Composite product, composite product production system, composite product production process, and system and method for reducing VOC emissions associated with composite product production

Abstract

This invention provides a system for producing a composite product comprising a substrate and a resin integrated with the substrate. The system includes: a press located between an upstream end of a system designed to incorporate the substrate and a downstream end of a system designed to convey the composite product from the system; a lower film supply located at the upstream end of the system and designed to introduce the lower film into the system in a direction downstream of the press; a substrate supply located at the upstream end of the system and designed to introduce the substrate onto the lower film in the system in a direction downstream of the press; and a resin dispenser located upstream of the press and downstream of the substrate supply, designed to dispense the resin... A resin is coated onto the substrate to form a resin-substrate assembly; an upper film supply, located downstream of the resin dispenser and structurally designed to introduce the upper film into the system in a downstream direction toward the press and onto the resin-substrate assembly; and a film removal station, located at the downstream end of the system and structurally designed to remove the lower film and the upper film from the resin-substrate assembly; and a press, located downstream of the upper film supply and upstream of the film removal station, positioned to apply pressure to the resin-substrate assembly via the upper and lower films when the resin-substrate assembly and the press are in the same position.

Description

[Technical Field]

[0001] This invention relates to a method for manufacturing reinforced composite products such as composite panels, the method providing at least one of the following: improved control, reduced emissions and reduced costs. [Previous Technology]

[0002] Prior art manufacturing methods for composite parts include conventional methods involving resin transfer molding (RTM) and vacuum-assisted RTM (VARTM). While these methods may be suitable for specific applications, there is a need for improved methods and systems for manufacturing reinforced composite products such as panels, which provide at least one of the following: improved control, reduced emissions, and reduced costs. [Summary of the Invention]

[0003] Panel Production Assembly (Equipment Assembly and Subassemblies) According to one embodiment of the present invention, a system for producing a composite product including a substrate and a resin integrated with the substrate is provided. The system includes: a press located between an upstream end of a system designed to incorporate the substrate into the system and a downstream end of a system designed to transfer the composite product from the system; a lower film supply located at the upstream end of the system and designed to introduce the lower film into the system in a direction downstream of the press; a substrate supply located at the upstream end of the system and designed to introduce the substrate onto the lower film in the system in a direction downstream of the press; and a resin dispenser located at the downstream end of the press. The system comprises an upstream and downstream substrate supply, and is structurally designed to coat resin onto the substrate to form a resin-substrate assembly; an upper film supply, located downstream of the resin dispenser, and structurally designed to introduce the upper film into the system, which is directed downstream of the press and introduces the film onto the resin-substrate assembly; and a film removal station, located at the downstream end of the system, and structurally designed to remove the lower and upper films from the resin-substrate assembly; and a press, located downstream of the upper film supply and upstream of the film removal station, which is positioned to apply pressure to the resin-substrate assembly via the upper and lower films when the resin-substrate assembly and the press are in the same position.

[0004] According to another aspect of the present invention, a mold assembly is provided for use with a press to form a composite product including a substrate and a resin integrated with the substrate. The mold includes: a lower film, structurally designed to move relative to the press in a downstream direction extending from an upstream end of the press to a downstream end of the press; the lower film having an upper surface disposed to support a combination of the substrate and the resin; and the lower film having a continuous length selected to extend beyond the upstream end of the press in the upstream direction and beyond the downstream end of the press in the downstream direction; and an upper film, structurally designed to extend from the upstream end of the press to a downstream end of the press. The direction of movement relative to the press includes an upper film having a lower surface positioned to contact the substrate and resin assembly, and the upper film also having a continuous length selected to extend beyond the upstream end of the press in the upstream direction and beyond the downstream end of the press in the downstream direction; and a seal formed by contact between the upper surface of the lower film and the lower surface of the upper film, the seal being positioned to at least partially surround the substrate, the seal extending along a portion of the continuous length of the lower and upper films, and the seal extending transversely to the continuous length of the lower and upper films; the lower film, the upper film, and the seal together define a mold interior structurally designed to be sealed into the substrate and resin assembly.

[0005] Panel Manufacturing Method (Steps of Panel Manufacturing) According to another aspect of the present invention, a method for manufacturing a composite product comprising a substrate and a resin integrated with the substrate is provided. The method includes: supplying a lower film to introduce the lower film in a downstream direction; supplying a substrate to introduce the substrate in a downstream direction and to introduce it onto the lower film; dispensing resin to coat the resin onto the substrate to form a resin-substrate assembly; supplying an upper film to introduce the upper film onto the resin-substrate assembly; applying pressure to the resin-substrate assembly via the upper film and the lower film; and removing the lower film and the upper film from the resin-substrate assembly.

[0006] According to yet another aspect of the present invention, a VOC capture assembly is provided for capturing volatile organic compounds (VOCs) during the production of a composite product including a substrate and a resin integrated with the substrate. The system includes: a resin dispenser disposed to coat the substrate with resin to form a resin-substrate assembly, the resin dispenser including a housing into which the substrate can be introduced when the housing is open, the housing being structurally designed to contain VOCs emitted into the housing when the housing is closed; a filter coupled to receive VOCs from the housing of the resin dispenser; and an exhaust device structurally designed to reduce the pressure within the housing and disposed to drive VOCs from the housing and into the filter, the exhaust device being operable when the housing is open to allow the substrate to enter the housing and the resin-substrate assembly to exit the housing.

[0007] According to another aspect of the present invention, a method for capturing VOCs during the production of a composite product comprising a substrate and a resin integrated with the substrate to form a resin-substrate assembly is provided. The method includes: opening an upstream gate of a housing; activating an exhaust device to reduce the pressure inside the housing when the upstream gate of the housing is opened; receiving the substrate into the housing via the upstream gate of the housing; closing the upstream gate of the housing; applying resin to the substrate to form a resin-substrate assembly in the housing; and discharging VOCs from the housing into a filter.

[0008] According to another aspect of the present invention, a reinforced composite product is provided, comprising: a substrate; and a resin integrated with the substrate; the reinforced composite product having an outer surface characterized by uniformity in at least one of color, weave pattern and surface masking appearance.

[0009] According to another embodiment of the present invention, a reinforced composite product is provided, comprising: a substrate; and a resin integrated with the substrate; the reinforced composite product is characterized by uniformity in at least one of the following: thickness, fiber content, thickness after secondary pressing, noise generation in ultrasonic C-scan, fiber content, and cross-section.

[0010] According to another aspect of the present invention, the resin content uniformity index of the reinforced composite product is 16 or greater, the resin content variation of the reinforced composite product is 5% or less, and / or the resin content uniformity of the reinforced composite product is 83% or greater.

[0011] According to another aspect of the present invention, the thickness uniformity index of the reinforced composite product is 8 or greater, the thickness variation of the reinforced composite product is 7% or less, and / or the thickness uniformity of the reinforced composite product is 61% or greater.

Implementation Method

[0013] Although the invention has been described and illustrated herein with reference to specific embodiments, it is not intended to be limited to the details shown. Rather, various modifications to the details may be made within the scope and within the equivalents of the claims and without departing from the invention.

[0014] Furthermore, various forms and embodiments of the present invention are illustrated in the figures. It should be understood that some or all of the features of any embodiment, combined with other embodiments and arrangements thereof, are specifically covered herein. Therefore, this detailed disclosure explicitly includes the specific embodiments described herein, combinations and sub-combinations of features of the described embodiments, and variations of the described embodiments.

[0015] It is acknowledged that panel manufacturing systems, including methods such as resin injection molding to impregnate substrates with resin for the production of composite materials, can lead to a higher risk of fabric pattern deformation. For example, a non-uniform surface appearance can be caused by the radial flow path of the polymer resin through the substrate in resin injection molding, which can result in varying degrees of resin distribution on the composite product. Radial resin flow peaks in resin injection molding can also lead to excessive resin waste. Furthermore, the radial resin flow in resin injection molding can prolong the substrate impregnation time when the substrate material may be non-circular. For example, in resin injection molding, the resin will take longer to reach and impregnate the corners of square or rectangular substrates. In addition, such manufacturing methods tend to use metal tool molds, which can make the laminate processing and curing processes lengthy.

[0016] In contrast to resin injection molding, some methods can be modified from resin injection molding, which include the following steps: coating, stacking and cooling pre-pressed portions of material for subsequent unpacking and pressing. For example, referring to Figure 23, the first method can be generally described as having four steps: step (A) resin mixing, step (B) prepreg production, step (C) prepreg book pressing and step (D) shelf production.

[0017] In step (A) of the first method, the components of the resin system are weighed, and a formulation of the components is determined and prepared. Although the mixing time may vary, resin mixing may take about 3 hours or longer. Thereafter, the mixed resin system is stored in a freezer for future use (possibly the next day).

[0018] In step (B), the prepared resin formulation is coated onto the desired substrate. Specifically, the resin is placed in a dispensing tank and then coated with a doctor blade. Furthermore, the resin-coated substrate is individually encapsulated in a layer of plastic film and stored in a freezer to allow the polymer to impregnate the substrate without initiating an exothermic reaction. This step can take 24 hours or longer and includes removing the resin from the freezer, coating the substrate with the resin, and storing the resin-coated substrate in the freezer (in some instances, this may require a minimum of 16 hours and can take up to 3 days).

