Patent ID: 7429305
Filing Date: 2008-09-30
Classification: B29B,B29C,B29K,B32B,Y10T

Abstract:
1. A machine for producing lightweight thermoplastic composite products in a continuous manner, said machine comprising at least one heating oven for heating a dry fabric sheet of commingled fibers of thermoplastic resin and reinforcing fiberglass or carbon fibers to a temperature slightly more than the melting point of said resin to insure melting and flow of said resin in voids of said commingled fibers, conveying means to feed said fabric sheet through said oven, a first pair of heated rollers at an outlet of said oven with said fabric sheet engaged in a gap between said first pair of heated rollers to maintain pressure, said rollers being heated to a predetermined temperature to avoid abrupt cooling at surfaces of said fabric sheet; further pairs of rollers, at least one pair of which is operating at reduced temperature from said first pair and engaging said fabric sheet in respective gaps whereby to maintain pressure and reduce the temperature of said sheet and control the pressure and thickness thereof as said commingled fibers consolidate to form a continuous composite consolidated sheet, at least one of said first and further pairs of rollers are drive rollers, said at least one of said first and further pairs of rollers being driven in controlled synchronism with said continuous composite sheet in engagement between said drive rollers; and a controller device for controlling the speed of said continuous composite sheet, the gap of all of said pairs of rolls, the temperature of said heating oven and said heated rollers, and for monitoring temperature of said composite sheet at different stages.