US 12,466,109 B2
Method for manufacturing a fibrous material pre-impregnated with thermoplastic polymer in a fluidised bed
Gilles Hochstetter, Colombes (FR); Thibaut Savart, Lacq (FR); Arthur Pierre Babeau, Lacq (FR); and Axel Salinier, Lacq (FR)
Assigned to ARKEMA FRANCE, Puteaux (FR)
Appl. No. 17/415,073
Filed by ARKEMA FRANCE, Colombes (FR)
PCT Filed Dec. 16, 2019, PCT No. PCT/EP2019/085282
§ 371(c)(1), (2) Date Jun. 17, 2021,
PCT Pub. No. WO2020/126996, PCT Pub. Date Jun. 25, 2020.
Claims priority of application No. 18306720 (EP), filed on Dec. 18, 2018.
Prior Publication US 2022/0063137 A1, Mar. 3, 2022
This patent is subject to a terminal disclaimer.
Int. Cl. B29B 15/12 (2006.01); B29K 77/00 (2006.01); B29K 307/04 (2006.01)
CPC B29B 15/12 (2013.01) [B29K 2077/00 (2013.01); B29K 2307/04 (2013.01)] 26 Claims
OG exemplary drawing
 
1. A method of manufacturing a pre-impregnated fibrous material comprising a fibrous material made of continuous fibers and at least one thermoplastic polymer matrix, wherein said pre-impregnated fibrous matrix is produced as a single unidirectional band or a plurality of unidirectional parallel bands and wherein said method comprises a step of pre-impregnating said fibrous material while it is in the form of a strand or several parallel strands with said at least one thermoplastic polymer matrix in powdered form, said pre-impregnation step being done by a dry process in a tank comprising a fluidized bed comprising at least one grooved roller component,
said strand(s) being in contact with part or all of the surface of said at least one grooved roller component and said strand(s) comprising up to 0.1% by weight of sizing,
and a control of an amount of said at least one thermoplastic polymer matrix in said fibrous material being done by controlling the dwell time of said fibrous material in the powder and by constant control of the tension of said strand(s) when it or they penetrate the fluidized bed,
wherein the minimum width of said strand(s) is greater than the width of the groove of said grooved roller component.