[0019] In step (C), after a predetermined time of several hours to ten hours, the resin-impregnated substrates are removed from the freezer. Subsequently, the outer plastic film layer is removed from each substrate. New plastic film layers are added to both sides of the resin-impregnated substrates. Additionally, more layers of release film or release paper, or specially coated fabrics such as polytetrafluoroethylene (PTFE), may be added as necessary or advantageous. Multiple such layers are manufactured, stacked, and prepared to cure / crosslink the resin system, thereby producing a final product such as a composite laminate. The duration of this step may vary, but it can be completed in approximately 2 hours.

[0020] In step (D), the prepared resin-impregnated substrate layer is cured under hydrostatic pressure or a combination of two or more hydrostatic pressure cycles. At the end of the pressing cycle, the material is removed from the press. The plastic film and any other one or more material layers that may have been used in step (C) are then removed. This produces a cured composite laminate. The duration of this step may vary, but it can take approximately 2 hours to complete.

[0021] As will be discussed in more detail below, the improved method according to the present invention can further improve the first method. For example, the improved method can be low-labor-intensive, requiring less manpower, fewer process steps, and fewer operators in the production panels / shelves. Furthermore, the improved method can reduce the amount of wasted raw materials, thus increasing overall process output. Additionally, the improved method does not require special freezers or frozen storage materials, and also provides an overall setup with a significantly reduced operational footprint.

[0022] To further improve such systems, the present invention can also produce fiber or fabric or substrate-reinforced composite panels impregnated with polymer or resin systems in a semi-continuous process. The semi-continuous process offers significantly improved control, reduces volatile organic compound (VOC) emissions from the polymer or resin system, and provides other advantages.

[0023] Referring generally to the figures, System 100 is one embodiment of a modified system for using resin impregnation of a substrate and avoiding the use of a resin injection concept. Thus, System 100 reduces or eliminates the radiative flow path of the polymer through the substrate, and reduces or eliminates the non-uniform surface appearance caused by varying degrees of resin distribution or fabric pattern deformation on the composite laminate. System 100 also avoids the use of metal tool molds that can prolong the laminate curing process. As an alternative to the tool mold concept, the modified System 100 can use a set of disposable films as a mold according to one aspect of the invention.

[0024] The improved method (such as the embodiment of system 100) also includes improvements to the first method described above. For example, the improved method may be less labor-intensive, requiring fewer personnel, reducing the number of process steps and the number of operators in the production panel / layer. Furthermore, the improved method may be semi-continuous or continuous. In addition, the improved method can reduce the amount of wasted raw materials, thus increasing overall process yield. Other advantages of the improved method are described elsewhere herein.

[0025] Although the process path of Figure 1 illustrates certain steps performed in a specific order, it should be understood that embodiments of the present invention can be practiced by adding one or more steps to the process, omitting steps in the process, and / or changing the order in which one or more steps are performed.

[0026] Referring generally to the figures, a system 100 for producing a composite product is disclosed, the composite product including a substrate, such as substrate 14; and a resin, such as resin 106, integrated with substrate 14. A lower film supply, such as lower film supply 12, is located at an upstream end 102 of system 100, the upstream end being structurally designed to incorporate substrate 14 into system 100. Lower film supply 12 is structurally designed to introduce a lower film, such as lower film 316, into system 100 in a downstream direction toward a downstream end 104 of system, the downstream end being structurally designed to convey a composite product, such as final laminate 108, from system 100. A substrate supply, such as substrate supply 13, is located at the upstream end 102 of system 100 and is structurally designed to introduce substrate 14 onto lower film 316 in system 100 in a downstream direction toward downstream end 104 of system.

[0027] In step (A) as illustrated in FIG1, substrate 14 may be cut at substrate indexing station located at the upstream end 102 of the system.

[0028] In step (B), a resin dispenser, such as resin dispenser 15 (FIG. 2), is located downstream of substrate supply 13 and is structurally designed to coat resin 106 onto substrate 14 to form a resin-substrate assembly, such as assembly 16. Furthermore, an upper film supply, such as upper film supply 17, is located downstream of resin dispenser 15 and is structurally designed to introduce upper film 317 onto resin-substrate assembly 16 in system 100. As indicated by the boxed phrase "reduced emissions" in FIG. 1, VOC emissions can be reduced or eliminated by placing a seal on the gate of resin dispenser 15. Furthermore, the reduction or elimination of VOC emissions is not limited to this step or this location. For example, the reduction or elimination of VOC emissions can be achieved at multiple locations along the assembly line where VOC emissions may escape. Specifically, VOC emissions can be reduced or eliminated by keeping the edges of the release liner closed as the resin-substrate assembly 16 moves toward the press 11 from a housing (such as a resin dispenser 15) in which resin is coated. In another embodiment, VOC emissions can be reduced or eliminated by sealing the press 11 to retain heat and resin within the press 11 and by conveying a more fully polymerized product, such as the laminate 108.

[0029] In step (C), as the resin-substrate assembly 16 exits the resin dispenser 15 and moves downstream toward the next station such as soaking station 1 (entry 37 in FIG. 3A) and soaking station 2 (entry 38), each of these stations is structurally designed to seal the edge of the upper membrane 317 to the edge of the lower membrane 316, thereby reducing VOC emissions.

[0030] In step (D), the resin-substrate assembly 16 is moved downstream toward a press, such as press 11, which is positioned to apply pressure to the resin-substrate assembly via an upper membrane 317 and a lower membrane 316 when the resin-substrate assembly 16 is in the same position as the press 11. According to one embodiment of the invention, the curing process includes a resin temperature and viscosity control step to control crosslinking and molecular weight accumulation. The temperature and viscosity control step may be structurally designed to be performed at one or more soaking stations with preheating stations designed to initiate or accelerate the polymer reaction. In yet another embodiment, the curing process includes one or more soaking stations that use vacuum to remove any unwanted trapped air, contaminants, and / or particles from the resin-substrate assembly 16.

[0031] In step (E), a membrane removal station, such as membrane removal station 18, is located at the downstream end 104 of the system and is structurally designed to remove the lower membrane 33b and the upper membrane 35b from the resin-substrate assembly 16. At the downstream end 104 of the system, a reinforced composite product 108 is conveyed from the system 100. In one example, the reinforced composite product 108 comprises a substrate such as substrate 14 and resin 106 integrated with substrate 14, and has an outer surface characterized by uniformity in at least one of color, weave pattern, and surface mask appearance. In another example, the reinforced composite product 108 comprises a substrate such as substrate 14 and resin 106 integrated with substrate 14, and has an outer surface characterized by uniformity in at least one of thickness, fiber content, resin content, thickness after secondary pressing, noise generation in ultrasonic C-scan, and cross-section.

[0032] As explained in more detail elsewhere, among other improved characteristics, the improved method according to embodiments of the present invention can achieve, for example, the following: improved color consistency, reduced surface deformation, and improved thickness uniformity. Therefore, the method can produce final products and components that can be used for downstream processing, resulting in higher quality and more predictable final products and components.

[0033] Panel Production Assembly Generally speaking, the modified panel production assembly 200 disclosed herein uses two forming molds, a continuous or semi-continuous conveying system, and a press to produce composite panels. Embodiments of the panel production assembly are illustrated in the figures and described below.

[0034] In one embodiment, as illustrated in Figures 1 and 3A to 3D, a system 300 is provided for producing a composite product 314 comprising a substrate 31a and a resin 106 integrated with or impregnated therein. The system 300 includes a substrate supply, such as a fabric feed station 31, located at an upstream end 102 of the system and structurally designed to introduce the substrate 31a into the system in a downstream direction toward the press 39.

[0035] A substrate 31a can be cut from a larger substrate at a substrate indexing station, such as a fabric indexing and cutting station 32, located at the upstream end 102 of the system and structurally designed to index the substrate position 320 relative to the position of the lower film 316. The fabric indexing and cutting station 32 includes a cutter 32b having a vacuum cleaner to collect loose fibers from the substrate 31a, and rollers 32c structurally designed to move the substrate 31a along a continuous or semi-continuous conveying system. As can be seen in FIG4A, the fabric indexing and cutting station includes a side indexing rod 32d and a front indexing rod 32a having an upstream gate, such as an entry gate 319, which opens to allow the substrate to enter a resin dispenser, such as a resin dispensing system 34.

[0036] The lower film supply, such as a lower polyethylene terephthalate (PET) feed 33, is located at the upstream end 102 of the system and is structurally designed to introduce the lower film 316 into the system in a downstream direction toward the press 39. The lower PET feed 33 supplies the lower film, such as a lower film 33b comprising polyethylene terephthalate. The lower PET feed 33 also includes a brake 33a to provide counter-tension.

[0037] The substrate 31a is placed on the lower film and downstream toward a housing such as the resin dispensing system 34, which is located upstream of the press 39 and downstream of the fabric feeding station 31 and is structurally designed to coat the resin 106 onto the substrate 31a to form a resin-substrate assembly 16. The resin dispensing system 34 includes a resin reservoir, such as a resin tank 34a with a pumping system, which includes a pump structurally designed to propel the resin 106 onto the substrate 31a. The resin dispensing system 34 further includes a housing, such as a gantry system 34b, which is structurally designed to spray the resin 106 onto the substrate 31a, and the housing includes (i) a spray box 321, (ii) a nozzle, and (iii) a cleaning and soaking station 34c, as seen in Figures 3C and 4C.

[0038] The resin distribution system 34 further includes an exhaust device, such as an exhaust pipe 34d, which is structurally designed to reduce the pressure within the resin distribution system 34 and is positioned to drive VOCs from the resin distribution system 34 into a filter, such as the filter 41a of FIG. 4B, which is coupled to receive VOCs from the resin distribution system 34. The exhaust collection pipe 34d is operable when the resin distribution system 34 is opened to allow the substrate 31a to enter the resin distribution system 34 and to allow the resin-substrate assembly 16 to exit the resin distribution system 34.

