Patent ID: 7987885

Claim:
A system for providing a reinforced thermoplastic structure, comprising: a resin wetting portion comprising a basin containing liquid plastisol, the resin wetting portion configured for impregnating a plurality of reinforcing filaments with the liquid plastisol; a die having (i) a first portion comprising a plurality of filament alignment channels for receiving the reinforcing filaments and the liquid plastisol in a wet and completely uncured state, (ii) a second portion for receiving a second resin, contacting the second resin with the reinforcing filaments, and at least partially solidifying the liquid plastisol and the second resins to form a reinforced thermoplastic structure; and (iii) a third portion for applying a third thermoplastic resin to an exterior surface of said reinforced thermoplastic structure; and wherein the second portion of the die comprises a curved flow channel, wherein respective distal ends of the plurality of filament alignment channels are positioned adjacent to the curved flow channel; and a cooling element positioned adjacent to proximal ends of the filament alignment channels for providing a cooling fluid flow adjacent to the proximal ends to maintain the liquid plastisol and the plurality of reinforcing filaments at a first temperature.