacted with the resin composition to form a resin-fiber amalgam, where the resin composition includes 50 wt. % or less of a total amount of the curing agent and the accelerator that is also present on the sized fibers. The resin-fiber amalgam may then be cured to form the fiber-reinforced composite.

Abstract: According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.

Abstract: According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.

Abstract: According to one embodiment, a system for manufacturing a fully impregnated thermoplastic prepreg includes a mechanism for moving a fabric or mat and a drying mechanism that removes residual moisture from at least one surface of the fabric or mat. The system also includes a resin application mechanism that applies a reactive resin to the fabric or mat and a press mechanism that presses the coated fabric or mat to ensure that the resin fully saturates the fabric or mat. The system further includes a curing oven through which the coated fabric or mat is moved to polymerize the resin and thereby form a thermoplastic polymer so that upon exiting the oven, the fabric or mat is fully impregnated with the thermoplastic polymer. During at least a portion of the process, humidity in the vicinity of the coated fabric or mat is maintained at substantially zero.

Abstract: Methods of making prepregs are described. The methods include the steps of forming a fiber-containing substrate, and contacting the fiber-containing substrate with a resin mixture. The resin mixture may include polymer particles mixed in a liquid medium, and the polymer particles may be coated on the fiber-containing substrate to form a coated substrate. The liquid medium may be removed from the coated substrate to form the prepreg. The prepregs may be used to make fiber-reinforced articles.

Abstract: Fiber-containing polymethyl methacrylate (PMMA) prepregs are described that include a first and second plurality of fibers. The second plurality of fibers is made from a different material than the first plurality of fibers. The PMMA prepregs also contain a polymerized resin that includes polymethyl methacrylate that has been formed from a reactive resin composition that includes methyl methacrylate. Methods of making fiber-containing PMMA prepregs are also described.

Abstract: Methods of making prepregs are described. The methods include the steps of forming a fiber-containing substrate, and contacting the fiber-containing substrate with a resin mixture. The resin mixture may include polymer particles mixed in a liquid medium, and the polymer particles may be coated on the fiber-containing substrate to form a coated substrate. The liquid medium may be removed from the coated substrate to form the prepreg. The prepregs may be used to make fiber-reinforced articles.

Abstract: Embodiments of the present technology may include a method of making a thermoplastic composite strand. The method may include melting a reactive thermoplastic resin to form a molten reactive resin. The method may also include fully impregnating a plurality of continuous fibers with the molten reactive resin in an impregnation device. The method may further include polymerizing the molten reactive resin to form a thermoplastic resin matrix. In addition, the method may include cooling the thermoplastic resin matrix to form a thermoplastic composite strand.