[0039] The resin dispensing system 34 also includes a downstream gate or exit gate 318, such as (for example) a pneumatic transfer gate (back) 34e, which opens to allow the resin-substrate assembly 16 to exit the resin dispensing system 34.

[0040] The upper film supply 17, such as the upper PET feed 35, is located downstream of or aligned with the resin dispensing system 34. The upper PET feed 35 supplies the upper film 317, such as an upper film 35b comprising polyethylene terephthalate. The upper PET feed 35 also includes a brake 35a to provide counter-tension.

[0041] The upper PET feeding 35 is structurally designed to introduce an upper film 317 into the system, which is introduced downstream of an upstream gate such as the pneumatic transfer gate (front) 34e of the resin dispensing system 34, and onto the resin-substrate assembly. When the resin-substrate assembly exits the downstream gate of the resin dispensing system 34, the upper film 317 prevents VOCs from escaping from the resin-substrate assembly. The upper film 317 can be introduced into the top of the housing via a gate at a position downstream of the nozzle that coats the resin onto the substrate. In this configuration, the upper film 317 moves downwards onto the surface of the resin-wetted substrate and then exits the housing via a downstream gate.

[0042] For example, sensors or encoders connected to rotating objects such as rollers are part of system automation. Encoder rollers, such as encoder roller 36, are programmed to measure the distance the material moves along the process flow direction to ensure consistent and accurate material placement in each process step. Encoder rollers can also be programmed for dynamic behavior, so that the material movement rate is smooth and without sudden starts and stops to ensure good process flow and continuity.

[0043] The resin-substrate assembly is pulled to one or more immersion stations such as immersion station 1 (37) and immersion station 2 (38), each of which includes an edge sealer containing one or more brushes (37a, 38a) designed to seal the edge of the upper membrane 317 to the edge of the lower membrane 316, thereby reducing VOC emissions when the resin-substrate assembly exits the downstream gate 34e of the resin dispensing system 34.

[0044] In one embodiment of the invention, at least one wetting station includes a heater, which is structurally designed to maintain its high temperature as the resin-substrate assembly moves downstream toward the press 39. Maintaining the high temperature of the resin-substrate assembly can be achieved by means of at least one of ultraviolet light, a heating lamp, or other temperature sources that will be understood by those skilled in the art.

[0045] The press 39 is located downstream of the upper film supply 35 and downstream of the film removal station 18, such as the peeling station 313. Furthermore, the press 39 is positioned to apply pressure to the resin-substrate assembly via the upper film 317 and the lower film 316 when the resin-substrate assembly is in the same position as the press 39. Additionally, as seen in Figures 5A and 5B, the press 39 is, in some cases, a heated hydraulic press having at least one of a top platen 51 and a bottom platen 52.

[0046] The press 39 is structurally designed to close on the lower film 316 and the upper film 317 when the resin-substrate assembly is between the lower film 316 and the upper film 317, until a seal is formed to seal at least a portion of the lower film 316, the upper film 317, and the resin-substrate assembly. When the top platen 51 and the bottom platen 52 are moved apart by moving at least one of the top platen 51 and the bottom platen 52, the press 39 opens and the seal is disengaged, and the resin-substrate assembly is pulled to the cooling station 311, which is located upstream of the film removal station 18, such as the peeling station 313.

[0047] System 300 also includes a traction station, such as station 312 having a puller 312a, which is structurally designed to pull the lower film 316 and the upper film 317 in a downstream direction when the resin-substrate assembly is between the lower film 316 and the upper film 317. The puller 312a is located upstream and downstream of a press in a film removal station such as a peeling station 313. The peeling station 313 is structurally designed to remove the lower film 316 and the upper film 317 from the resin-substrate assembly. The peeling station 313 includes an unwinder such as a winding machine 313a, which is structurally designed to wind the lower film 316 and the upper film 317 onto separate rolls (313b, 313c) of the lower film 316 and the upper film 317. The winding machine 313a includes a drive motor, a gearbox, and a clutch (if applicable).

[0048] At the downstream end 104 of the system, a reinforced composite product 314 is conveyed from the system 300. In one example, the reinforced composite product 314 includes a substrate such as a substrate 31a, resin 106 integrated with the substrate 31a, and has an outer surface characterized by uniformity in at least one of color, weave pattern, and surface mask appearance. In another example, the reinforced composite product 314 includes a substrate such as a substrate 31a, resin 106 integrated with the substrate 31a, and has an outer surface characterized by uniformity in at least one of thickness, fiber content, thickness after secondary pressing, noise generation in ultrasonic C-scan, resin content, and cross-section.

[0049] Referring now to Figure 2, press 11 is located downstream of upper membrane supply 17 and upstream of membrane removal station 18. Furthermore, press 11 is positioned to apply pressure to resin-substrate assembly 16 via upper and lower membranes when resin-substrate assembly 16 is in the same position as press 11. Press 11 is structurally designed to apply pressure to resin-substrate in an amount suitable for a specific coating. For example, press 11 can apply pressure from 0 psi to 300 psi, preferably from 10 psi to 200 psi, or even more preferably from 20 psi to 150 psi.

[0050] The press 11 is also structurally designed to apply pressure for a predetermined time. For example, the press 11 may be structurally designed to apply pressure for 4 to 60 minutes, preferably 5 to 30 minutes, or even better, 5 to 10 minutes. In one embodiment, the press 11 is structurally designed to apply pressure as a function of time. As illustrated in Figure 4B, a process control station, such as the control system 42, is structurally designed to control various process parameters, including press parameters such as pressure, time, and temperature. These parameters may be programmed for operation in automatic or manual mode.

[0051] As seen in Figures 5A and 5B, the press 39 includes a top platen 51 and a bottom platen 52, which are mounted to move relative to each other. When the top platen 51 and bottom platen 52 are moved toward each other by moving at least one of them, the press 39 can close on the lower film 316 and upper film 317 while the resin-substrate assembly 16 is between the lower film 316 and the upper film 317, until a seal is formed to seal at least a portion of the lower film 316, the upper film 317, and the resin-substrate assembly 16. When the top platen 51 and bottom platen 52 are moved apart by moving at least one of them, the press 39 opens and the seal disengages.

[0052] The bottom platform 52 is mounted on the press 53, which is structurally designed to move relative to the pressure top 54. The press 53 and the pressure top 54 are spaced apart by a fixed distance D defined by a plurality of vertical guide posts 55. The distance between the top platform 51 and the bottom platform 52 decreases when the top platform 51 and the bottom platform 52 are moved toward each other by moving at least one of them. The press 39 further includes an oil tank 56, which is structurally designed to supply working fluid and includes a pressure relief valve.

[0053] In one embodiment, as seen in Figures 3A, 4A, and 4B, the press is a hydraulic press. Furthermore, as seen in Figures 3A, 4A, and 4B, at least one of the top platen 51 and the bottom platen 52 can be heated. At least one of the top platen 51 and the bottom platen 52 can be heated to a high temperature, for example, 60℉ to 400℉, preferably 70℉ to 300℉, or even more preferably 80℉ to 250℉.

[0054] In one embodiment, as shown in FIG3A, system 100 further includes a heater, such as an oil heater 315, which is structurally designed to heat the substrates (51, 52) to a high temperature above ambient temperature. The high temperature is selected to accelerate the curing or polymerization of the resin 106 of the resin-substrate assembly. The high temperature is also selected to control the reaction rate and the molecular weight of the crosslinked polymer in the final composite. In one example, heater 351 is structurally designed to heat the resin-substrate assembly to temperatures up to 240℉ (or higher, depending on the selected materials and process parameters). Heater 351 can heat to temperatures from 60℉ to 400℉, preferably from 70℉ to 300℉, or even more preferably from 80℉ to 250℉. In another example, the temperature is selected via a process control station such as control system 42 of FIG4B.

[0055] In one embodiment, as shown in FIG8A, a substrate supply 13, such as fabric 81, is structurally designed to introduce a substrate 31a, such as a roll of fabric 81a, into the system 300 in a downstream direction toward the resin dispenser 15 including the gantry 321. The substrate 81a can be cut from a larger substrate at a cutting station 32, such as a fabric cutter 82, located at the upstream end 102 of the system.

[0056] The substrate 14 may include fibrous materials, non-fibrous materials, or combinations thereof. Furthermore, the substrate 14 may include metallic materials, non-metallic materials, or combinations thereof. For example, the substrate 14 may include one or more of the following: glass, carbon, ceramic, basalt, steel, and cellulose fiber materials and combinations thereof. Additionally, the substrate 14 may include one or more of the following: continuous, discontinuous, woven, non-woven, pressed, non-pressed, unidirectional, multidirectional, porous, and non-porous materials and mixtures or combinations thereof.

[0057] In a particular embodiment, the substrate 14 is substantially planar and has an outer periphery. Furthermore, as illustrated in FIG9C, the outer periphery of the substrate 14 may be a geometric shape, a predetermined shape, or an arbitrary shape. In one embodiment, for example, as seen in FIG9C, the geometric shape may be rectangular or square.

[0058] As illustrated in Figures 2 and 3A, the substrate 14 can be cut from a larger substrate at the upstream end 102 of the system. Furthermore, the system 100 can be structurally designed to receive the substrate 14 cut using CNC or nesting operations. The thickness of the substrate 14 can vary. For example, the substrate 14 can have a thickness not exceeding approximately 5 mm, but it can also be thicker or thinner.

