An apparatus comprises a nozzle for supplying a flow of polymeric material, a separating element for separating a dose of polymeric material from the flow supplied by the nozzle, at least one mould for making an object by compression moulding the dose, at least one conveying element for conveying the dose separated by the separating element towards the mould. The conveying element is movable along a path in an atmospheric environment. The apparatus further comprises a recycling device intended for receiving a polymeric material to be recycled and for providing at its outfeed a melted regenerated polymeric material suitable for being moulded. The nozzle is connected to the recycling device so that the nozzle is fed with the regenerated polymeric material coming from the recycling device.

An apparatus comprises a nozzle for supplying a flow of polymeric material, a separating element for separating a dose of polymeric material from the flow supplied by the nozzle, at least one mould for making an object by compression moulding the dose, at least one conveying element for conveying the dose separated by the separating element towards the mould. The conveying element is movable along a path in an atmospheric environment. The apparatus further comprises a recycling device intended for receiving a polymeric material to be recycled and for providing at its outfeed a melted regenerated polymeric material suitable for being moulded. The nozzle is connected to the recycling device so that the nozzle is fed with the regenerated polymeric material coming from the recycling device.

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.

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.

The invention relates to a method in which a polyester melt containing one or more polyesters is produced, the polyester melt being foamed by a blowing agent and a foamed granulate is produced from the foamed polyester melt. The intrinsic viscosity (IV) of the polyester melt is reduced by the blowing agent about at least 0.05 dl/g, measured according to ASTM D4603, and the IV of the foamed granulate is then increased by means of a solid phase polycondensation (SSP).

A method for producing a three-dimensional preform from reinforcing fibers for producing a component from a fiber-reinforced plastic comprises the steps of introducing at least one layer of fibers having a binder into a draping mold, forming the at least one layer of fibers by at least one forming element which is displaceable along the draping mold, applying an airtight film to the at least one layer of fibers during or directly after the forming, creating a negative pressure in the intermediate space between the airtight film and the draping mold, activating the binder and removing the negative pressure after curing of the binder.

A method for producing a three-dimensional preform from reinforcing fibers for producing a component from a fiber-reinforced plastic comprises the steps of introducing at least one layer of fibers having a binder into a draping mold, forming the at least one layer of fibers by at least one forming element which is displaceable along the draping mold, applying an airtight film to the at least one layer of fibers during or directly after the forming, creating a negative pressure in the intermediate space between the airtight film and the draping mold, activating the binder and removing the negative pressure after curing of the binder.

Methods of making fiber-containing prepregs are described. The methods may include the steps of providing a plurality of fibers, and applying a reactive resin composition to the plurality of fibers to make a mixture of the plurality of fibers and the resin composition. The reactive resin composition may include at least one of monomers and oligomers capable of polymerizing into a polymerized resin matrix. The mixture may be heated to a polymerization temperature where the monomers, oligomers, or both polymerize to form a fiber-resin amalgam that includes the polymerized resin matrix. The fiber-resin amalgam may be formed into the fiber-containing prepreg. Also described are methods of forming a fiber-reinforced composite that includes the prepreg.

Methods of making fiber-containing prepregs are described. The methods may include the steps of providing a plurality of fibers, and applying a reactive resin composition to the plurality of fibers to make a mixture of the plurality of fibers and the resin composition. The reactive resin composition may include at least one of monomers and oligomers capable of polymerizing into a polymerized resin matrix. The mixture may be heated to a polymerization temperature where the monomers, oligomers, or both polymerize to form a fiber-resin amalgam that includes the polymerized resin matrix. The fiber-resin amalgam may be formed into the fiber-containing prepreg. Also described are methods of forming a fiber-reinforced composite that includes the prepreg.

A system for manufacturing a thermoplastic prepreg includes a double belt mechanism that is configured to compress a fiber mat, web, or mesh that is passed through the double belt mechanism, a resin applicator that is configured to apply monomers or oligomers to the fiber mat, web, or mesh, and a curing oven that is configured to effect polymerization of the monomers or oligomers and thereby form the thermoplastic polymer as the fiber mat, web, or mesh is moved through the curing oven. The double belt mechanism compresses the fiber mat, web, or mesh and the applied monomers or oligomers as the fiber mat, web, or mesh is passed through the curing oven so that the monomers or oligomers fully saturate the fiber mat, web, or mesh. Upon polymerization of the monomers or oligomers, the fiber mat, web, or mesh is fully impregnated with the thermoplastic polymer.