A system for densification of recycled pre-preg fibers may include a cutting device configured to receive the recycled pre-preg fibers having various lengths, and cut the recycled pre-preg fibers to produce cut fibers having a desired length, and a mixer configured to mix wetted, cut fibers to generate bound fibers having an increased bulk density relative to a bulk density of the cut fibers.

A system and method for creating a rigid foam substitute is provided. By using natural binding materials and natural fiber materials, the system and method may be used to create environmentally friendly substitutes for expanded polystyrene. The system generally comprises a processing room and molding facility. The processing room may comprise an opener, cleaner, and blower, which may be used to break up and clean the natural fiber material. The molding facility may comprise a mixer, molder, and kiln, which may be used to create casts. The method generally entails processing a natural fiber material before mixing it with a natural binding material and fluid to create a fluidic mixture, wherein said fluidic mixture is subsequently molded and cured to create a finished product.

A process and system are provided for introducing a blend of chopped and dispersed fibers on an automated production line amenable for inclusion in molding compositions as a blended fiber mat for structural applications. The blend of fibers are simultaneously supplied to an automated cutting machine illustratively including a rotary blade chopper disposed above a vortex supporting chamber. The blend of chopped fibers and binder form a chopped mat. The chopped mat has a veil mat placed on either side, and is consolidated with the veil mat using heated rollers maintained at the softening temperature of thermoplastic binder, with consolidated mats being amenable to being stored in rolls or as flat sheets. A charge pattern is made using the consolidated mat, and the charge pattern can be compression molded in a mold maintained at a temperature lower than the melting point of the thermoplastic fibers.

This application relates to a method of manufacturing a metal-polymer composite material having high thermal conductivity and electrical insulating properties. The method may include preparing a powder mixture comprising polymer powder and metal powder, and spark plasma sintering (SPS) the powder mixture to produce a composite material. This application also relates to a metal-polymer composite material having high thermal conductivity and electrical insulating properties, manufactured by the method.

The present invention addresses the problem of providing a molding method capable of molding a molded article having excellent strength and reducing manufacturing costs by shortening a molding cycle when obtaining a molded article from a fiber-reinforced thermoplastic resin by compression molding. The present invention relates to a molding method which obtains a fiber-reinforced thermoplastic resin by kneading a thermoplastic resin and a reinforcing fiber (14), and a molded article from the fiber-reinforced thermoplastic resin by compression molding. The molding method of the molded article comprising the fiber-reinforced thermoplastic resin according to the present invention comprises: a molding step for obtaining a first molded article from a predetermined amount of a fiber-reinforced thermoplastic resin through a molding die (4); a carrying-in step for opening the molding die (4), taking out the first molded article, and inserting the first molded article into a cooling die (5); and a compression cooling step for cooling the first molded article by compressing the first molded article through the cooling die (5).

In order to be capable of reliably supplying a prescribed amount of fiber materials into a heating cylinder for each cycle and continuously manufacturing a homogeneous composite material, a plasticizing unit is provided with a fiber supply device 3 that supplies prescribed amount of fiber materials A2 having a prescribed length into the heating cylinder 1. The fiber supply device 3 is provided with: a cutting section 12 that cuts off a long fiber material A1 pulled out from a reel 11 into a prescribed length; a pressure-feeding section 13 that presses the fiber materials A2 having the prescribed length cut off by the cutting section 12 into the heating cylinder 1; and a fiber transfer device 45 that forcibly transfers the fiber materials A2 accumulated in the cutting section 12 to the pressure-feeding section 13. The pressure-feeding section 13 is constituted by a press cylinder 41 and a press piston 42, and the fiber transfer device 45 is constituted by a vacuum device.

A system for debundling fiber tow into chopped fibers is provided that has one or more reels of fiber tow, a cutting element configured to receive the fiber tow to form chopped fiber, and a tube with introduced gas flow configured to receive the chopped fiber. A moving belt is positioned under the tube to collect the chopped fiber. A dispenser is positioned along the moving belt for applying a binder or additive. A treatment chamber receives the treated chopped fiber. A process for debundling fiber tow into chopped fibers is provided that supplies one or more reels of fiber tow to a cutting system, drops the chopped fiber into a tube with introduced gas flow to debundle the chopped fiber with a vortex, collects the chopped fiber exiting the tube onto a moving belt, chemically treats the chopped fiber, and provides the chemically treated chopped to a treatment chamber.

A method of making polymeric composite particles from polymeric scrap material, virgin polymeric material, or mixtures thereof and glass particles by subjecting a mixture of the polymeric particles and glass particles to a solid state shear pulverization and in-situ polymer compatibilization.

A system for debundling fiber tow into chopped fibers is provided that has one or more reels of fiber tow, a cutting element configured to receive the fiber tow to form chopped fiber, and a tube with introduced gas flow configured to receive the chopped fiber. A moving belt is positioned under the tube to collect the chopped fiber. A dispenser is positioned along the moving belt for applying a binder or additive. A treatment chamber receives the treated chopped fiber. A process for debundling fiber tow into chopped fibers is provided that supplies one or more reels of fiber tow to a cutting system, drops the chopped fiber into a tube with introduced gas flow to debundle the chopped fiber with a vortex, collects the chopped fiber exiting the tube onto a moving belt, chemically treats the chopped fiber, and provides the chemically treated chopped to a treatment chamber.

A method of making polymeric composite particles from polymeric scrap material, virgin polymeric material, or mixtures thereof and glass particles by subjecting a mixture of the polymeric particles and glass particles to a solid state shear pulverization and in-situ polymer compatibilization.