[0059] Resin Dispenser The resin dispenser 15 may be structurally designed to be coated with a resin, such as resin 106, which includes a thermoplastic or thermosetting polymer having a viscosity of up to 5000 cp. In another example, the resin dispenser 15 may be structurally designed to be coated with resin 106, the resin including a thermoplastic or thermosetting polymer having a lower viscosity of up to 500 cp, preferably up to 250 cp, or more preferably about 100 cp or lower. The resin dispenser 15 may also be structurally designed to be coated with resin 106, the resin including crosslinkable polymers, monomers, or combinations thereof. Furthermore, the resin dispenser 15 may also be structurally designed to be coated with resin 106, the resin including one or more of the following: colored packaging, reaction initiators, reaction inhibitors, impact modifiers, flame retardants, lubricants, light stabilizers, conductive or thermally conductive additives, and antioxidants.

[0060] In another embodiment, the resin dispenser 15 may be configured to coat resin 106, the resin comprising a thermoplastic polymer soluble in a solvent to reduce viscosity. In one example, the resin dispenser 15 may be configured to coat resin 106, the resin comprising polycarbonate dissolved in a suitable solvent such as dichloromethane (DCM). As illustrated in Figures 9B to 9D, the resin dispenser is configured to coat resin 106 by spraying. Alternatively, those skilled in the art will readily understand that resin 106 may also be coated by dripping, dipping, cascading, water bath, blade application, and other coating methods.

[0061] Referring now more closely to Figures 1 and 9A, a resin dispenser 15, such as a resin dispenser 91, includes a housing such as a gantry system 919, which is structurally designed to spray a resin, such as resin 106, onto a substrate 14. The resin dispenser 91 has an upstream gate or inlet gate 319, such as a front pneumatic gate 911, which opens to allow the substrate 14 to enter the resin dispensing system 91. The resin dispenser 91 further includes nozzles, such as spray heads 921, for spraying resin 106 onto the substrate 14. The spray head 921 is coupled to a support such as a spray head holder 913, which is movable in a direction downstream of the system.

[0062] In one embodiment, the nozzle 921 is movable in a first direction and is structurally designed to spray resin 106 onto the substrate 14 in a single pass. In another embodiment, the nozzle 921 is immovable and is structurally designed to spray resin 106 onto the substrate 14 as it moves downstream of the system. In one embodiment, the resin dispenser 91 includes a plurality of nozzles 921 structurally designed in a sequence, each nozzle being structurally designed to move in the first direction to spray resin 106 onto the substrate 14 in at least one pass. In yet another embodiment, the resin dispenser 91 includes a plurality of nozzles 921 structurally immovable, so that the nozzles 921 coat the substrate 14 with resin 106 as it moves downstream of the system. Furthermore, each nozzle may be structurally designed to spray different formulations of resin 106 along a predetermined pattern. In other words, different resin formulations can be coated in parallel or simultaneously using different nozzles or sprayers.

[0063] The upper membrane supply 17 (not shown in Figures 1 and 9A) is located downstream of the resin dispenser 91 and is structurally designed to introduce an upper membrane 317 (not shown) onto the resin-substrate assembly 16. The upper membrane supply 17 is structurally designed to introduce the upper membrane 317 into the system via an upper membrane gate, such as a gate 916. The upper membrane supply 17 introduces the upper membrane 317 in a downstream direction toward an upstream gate (such as a front pneumatic gate 911) of the resin dispensing system 91 and onto the resin-substrate assembly 16. When the resin-substrate assembly 16 exits the downstream gate of the resin dispenser 91 or exits through a gate 318 (such as a rear pneumatic gate 917), the upper membrane 317 provides a barrier to prevent VOCs from escaping from the resin-substrate assembly 16. The rear gate 917 opens to allow the resin-substrate assembly 16 to exit the resin dispenser 91. The resin dispenser 91 further includes (i) a first gantry motor and gearbox 912, (ii) a washing and soaking station 914, (iii) a second gantry motor and gearbox 915 and (iv) a gantry bracket 918.

[0064] Finally, the resin distributor also includes an exhaust device, such as an exhaust collection pipe 920, which is structurally designed to reduce the pressure in the gantry system 919 and is positioned to drive VOCs from the gantry system 919 to a filter, such as filter 41a in FIG. 4B, which is coupled to receive VOCs from the gantry system 919 of the resin distributor 91. The exhaust collection pipe 920 can operate when the gantry system 919 is opened to allow the substrate 14 to enter the gantry system 919 and to allow the resin-substrate assembly 16 to exit the gantry system 919.

[0065] As illustrated in Figures 3A and 9A to 9B, the resin dispenser 91 may include a reservoir, such as a resin tank 34a, for containing resin 106; and a nozzle, such as a nozzle 921, coupled to receive resin 106 from the reservoir 34a and for spraying resin 106 onto the substrate 14. Furthermore, the resin dispenser 91 may include a nozzle support, such as a nozzle holder 913, which is movable in a direction downstream of the system.

[0066] Referring now to FIG. 9C, the resin dispenser 91 may be structurally designed to spray resin 106 onto substrate 31a along a pattern. In one example, as seen in pattern 93, the spray pattern corresponds to the periphery 931 of a component such as substrate 31a. In another embodiment, as seen in pattern 94, the spray pattern corresponds to the shape 941 of a component such as substrate 31a. In yet another example, the spray patterns (93, 94) correspond structurally to a plurality of nozzles such as nozzles 921, each nozzle 921 being designated and connected to dispense a formulation of resin 106 onto substrate 31a. In yet another embodiment, the pattern may be predetermined.

[0067] As illustrated in Figure 9B, a nozzle such as nozzle 921 may have an eye-shaped structure 921b or a square structure 921a. Furthermore, the eye-shaped structure 921b may have opposing oblique holes forming a flat shape. Additionally, the eye-shaped structure 921b may have a specific angle and hole diameter structure. Moreover, those skilled in the art should readily understand that various nozzles such as nozzle 921 can be used.

[0068] As shown in Figures 9A to 9C, the resin dispenser 91 may include a support for the nozzle, such as a nozzle holder 913. Referring now to Figure 9A, the resin dispenser 91 may further include a controller or control system, which includes a first gantry motor and gearbox 912 and a second gantry motor and gearbox 915 coupled to the support 913. As seen in Figure 9D, the controllers (912, 915) may be structurally designed to control the movement of the nozzle 921 at least partially based on the shape of the substrate along a predetermined pattern 95 in the xy coordinates. Those skilled in the art will readily understand that the predetermined pattern in the xy coordinates is defined using a programming language.

[0069] Referring now to FIG. 6A, a lower membrane supply, such as a lower feeder 61, is structurally designed to supply a lower membrane 316. In one embodiment, as seen in FIG. 3A, a lower membrane supply 12, such as a lower membrane 33b, comprises polyethylene terephthalate or polycarbonate. The lower membrane supply 12 may be structurally designed to supply a lower membrane 316 with a thickness of 0.01 inches or less. Furthermore, the lower membrane supply 12 may be structurally designed to supply a lower membrane 316 having a nominal thickness of 0.075 mm.

[0070] Referring now to FIG. 7A, the upper membrane supply, such as upper membrane feed 71, is structurally designed to supply upper membrane 317. In one example, as seen in FIG. 3A, upper membrane 317, such as upper membrane 35b, comprises polyethylene terephthalate or polycarbonate. Furthermore, upper membrane supply 17 may be structurally designed to supply upper membrane 317 with a thickness of 0.01 inch or less. In one embodiment, upper membrane supply 17 may be structurally designed to supply upper membrane 317 having a nominal thickness of 0.075 mm.

[0071] Referring now to FIG. 3C, the lower film supply, such as the lower film supply 33, and the upper film supply, such as the upper film supply 35, include an uncoiler, such as an uncoiler 322, which is structurally designed to supply the lower film 316 and the upper film 317 from separate rolls (33, 35) of the lower film 316 and the upper film 317. For example, a roll of fabric or a combination of rolls of fabric can be unrolled and cut into finite segments.

[0072] In one embodiment, as seen in FIG10, the membrane removal station 1001, such as the peeling station 313, includes a winding machine such as a winding machine 1006, which is configured to wind a lower membrane such as a lower membrane 1004 and an upper membrane such as an upper membrane 1003 onto separate rolls such as a lower take-up 1004 and an upper take-up 1002. The membrane removal station 1001 is configured to remove the lower membrane 1004 and the upper membrane 1003 from the resin-substrate assembly.

[0073] At the downstream end 104 of the system, a reinforced composite product, such as a laminate 1005, is conveyed from the system. In one example, the reinforced composite product 1005 has an outer surface characterized by uniformity in at least one of color, weave pattern, and surface masking appearance. In another example, the reinforced composite product 1005 has an outer surface characterized by uniformity in at least one of thickness, fiber content, thickness after secondary pressing, noise generation in ultrasonic C-scan, resin content, and cross-section.

[0074] In another embodiment, as seen in Figures 3A to 3C, system 300 includes a traction station such as station 312, which is structurally designed to pull the lower film 316 and the upper film 317 in a downstream direction when the resin-substrate assembly 16 is between the lower film 316 and the upper film 317. In one example, traction station 312 is located downstream of press 39. In another example, traction station 312 is located upstream of film removal station such as peeling station 313. The traction station may include puller 312a. The traction station can be used to control the predetermined distance traveled by the overall system as part of a semi-continuous operation of the process, which consists of a substrate, a resin-coated substrate, a composite laminate, a bottom film, and a top film.

