Patent ID: 7993122

Claim:
A device for forming a wrapped assembly comprising at least one center core member wrapped with reinforced thermoplastic resin, the wrapping having fully dispersed and fully wet out individual fiber filaments that retain their cut length, the device comprising: an entrainment die having an inner chamber with an inner diameter and length and a volumetric capacity, at least one fiber guide nozzle in fluid communication with entrainment die inner chamber, a resin nozzle in fluid communication with the inner chamber of the entrainment die, wherein at least one continuous length of reinforcing fiber comprising a plurality of individual filaments is admitted through the at least one fiber guide nozzle, entrained and coated with molten resin; a cutting assembly comprising a housing, cutting blade, bed knife and defining a cutting chamber having a length and a motor operatively connected with the cutting blade, the cutting assembly in fluid communication with the inner chamber of the entrainment die, wherein the at least one continuous length of entrained and coated reinforcing fiber is selectively cut to desired length; and a down screw assembly comprising a barrel having an inner diameter, a down screw rotatingly housed within barrel and a motor operatively connected with the down screw, the down screw comprising an axis and two or more flites disposed thereon, each flite having a pitch and a depth, and at least two low shear apertures, the down screw assembly having a volumetric capacity that is substantially greater than said volumetric capacity of said entrainment die and the down screw capable of rotational speeds between 10 rpm and 100 rpm, wherein the cut fiber filaments are unbundled and wet out while retaining the selected cut length as the cut fiber filaments avoid high-pressure induced tension and shear within said down screw assembly and upon exiting of said down screw assembly through said at least two low shear apertures; and a cross die in operative communication with the down screw assembly, the cross die comprising at least one entry port and at least one exit port, the at least one entry port and at least one exit port in fluid communication with an inner coating chamber therebetween whereby the at least one center core member passes through said inner coating chamber and is wrapped with reinforced thermoplastic resin containing the cut fiber filaments with retained selected cut length within said inner coating chamber.