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Abstract

An apparatus for producing a consolidated, fiber-reinforced composite tape from a plurality of powder pre-impregnated fiber tow bundles having a fiber and a polymeric matrix comprise six (6) major components. Starting at the supply end of the manufacturing line, the components include a pay-out creel, a collimation device, a processing component with an impregnation bar assembly, variable-dimension forming nip-rollers, a self-contained driving mechanism, and a motorized take-up spool. These six components are positioned inoperable relationship to one another. The method of producing the consolidated composite tape includes the steps of: (a) feeding the plurality of the tow bundles through the collimation device to align the tow bundles laterally; (b) heating the tow bundles to a specific processing temperature which melts the polymeric matrix of the tow bundles; (c) spreading the heated tow bundles over the impregnation bar assembly to wet-out the filament array of the heated tow bundles and to form the heated tow bundles to an initial width and shape; (d) re-shaping the heated tow bundles into a pre-determined width by pulling the heated tow bundles through the variable-dimension forming nip rollers; (e) pulling the shaped tow bundles through the self-contained drive mechanism, thereby enabling the polymeric matrix of the shaped tow bundles to consolidate fully into the fiber-reinforced composite tape; and (f) taking-up the consolidated fiber-reinforced composite tape onto the spool.

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First Claim