[0075] In one embodiment, the system includes at least one wetting station designed to facilitate the integration of resin 106 into the substrate of the resin-substrate assembly. Systems such as system 300 may include a plurality of wetting stations. In one embodiment of the invention, at least one wetting station includes a preheating station designed to initiate the polymer reaction and maintain its high temperature as the resin-substrate assembly moves downstream of the system. Maintaining the high temperature of the resin-substrate assembly can be achieved by means of ultraviolet light, a heating lamp, or other heating methods that should be understood by those skilled in the art. In yet another embodiment, at least one wetting station is designed to use a vacuum to remove any unwanted stagnant air, contaminants, and / or particles.

[0076] Furthermore, as seen in FIG3A, immersion stations such as immersion station 1 (37) and immersion station 2 (38) may be located downstream of a resin dispenser such as resin dispensing system 34. In one example, at least one immersion station such as immersion station 1 (37) and immersion station 2 (38) is located upstream of press 39. In one embodiment, the immersion station may include an edge seal, which is structurally designed to seal the edge of the upper membrane to the edge of the lower membrane, thereby reducing VOC emissions. The edge seal may include one or more brushes (37a, 38a). The edge seal will remove or resist or prevent the entry of any unwanted dust, impurities, foreign matter and / or other contaminants or unwanted materials from resin-substrate assembly 16 that may cause unacceptable defects in the final product 314.

[0077] In another embodiment, as seen in Figures 3A to 3D, system 300 includes a substrate indexing station, such as a fabric indexing and cutting station 32, which is structurally designed to index substrate positions, such as position 320, relative to the position of the lower film 316. In one example, substrate indexing station 32 includes stations in which a plurality of substrates 31a are stacked, juxtaposed, fully overlapped, or partially overlapped in a predetermined pattern coated with resin. In one embodiment, substrate indexing station 32 includes an inspection station structurally designed to detect deformation in one or more substrates 31a prior to resin coating.

[0078] Referring now to Figures 3A to 3D, the system further includes a cutter such as cutter 32b, which is structurally designed to cut a substrate such as substrate 31a. In one example, cutter 32b includes a CNC cutter. In another example, the cutter is coupled to a vacuum cleaner capable of removing unwanted dust / residue.

[0079] As illustrated in Figure 3A, the system 300 further includes a cooling station such as cooling station 311, which is located upstream of a film removal station such as stripping station 313. Cooling station 311 may include active cooling functions (e.g., by airflow or cooling air or cooling surfaces). Alternatively, it may provide a resting place for the material and be cooled by passive heat transfer to the room air.

[0080] As seen in Figures 1A and 3A, a resin dispenser with a pump, such as a resin dispensing system 34, includes a pumping system 34a having a pump designed to propel resin, such as resin 106, onto a substrate, such as a substrate 31a. The pump of system 34a can be, for example, a peristaltic pump, a metering pump, a gear pump, a diaphragm pump, or a Stokes pump. Furthermore, the pump system 34a is selected depending on the resin 106 used and can be a single-component or multi-component system.

[0081] In one embodiment, as illustrated in Figures 1A, 9A to 9D, a resin dispenser 91 is configured to apply a resin, such as resin 106, by spraying, dripping, dipping, flowing, or bathing the resin 106 into or onto a substrate, such as substrate 31a. In the illustrated embodiment, the resin dispenser 91 is configured to spray resin 106 onto substrate 31a. In this embodiment, the resin dispenser 91 includes a nozzle, such as a spray head 921, configured to apply resin 106 along a pattern, such as a planar pattern (93, 94).

[0082] As described above and illustrated in the figures, the panel production system can use a plastic carrier film (316, 317) under the cut fabric or substrate 31a, wherein the film (316, 317) extends at least partially or all the way to the other end of the production line (from the upstream end 102 to the downstream end 104). A puller, such as a puller 312a, located at the downstream end of the production line, pulls the carrier film (316, 317) and the fabric or substrate 31a thereon.

[0083] In an exemplary embodiment, a substrate, such as substrate 31a, in the form of a dry fabric, is pulled into a housing, such as gantry 321. The resin, such as resin 106, comprises a premixed MMA / PMMA formulation and components such as reaction initiators (peroxides), reaction inhibitors, color packaging, fillers (such as fine clay), surfactants (for reducing surface tension), impact modifiers, and other additives as applicable. These components are sprayed onto the fabric or substrate 31a. Referring to FIG. 14A, housing 321 ensures that all or substantially all VOCs are contained, and an exhaust device, such as fan 1406, continuously blows or draws unwanted air into or into one or more containers, such as cylinders 41a, which have filter materials such as activated carbon to capture VOCs.

[0084] The low viscosity of the resin mixture 106 (e.g., <500 cp or more preferably up to 250 cp or most preferably about 100 cp or less) results in rapid impregnation of the fabric or substrate material 31a when the substrate is driven by capillary forces. Although viscous forces can be used, the lower viscosity resin 106 can reduce the soaking time required to adequately wet the fabric or substrate 31a.

[0085] The substrate-resin assembly 16 is pulled out of the outer shell, such as the gantry box 321, by means of a puller 312a. When pulling out the substrate, another layer of plastic film 317 is added to the wet fabric or the substrate 16. This film 317, which is very similar to the bottom film 316 described above, is pulled out using the same puller 312a.

[0086] The top film layer 317, the wetted fabric / substrate 16, and the bottom film layer 316 form a closed system that restricts or prevents VOC emissions. Therefore, the top and bottom films (317, 316) form a mold such as mold 1101 in FIG. 11A. The combination of materials and components forming mold 1101 (top film layer, wetted fabric / substrate, and bottom film layer) is drawn into a preheated and pre-programmed press such as press 39. The reaction begins under optimized temperature, pressure, and time conditions, and the resin cures. After a pressing cycle, the film / layer / film combination 1101 is pulled over pressure rollers, and panels such as layer 1005 are removed. The top and bottom film layers (1003, 1004) are rolled into rolls (1002, 1004) for handling and removal.

[0087] Toolless Mold Assembly Referring now to Figures 1A, 3A, 10A and 11A, a mold 1101 is provided for use with a press 39 to form a composite product (such as a laminate 1005) including a substrate 31a and a resin (such as resin 106) integrated with the substrate 31a. The mold 1101 includes a lower film, such as film 1103, which is structurally designed to move relative to the press 39 in a downstream direction extending from an upstream end of the press 39 to a downstream end of the press 39. The lower film 1103 has an upper surface, such as surface 1103a, disposed to support an assembly of the substrate and the resin (such as assembly 1104). The lower film 1103 also has a continuous length selected to extend beyond the upstream end of the press 39 in the upstream direction and beyond the downstream end of the press 39 in the downstream direction.

[0088] Mold 1101 also includes an upper membrane 1102, which is structurally designed to move relative to press 39 in a downstream direction, extending from the upstream end of press 39 to the downstream end of press 39. The upper membrane 1102 has a lower surface, such as 1102a, which is positioned and structurally designed to contact the substrate and resin assembly 1104. As with the lower membrane 1103, the upper membrane 1102 also has a continuous length selected to extend beyond the upstream end of press 39 in the upstream direction and beyond the downstream end of press 39 in the downstream direction.

[0089] In mold 1101, the seal is formed by contact between the upper surface 1103a of the lower film 1103 and the lower surface 1102a of the upper film 1102. The seal thus formed is positioned to at least partially surround the substrate. The seal extends along a portion of the continuous length of the lower film 1103 and the upper film 1102. The seal also extends laterally along the continuous length of the lower film 1103 and the upper film 1102. The lower film 1103, the upper film 1102, and the seal together define the interior of the mold, which is structurally designed to be sealed into the assembly 1104 of the substrate and the resin 106.

[0090] In one embodiment, the encapsulation is formed to at least partially surround the periphery of the substrate 31a. The periphery has a shape that generally corresponds to the shape of the substrate 31a, thereby reducing the amount of resin 106 extruded from the substrate 31a when pressure is applied.

[0091] The lower membrane may comprise polyethylene terephthalate or polycarbonate, such as lower PET feedstock 33. In one embodiment, the lower membrane may comprise polyethylene or polyetherimide or other suitable polymeric material. In one example, the thickness of the lower membrane 1103 is 0.01 inches or less. In another example, the lower membrane 1103 has a nominal thickness of 0.075 mm.

[0092] Similarly, the upper film may include polyethylene terephthalate or polycarbonate, such as upper PET feed 35. In one embodiment, the upper film 1102 has a thickness of 0.01 inches or less. Furthermore, the upper film 1102 may have a nominal thickness of 0.075 mm. The upper film 1102 may be identical to the lower film 1103 in at least one of the following: size, composition, and source.

[0093] According to one example, the film substrate (1102, 1103) is formed of polyethylene terephthalate, with a width of 60 to 63 inches and a thickness of 0.075 mm. The thickness can be up to 0.254 mm (0.01 in) or thicker. Depending on the substrate, such as substrate 31a, and the finished product size, such as layer 1005, the width of the film (1102, 1103) is determined by the process dimensions and can be up to 5 meters wide.

[0094] Although the same membrane is expected to be used for both the top and bottom membranes (1102, 1103), different materials may be used for both the top and bottom membranes (1102, 1103). Furthermore, other membrane materials may be used depending on the type of polymer and resin to be used in a particular product and the release characteristics of the selected resin matrix. Thermosetting resin systems may also require additional membranes and / or release films.

[0095] As described above, the system according to the present invention may form a closed "mold" such as mold 1101 without the need for injection or introduction of resin such as resin 106 into the mold. In other words, the top and bottom films (1102, 1103) become the mold, and the seal formed between the top and bottom films by the press 39 (to prevent liquid resin from flowing out under pressure) becomes part of the mold.

