US 11,772,336 B2
System for producing a fully impregnated thermoplastic prepreg
Mingfu Zhang, Highlands Ranch, CO (US); Klaus Friedrich Gleich, Nuremberg (DE); Asheber Yohannes, Littleton, CO (US); Michael John Block, Centennial, CO (US); Jawed Asrar, Englewood, CO (US); Derek Cooper Bristol, Littleton, CO (US); and Christopher P Sandoval, Littleton, CO (US)
Assigned to Johns Manville, Denver, CO (US)
Filed by JOHNS MANVILLE, Denver, CO (US)
Filed on Aug. 11, 2020, as Appl. No. 16/990,723.
Application 16/032,291 is a division of application No. 14/845,007, filed on Sep. 3, 2015, granted, now 10,105,871, issued on Oct. 23, 2018.
Application 16/990,723 is a continuation of application No. 16/032,291, filed on Jul. 11, 2018, granted, now 10,773,474.
Prior Publication US 2020/0368979 A1, Nov. 26, 2020
This patent is subject to a terminal disclaimer.
Int. Cl. C08K 7/14 (2006.01); B29C 70/50 (2006.01); D06M 15/51 (2006.01); D06M 15/61 (2006.01); D06M 15/71 (2006.01); C08J 3/24 (2006.01); C08L 77/02 (2006.01); B05C 5/02 (2006.01); B29B 15/12 (2006.01); B32B 5/28 (2006.01); C08J 5/24 (2006.01); B05C 9/10 (2006.01); B05C 9/12 (2006.01); B05C 9/14 (2006.01); B05C 11/02 (2006.01); B05D 1/40 (2006.01); B05D 3/02 (2006.01); B29B 13/02 (2006.01); B29B 13/06 (2006.01); B29B 15/14 (2006.01); B29C 70/06 (2006.01); B29B 11/12 (2006.01); B29B 11/16 (2006.01); D06M 15/705 (2006.01); B29K 105/08 (2006.01); B29K 105/00 (2006.01); B29L 7/00 (2006.01); B29L 9/00 (2006.01); B29K 33/00 (2006.01)
CPC B29C 70/50 (2013.01) [B05C 5/0245 (2013.01); B05C 5/0254 (2013.01); B05C 9/10 (2013.01); B05C 9/12 (2013.01); B05C 9/14 (2013.01); B05C 11/021 (2013.01); B05D 1/40 (2013.01); B05D 3/0227 (2013.01); B05D 3/0272 (2013.01); B29B 11/12 (2013.01); B29B 11/16 (2013.01); B29B 13/02 (2013.01); B29B 13/06 (2013.01); B29B 15/12 (2013.01); B29B 15/122 (2013.01); B29B 15/14 (2013.01); B29C 70/06 (2013.01); B29C 70/504 (2013.01); B32B 5/28 (2013.01); C08J 3/242 (2013.01); C08J 3/247 (2013.01); C08J 5/244 (2021.05); C08K 7/14 (2013.01); C08L 77/02 (2013.01); D06M 15/51 (2013.01); D06M 15/61 (2013.01); D06M 15/71 (2013.01); B29K 2033/12 (2013.01); B29K 2105/089 (2013.01); B29K 2105/0872 (2013.01); B29K 2105/256 (2013.01); B29L 2007/002 (2013.01); B29L 2009/00 (2013.01); D06M 15/705 (2013.01); Y10T 442/2992 (2015.04)] 16 Claims
 
1. A system for manufacturing a fully impregnated thermoplastic polyurethane prepreg, the system comprising:
a mechanism for moving a fabric or mat from a starting point to an ending point, the fabric or mat being subjected to a plurality of processes between the starting point and the ending point and the fabric or mat being in substantially constant movement between the starting point and ending point;
a resin applicator that is configured to apply a pre-polymer to the fabric or mat as the fabric or mat is moved past the resin applicator, the pre-polymer being in contact with a curative upon application of the pre-polymer to the fabric or mat, the curative facilitating in polymerizing the pre-polymer to form thermoplastic polyurethane (TPU);
a press mechanism that is configured to press the pre-polymer through the fabric or mat as the fabric or mat is moved past or through the press mechanism such that the pre-polymer fully saturates the fabric or mat during polymerization of the pre-polymer; and
a curing oven that is configured to effect polymerization of the pre-polymer and thereby form TPU as the fabric or mat is moved through the curing oven such that the fabric or mat is fully impregnated with TPU upon exiting the curing oven;
wherein the resin applicator is positioned above a lower belt of the press mechanism so that the pre-polymer is applied to the fabric or mat as the fabric or mat is passed under the resin applicator and atop the lower belt.