Apparatus and manufacturing method for in-situ impregnation of continuous fiber tows with thermoplastic resin for use in additive manufacturing.
RPI ID:
2018-034-401
Innovation Summary:
This system spreads continuous fiber tows over convex pins, then impregnates the widened tow in‑situ using a heated die with opposing resin supply conduits. After wet‑out, a converging die meters excess resin and shapes the prepreg, followed by cooling and take‑up. An angled drive roller provides controlled traction to overcome dry and viscous friction across the path. Tow spreading increases surface area, enabling rapid, uniform melt infiltration without solvent baths. The process can run continuously from commodity spools to narrow tapes, avoiding wide-roll coating and slitting. Resins include high‑performance thermoplastics (PEEK, PEKK, PES, PEI, etc.) and fibers include carbon or glass. The line is compact and suitable for on-demand widths for AFP/AM feedstock. Overall, it reduces cost, fiber damage, and environmental burden versus slurry or solvent methods.
Challenges/Opportunities:
Achieving void‑free impregnation at high line speeds requires precise temperature and pressure control in the die. Resin rheology windows differ across polymers; recipe libraries and closed‑loop control are opportunities. Die wear, pin coatings, and carbon‑fiber abrasion must be managed for uptime. Inline QA (IR thermography, laser thickness, porosity sensing) can certify tape quality in real time. Downstream compatibility with AFP, filament winding, and AM needs consistent width/thickness tolerances. Market pull exists for affordable PEEK/PEKK tapes; partnerships with aerospace and AM OEMs are strategic. ESG advantages (no solvent, lower energy) can support adoption if quantified. Modular multi-tow scaling and quick‑change dies offer capacity expansion.
Key Benefits:
✓ Solvent‑free, continuous impregnation
✓ Lower fiber damage vs tortuous-path injection
✓ Uniform wet‑out via dual‑sided resin delivery
✓ Reduced cost versus wide-roll coat & slit
✓ Compact line for on‑demand narrow tapes
✓ Compatible with high‑performance resins
Applications:
• Prepreg tape for AFP/automated layup
• Continuous‑fiber AM feedstock
• Filament winding and pultrusion inputs
• Rapid prototyping of custom tow widths
• On-site prepregging for R&D lines
Keywords:
Thermoplastic prepreg, tow spreading, impregnation die, converging die, PEEK, PEKK, carbon fiber, continuous fiber, AFP, additive manufacturing
Intellectual Property:
US Patent Application No. 20220126532A1 (published) |
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