[0096] Referring now to Figures 1A, 2A, 3A to 3D and 12A, one embodiment of a method for producing a composite product including a substrate 31a and a resin (such as resin 106) integrated with the substrate or fabric 31a includes supplying a lower film 316 to be introduced in a downstream direction.

[0097] In step (A), the lower membrane 316 is supplied to introduce the lower membrane 316 in the downstream direction.

[0098] In step (B), substrate 31a is supplied to be introduced into the substrate 31a in the downstream direction and introduced onto the lower film 316.

[0099] In step (C), resin 106 is dispensed to coat the substrate 31a with resin 106 to form resin-substrate assembly 16.

[0100] In step (D), the upper film 317 is supplied to introduce the upper film 317 onto the resin-substrate assembly 16.

[0101] In step (E), pressure is applied to the resin-substrate assembly 16 via the upper film 317 and the lower film 316.

[0102] Finally, in step (F), the lower film 316 and the upper film 317 are removed from the resin-substrate assembly 16.

[0103] Referring now to FIG1A, FIG3A to FIG3D and FIG12B, a method for producing a composite product according to one embodiment of the present invention is disclosed.

[0104] In step (A), a lower membrane supply such as a lower membrane supply 33 is structurally designed to introduce a lower membrane such as a lower membrane 33b into the system in a direction downstream toward the press 39.

[0105] In step (B), the upper membrane supply, such as the upper membrane supply 35, is structurally designed to introduce the upper membrane, such as the upper membrane 35b, into the resin dispenser, such as the resin dispensing system 34, in a downstream direction toward the resin dispenser 34.

[0106] In step (C), a substrate, such as a substrate or fabric 31a, is supplied to introduce the substrate 31a in a downstream direction.

[0107] In step (D), a resin such as resin 106 is prepared and coated onto substrate 31a.

[0108] In step (E), substrate 31a is cut from the larger substrate.

[0109] In step (F), the substrate supply, such as station 31, supplies substrate 31a onto the lower film 33b in a downstream direction toward resin dispenser 34.

[0110] In step (G), resin dispenser 34 dispenses resin 106 to coat the resin 106 onto substrate 31a to form a resin-substrate assembly such as assembly 16.

[0111] In step (H), an upper film, such as an upper film 35b, is coated onto the resin-substrate assembly 16. As the resin-substrate assembly 16 exits the resin dispenser 34 and moves downstream toward a station such as soaking station 1 (37) and soaking station 2 (38), the upper film 35b prevents VOCs from escaping from the resin-substrate assembly. Each of these stations includes an edge seal containing one or more brushes (37a, 38a) designed to seal the edge of the upper film 35b to the edge of the lower film 33b, thereby reducing VOC emissions. Furthermore, resin temperature and viscosity control, including controlling the temperature at one or more soaking or wetting stations, can be performed to control crosslinking and molecular weight accumulation.

[0112] In step (I), the resin substrate assembly moves in a downstream direction toward a press such as press 39.

[0113] In step (J), the press 39 is structurally designed to apply pressure to the resin-substrate assembly 16 via the upper membrane 35b and the lower membrane 33b when the resin-substrate assembly 16 and the press 39 are in the same position.

[0114] In step (K), the press 39 is turned on and the resin-substrate assembly 16 is pulled to the cooling station 311, which is located upstream of the film removal station 18, such as the peeling station 313.

[0115] In step (L), a traction station, such as a station 312 having a puller 312a, is structurally designed to pull the lower film 33b and the upper film 35b in a downstream direction when the resin-substrate assembly 16 is between the lower film 33b and the upper film 35b. At the downstream end 104 of the system, the reinforced composite product 314 is conveyed.

[0116] In one example, the reinforced composite product 314 includes a substrate such as substrate 31a, resin 106 integrated with substrate 31a, and an outer surface characterized by uniformity in at least one of color, weave pattern, and surface mask appearance. In another example, the reinforced composite product 314 includes a substrate such as substrate 31a, resin 106 integrated with substrate 31a, and an outer surface characterized by uniformity in at least one of thickness, fiber content, thickness after secondary pressing, noise generation in ultrasonic C-scan, resin content, and cross-section.

[0117] Referring now to FIG12C, a method for producing a composite product according to an embodiment of the present invention is disclosed, which generally follows the following steps: Step (A): Mode selection Step (B): Injection and movement while the press is open Step (C): Cutting and indexing the fabric Step (D): Activating the fabric preparation button Step (E): The system will start the cycle. If the process has already been run, the next cycle will begin before the press is opened. Step (F): The cleaning station will be lowered. Step (G): The H-bot will move to the starting position. Step (H): The pump will start and the nozzle will open. Step (I): Resin is applied to the fabric with the spray pattern. Step (J): At the end of the spray pattern, the nozzle will move to the middle of the fabric. Step (K): The carbon filter fan will start. Step (L): The nozzle will pause and the spray gun will close. Step (M): Move to the soaking station. Step (N): The cleaning station will rise. After the previous spraying operation is completed, it is expected that some residual polymer will remain on the polymer nozzle. For reactive polymer systems or polymer systems that can harden over time, it is important to ensure that the nozzle remains operational and ready for the next spraying cycle. The cleaning station in step (N) is designed to contain a suitable solvent that can dissolve the polymer used. At the end of each spraying cycle, the nozzle returns to the pre-programmed "home" position as needed. Thereafter, the cleaning station containing the solvent rises to immerse the nozzle in the solvent. Alternatively, the nozzle may be lowered into the solvent. This allows the solvent to dissolve the polymer and remove the polymer from the nozzle, or at least keeps the polymer soft enough to ensure process continuity and prepare the resin nozzle for the next round of coating the substrate with the polymer formulation. Step (O): The spray box and fabric indexing gate will open. Step (P): Material receiving will begin. Step (Q): The puller will begin. Step (R): The fabric and film will be moved and indexed to the next station. Step (S): The finished panel will be peeled off the PET film. Step (T): The finished panel will detach from the receiving system. Step (U): The puller will stop during indexing. Step (V): The receiving system will stop. Step (W): The spray box and fabric indexing gate will close. Step (X): The process will repeat in approximately 5 minutes (returning to step (C)).

[0118] Referring now to FIG12D, a method for producing a composite product according to another embodiment of the present invention is disclosed, which generally follows the following steps: Step (A): Mode selection Step (B): Injection and movement while the press is open Step (C): Cutting and indexing the fabric Step (D): Activating the fabric preparation button Step (E): The system will start the cycle. If the process has already been run, the next cycle will begin before the press is opened. Step (F): The cleaning station will be lowered. Step (G): The H-bot will move to the starting position. Step (H): The pump will start and the nozzle will open. Step (I): Resin is applied to the fabric with the spray pattern. Step (J): At the end of the spray pattern, the nozzle will move to the middle of the fabric. Step (K): The carbon filter fan will start. Step (L): The nozzle will pause and the spray gun will close. Step (M): Move to the soaking station. Step (N): The cleaning station will rise. As described above, the cleaning station containing solvent will rise to immerse the nozzles and dissolve or soften any residual resin from the previous spraying operation. Step (O): The press will open. Step (P): The spray box and fabric indexing gate will open. Step (Q): Receiving will begin. Step (R): The puller will begin. Step (S): The fabric and film will move and index to the next station. Step (T): The finished panel will be peeled from the PET film. Step (U): The finished panel will detach from the receiving system. Step (V): The puller will stop during indexing. Step (W): The receiving system will stop. Step (X): The press will close. Step (Y): The spray box and fabric indexing gate will close. Step (Z): The process will repeat in approximately 5 minutes (back to step (C)).

[0119] In one embodiment, the process path of any of 12A to 12D includes heating the resin-substrate assembly 16 to a high temperature above ambient temperature. The high temperature is selected to accelerate the curing or polymerization of the resin in the resin-substrate assembly.

[0120] In yet another embodiment, the process path of any of 12A to 12D further includes sealing the periphery of the lower film 316 and the upper film 317 to at least partially surround the substrate 31a. The periphery may have a shape that generally corresponds to the shape of the substrate 31a, thereby reducing the amount of resin extruded from the substrate when pressure is applied.

[0121] In one example, the process path of any of 12A to 12D includes applying pressure to the resin-substrate assembly 16 for a predetermined period of time. The process may include varying the amount of pressure applied to the resin-substrate assembly 16 over time during the predetermined period of time.

[0122] Due to the varying national and local government regulations on the release of volatile organic compounds (VOCs), the amount of methyl methacrylate (MMA) that can be used during manufacturing is limited. Therefore, process improvements are beneficial and necessary. In order to reduce the amount of VOCs released, the methods and systems described herein are designed to reduce emissions and minimize potential manufacturing output.

[0123] To capture VOCs, composite products in panel form are cured between two films (316, 317), such as polyester release liner. A substrate, such as fabric 31a, is carried on film 316 as the substrate moves from and exits the resin coating area, such as spray box 321, to hot press 39. To monitor VOC emissions, the weight of the fabric and release liner is recorded throughout the process, and can be subtracted from the weight of the cured panel, such as layer 1005, at the end of the process line. The final resin weight can be calculated using this method. The initial weight of a carbon filter cylinder, such as container 41a, can also be recorded, and the net weight of the captured VOCs can be obtained by subtracting the initial weight from the final weight.

[0124] Compared with other manufacturing methods such as the first method described herein, the method according to the present invention unexpectedly provides the following improvements: in terms of VOC emission reduction, the improvement is greater than 50%, more preferably greater than 60%, and even more preferably greater than 70%. This improvement over other manufacturing methods makes the improved method an important step in the direction of reducing VOCs while simultaneously increasing productivity.

[0125] Method improvements have been made to reduce VOC releases during manufacturing, while closely monitoring the release of volatile organic compounds (VOCs) and regulating the amount of usable materials such as methyl methacrylate (MMA). Therefore, the reduction in released VOCs will increase the amount of MMA available for processing.

[0126] The methods described herein employ resin infusion methods for manufacturing thermoplastic composite panels. These methods are designed to operate as substantially or completely closed systems, allowing MMA to fully polymerize and capturing any VOCs that could otherwise escape during processing.

[0127] According to one embodiment, as illustrated in FIG13A, a method for capturing VOCs during the production of a composite product is disclosed, the composite product comprising a substrate and a resin integrated with the substrate.

[0128] In step (A), a substrate such as substrate 31a is introduced into the housing (such as gantry box 321) of a resin dispenser such as resin dispensing system 34.

[0129] In step (B), a resin such as resin 106 is coated onto substrate 31a to form a resin-substrate assembly such as assembly 16.

[0130] In step (C), the gantry box 321 is structurally designed to contain VOCs that are emitted into the gantry box 321 when the gantry box 321 is closed.

[0131] In step (D), an exhaust device such as fan 1406 is structurally designed to reduce the pressure inside gantry box 321 and to drive VOC from gantry box 321 to filters such as carbon filters 1404 and 1405.

[0132] In step (E), one or more filters, such as carbon filters 1404 and 1405, are structurally designed to receive VOCs from gantry box 321.

[0133] As explained above, VOC capture is accomplished using one or more activated carbon cylinder filters, such as filters 1404 and 1405. In one embodiment, as seen in Figure 14A, two activated carbon cylinder filters are used. A scale is used to weigh the captured VOCs. The precision of the scale can be selected to achieve the required accuracy for measuring the percentage captured. For example, accuracy can be improved by using a more precise scale and / or a smaller filter cylinder. However, it is preferable to use a larger cylinder in production for cost-effectiveness.

[0134] In some cases, the gross loss of a substantially closed system can be greater than one percent. Such losses can be caused by one or more of three sources, or any combination thereof. One source is excessive resin spraying. Another source is VOC leakage during processing. Yet another source is incomplete polymerization of the resin formulation due to the formulation and / or the duration of heating. Therefore, any VOC capture loss can be controlled by reducing or eliminating excessive resin spraying, reducing or eliminating VOC leakage during processing, and / or promoting enhanced or complete polymerization of the resin formulation. As illustrated in Figure 4B, a process control station, such as control system 42, is structurally designed to control various process parameters, including activating the fan (on / off) of the VOC capture system. The parameters can be programmed to operate in automatic or manual mode.

[0135] A VOC detection system using a MiniRAE 300 PGM7320 VOC meter, such as the RAE System, can detect VOCs escaping from the self-made process system at various locations within the system. For example, during the resin dispensing process, VOCs can be monitored at the exit gate, such as the exit gate 318 in FIG. 3D, when the gate is in the closed position; at the edge of the polymer release liner in the soaking station 1 (37) and soaking station 2 (38) in FIG. 3A and the wet station 2 in FIG. 17, where the resin-impregnated fabric 16 is placed while awaiting transfer to the hot press; and after the panel has cured and the polymer release film has been removed as it moves downstream of the system and leaves the hot press. VOC emissions at these locations can be reduced or eliminated by: placing a seal on the gate, bringing the release liner close to its edge as it moves from the gantry 321 (or other form of housing in which resin is coated, such as a resin dispenser 91) to the press 31, and / or sealing the press 39 to retain heat and resin within the press 39 and to convey more fully polymerized products such as the shelf 1005.

[0136] VOC Capture Assembly (Equipment Assembly and Subassemblies) According to one embodiment of the present invention, as illustrated in FIG14A, a system for capturing VOCs during the production of a composite product comprising a substrate and a resin integrated with the substrate is provided. The system includes a resin dispenser 1401 disposed for coating a resin, such as resin 106, onto a substrate 31a to form a resin-substrate assembly 314. The resin dispenser 34 includes a housing, such as a gantry 1402, into which the substrate 31a can be introduced when the housing 1402 is opened, the housing 1402 being structurally designed to contain VOCs emitted into the housing 1402 when the housing 1402 is closed. The system also includes filters, such as carbon filters 1404 and 1405, coupled to receive VOCs from the housing 1402 of the resin dispenser 1401. The system also includes an exhaust device such as fan 1406, which is structurally designed to reduce the pressure inside housing 1402 and is positioned to drive VOCs from housing 1402 and into filters (1404, 1405). The exhaust device 1406 can operate when the gate, inlet, or outlet of housing 1402 is opened to allow substrate 31a to enter housing 1402 and resin-substrate assembly 314 to exit housing 1402.

[0137] As illustrated in Figures 3A to 3D and 9A, the resin dispenser 91 includes a nozzle such as a spray head 921, and the housing 34 includes a spray box 321 having an upstream gate such as an inlet gate 319 that opens to allow the substrate 31a to enter the housing 34, and a downstream gate such as an outlet gate 318 that opens to allow the resin-substrate assembly 314 to exit the housing 34.

[0138] In one embodiment, the system includes an upper membrane supply 17 located upstream of a downstream gate (such as an exit gate 318) of the housing 34 and configured to introduce the upper membrane 317 into the system and onto the resin-substrate assembly 314 in a downstream direction toward the downstream gate 318 of the housing 34. When the resin-substrate assembly 314 exits the downstream gate 318 of the housing 34, the upper membrane 317 prevents VOCs from escaping from the resin-substrate assembly 314. The housing 34 of the resin dispenser 91 may also include an upper membrane gate, such as a gate 916, positioned to allow the upper membrane 317 to enter the housing 34. In one example, the upper membrane gate 916 is positioned at the top of the housing 34 to allow the upper membrane 317 to move toward the upper surface of the substrate 31a.

[0139] As shown in Figure 14A, the filter includes cans (1404, 1405) containing a filter substrate. The filter may include a plurality of cans (1404, 1405) connected in parallel or in sequence. In one example, the filter includes a UV radiation source. In another example, the filter includes a vapor condenser structured to capture VOCs. Alternatively, the filter substrate may include activated carbon.

[0140] Referring to Figures 3A to 3D, 14A and 15A, a method is provided for capturing VOCs while producing a composite product including a substrate 31a and a resin (such as resin 106) integrated with the substrate 31a to form a resin-substrate assembly 314.

[0141] In step (A), the method includes opening an upstream gate (such as an entry gate 319) of the housing 34 and activating an exhaust device such as a fan 1406 to reduce the pressure in the housing 34 when the upstream gate 319 of the housing 34 is opened to allow the substrate 31a into the housing 34 and when the upstream gate 319 of the housing 34 is closed after the substrate 31a has entered.

[0142] In step (B), resin is coated onto substrate 31a to form resin-substrate assembly 314 in housing 34, and VOCs are discharged from housing 34 into filters (1404, 1405).

[0143] In step (C), the method includes activating the venting device 1406 to reduce the pressure in the housing 34, opening a downstream gate of the housing 34 such as an exit gate 318, and transferring the resin-substrate assembly 314 from the housing 34 via the downstream gate 318 of the housing 34.

[0144] In one embodiment, the method may also include introducing an upper membrane 317 in a downstream direction toward the downstream gate 318 of the housing 34 and onto the resin-substrate assembly 314, wherein the upper membrane 317 prevents VOCs from escaping from the resin-substrate assembly 314 when the resin-substrate assembly 314 exits the downstream gate 318 of the housing 34.

[0145] In yet another embodiment, the method may also include a downstream gate 318 relative to the upper membrane 317 sealing the housing 34. This seal may be provided in various ways, such as by using a sealing surface. This sealing surface may include, for example, a gasket or contact blade or other structure capable of reducing or preventing the passage of gas from within the housing.

[0146] Furthermore, the method may include activating the venting device 1406 when the upstream gate 319 of the housing and the downstream gate 318 of the housing 34 are closed. Resin may be applied when the venting device 1406 is activated and when the upstream gate 319 of the housing 34 and the downstream gate 318 of the housing 34 are closed. When the venting device 1406 is activated, at least one of the upstream gate 319 and the downstream gate 318 of the housing 34 may be opened, and when the venting device 1406 is activated, the resin-substrate assembly 314 may be transferred from the housing 34 via the downstream gate 318. When both the upstream gate 319 and the downstream gate 318 of the housing 34 are closed, the venting device may be stopped.

[0147] In addition to the improvements mentioned above, the system and method according to embodiments of the present invention produce reinforced composite panels with improved properties. Among other improvements, the reinforced composite panels have improved surface properties and reduced variation in properties across the entire panel.

[0148] According to one embodiment of the present invention, the reinforced composite product 1501 includes a substrate 31a and a resin integrated with the substrate 31a. The reinforced composite product 1501 has an outer surface 1502 characterized by uniformity in at least one of color, weave pattern and surface mask appearance.

[0149] The substrate, such as substrate 31a, may include fibrous materials, non-fibrous materials, or combinations thereof. In one example, the substrate includes metallic materials, non-metallic materials, or combinations thereof. In another example, the substrate includes one or more of the following: glass, carbon, ceramic, basalt, steel, and cellulose fiber materials. In yet another embodiment, the substrate includes one or more of the following: continuous, discontinuous, woven, non-woven, pressed, non-pressed, unidirectional, multidirectional, porous, and non-porous materials, and mixtures or combinations thereof.

[0150] The substrate 31a may be substantially planar and have an outer perimeter. In one example, the outer perimeter of the substrate 31a is a geometric shape, a predetermined shape, or an arbitrary shape. For example, the geometric shape may be rectangular or square.

[0151] In one embodiment, substrate 31a is cut from a larger substrate. Substrate 31a can be cut using CNC or nesting operations. It can be provided in any regular or irregular shape by programming the CNC to cut substrate 31a. Substrate 31a can be cut or otherwise formed into the desired shape according to a composite production line, so the process can be continuous or semi-continuous. Alternatively, substrate 31a can be pre-cut or pre-formed for subsequent processing in a composite production line.

[0152] In one example, the substrate 31a has a thickness (T) of no more than about 5 mm. However, depending on the final product to be manufactured, the substrate 31a may be thicker or thinner than 5 mm.

[0153] Resins such as resin 106 may include thermoplastic or thermosetting polymers having a viscosity of up to 5000 cp. In another example, resin 106 includes thermoplastic or thermosetting polymers having a viscosity of up to 500 cp or more preferably up to 250 cp or preferably about 100 cp or less.

[0154] In addition, resin 106 may include crosslinkable polymers, monomers, or combinations thereof. Furthermore, resin 106 may include one or more of the following: colored packaging, reaction initiators, reaction inhibitors, impact modifiers, flame retardants, lubricants, light stabilizers, conductive or thermally conductive additives, and antioxidants, or combinations thereof.

[0155] Furthermore, resin 106 may include a thermoplastic polymer that is soluble in a solvent to reduce viscosity. In one example, resin 106 includes polycarbonate dissolved in dichloromethane (DCM). Finally, resin 106 may be structurally designed for spray coating as indicated above.

[0156] According to another aspect of the present invention, the panel 314 produced according to the method described herein may have a narrower characteristic distribution in terms of at least one of color, mechanical properties, thickness, and C-scan. Furthermore, compared to the previous method, the characteristics may have a narrower distribution on a bell curve, the position of which may be increased (moved to the right side of the bell curve) or decreased (moved to the left side of the bell curve).

[0157] Referring now to FIG16A, the reinforced composite product 1501 includes a substrate 31a and a resin (such as resin 106) integrated with the substrate 31a, and the reinforced composite product 1501 is characterized by at least one of the following: thickness, fiber content, thickness after secondary pressing, noise generation in ultrasonic C-scan, resin content, and cross-section having uniformity.

[0158] Example VOC capture system: A triplet mass balance experiment was conducted to determine VOC emissions from the composite board production system. The mass balance experiment was performed in triplicate over three days under environmental conditions. Resin intermediates included monomer (MMA) and initiator (BP-75). The mass of resin added to the storage tank was recorded as the initial weight.

[0159] The panel is cured between two polyester release liner sheets. When the fabric is moved from the spray box to the hot press and removed, the fabric is on the release liner sheets. The weights of the fabric and release liner sheets are recorded throughout the process, so that these weights can be subtracted from the weight of the cured panel at the end of the process line. The final resin weight is calculated using this method.

[0160] Before each of the three tests, record the initial weight of the carbon filter cartridge. At the end of each test, subtract the initial weight from the final weight to obtain the net weight of the captured volatiles.

[0161] Compared to the first method described herein, the composite board production system and the improved method offer a 70.6% improvement in VOC reduction. The improvement to the first method makes the composite board production system an important step in reducing VOC and increasing productivity.

[0162] In each test, resin was weighed and added to the composite board production machine, allowing it to pass through the system. Losses were calculated by subtracting the resin output from the input. An activated carbon filter was used in conjunction with an exhaust fan to discharge exhaust gases from the modified closed distribution gantry when the system was open (whether during normal operation or troubleshooting). Here, emissions from the composite board production system and the modified method are considered to be gross losses (excluding carbon filter collection) and net losses (including carbon filter collection) related to the difference between resin entry and resin exit.

[0163] The following equipment was used in the test: • Fairbanks Scales 250 lb cylinder scale • UWE APM-150, 300 lb scale • Intelligent 3200 g scale • Intelligent Intill-Lab Balance PC-6001, 6000 g scale • Amprobe temperature and relative humidity recorder • RAE Systems MiniRAE 300 PGM7320 VOC meter • H-Bot resin infusion spraying system • Liquiflo® gear pump • Moog Animatics SmartMotor™ (× 3) • MVP spray gun • Dah Tyan hydraulic press (single-opening hot press) • Model: DTEA-150

[0164] The following materials were used in the test: • MMA (methyl methacrylate monomer), such as those commercially available monomers from Arkema or Roehm • 75% diphenylmethyl peroxide initiator (Arkema - A75; Akzo Nobel - Perkadox L-W75) • BW-1000 ○ 2×2 12k carbon and glass fiber fabric ○ 0.055" nominal thickness ○ 1035 ± 25 g / m2 unit area weight • Polyester release film (Melinex 516 or PCI D2-2; 0.075 mm nominal thickness)

[0165] The following test conditions were used in the experiment: • Room temperature was subject to change due to environmental conditions. The temperature ranged from 40℉ to 60℉ throughout the day. • The indoor relative humidity was maintained to a certain extent at 40 ± 5%.

[0166] As illustrated in Figure 17, the following experimental procedures were used in the experiment: • Before running the composite board production system using a Fairbanks Scales cylinder scale, the activated carbon canisters were weighed and recorded. Emissions are passed through these canisters to help capture VOCs present in the spray gantry when the resin is applied to the fabric. • The operator weighed and mixed the resin formulation (monomers and initiators) using a UWE and Intelligent electronic scale. The resin was poured into a resin reservoir located near the resin coating structure 3. The resin barrel was weighed using the gross weight-package weight-net weight method to accurately measure and record the amount of resin added to the composite board production system. • Each piece of fabric cut to size (as shown in Fabric 1 in Figure 17) was weighed and recorded on an Intell-Lab balance before each fabric was passed through the composite board production machine. • The fabric was then pulled into the impregnation station 1. The resin was applied to the fabric using a programmed H-bot spraying system. The resin-impregnated fabric was then moved down the production line to press 5, where it was cured. • Based on the selected method cycle, the hot press has specified time, pressure, and heat parameters. See Table 1 below; this experiment was conducted using pressing cycle 9 operating at 235℉. • After leaving press 5, the cured panel moves to the traction station 6 and is ejected at the film removal station 7 at the end of the composite panel production line. However, the polyester release film remains, encapsulating the cured panel and all infusions. • The polyester film containing the cured panel is cut to a predetermined size, and the panel with the release liner is weighed using an Intell-Lab balance. • Throughout the process, the polyester film is cut and weighed to the same predetermined size as the cured panel with the packaged polymer film. This process is repeated intermittently 5 times throughout the process to obtain the average value of the polymer film cut to the predetermined size. This average value is used in conjunction with the individual fabric weight to determine the cured resin content of each panel. • The weight of the resin associated with each individual panel is obtained by subtracting the average value of the polymer film and the weight of the dried fabric from the total weight of the cured panels packaged in the polymer film. • After the system has run until the resin is completely consumed, record the total number of panels. Sum the individual panel values ​​of resin content on the cured panels to obtain the total resin output value. • Weigh the activated carbon tank at the end of the run / day. Record the weight. Record the difference between the ending weight and the initial weight as the total VOCs captured in the tank. • Subtract the total resin weighed from the output from the total resin added to the system. Record the difference as the gross loss. • Subtract the weight of VOCs captured in the tank from the gross loss weight to obtain the net loss. Record this value. Table 1: Pressing Cycle 9 Step 1 Step 2 Step 3 Step 4 +55.00 PSI +60.00 PSI +70.00 PSI +75.00 PSI 30 SEC 30 SEC 30 SEC 180 SEC

[0167] Three tests were conducted. As shown in Table 2 and Figure 18, Test 1 produced the highest "resin loss" and "collection in the filter cartridge". Table 2: Resin used, cured and collected VOCs Test number Resin input (g) Resin output (g) Resin loss (g) C - Items collected in the filter cartridge (g) 1 26,160 24,895 1,264 362 2 30,256 29,921 335 136 3 27,821 27,368 452 124

[0168] As seen in Table 3 below, Experiment 1 also produced the highest percentage of gross and net losses. Gross loss is calculated to indicate VOC losses prior to any collection process used. This result represents the amount of material lost during processing due to process and equipment limitations. The resin used was cured to the extent specified in the resin product data sheet. Net loss values ​​represent process and equipment losses after the use of the carbon filter collection cartridge. Table 3: Resin Losses and Capture Percentages and Planned Emissions Test number Total resin (kg) Gross loss C - Filter collection volume (percentage of collected gross loss) Net loss VOC loss and uncaptured VOCs (kg) 1 26.160 4.83% 28.70% 3.45% 0.902 2 30.257 1.11% 40.52% 0.66% 0.200 3 27.821 1.63% 27.56% 1.18% 0.328

[0169] Referring to Tables 2 and 3, the carbon filter collection cartridge collected an average gross loss of 32%. Variations between tests can be attributed to the resolution of the cartridge balance used to measure relatively small quantities. Measuring a hundred grams close to 100 grams in the cartridge with a precision limit of 45 grams will introduce an unavoidable error of approximately + / - 10% in the cartridge collection percentage. All tests were conducted with as few adjustable variables as possible. The differences between Test 1 and Tests 2 and 3 are due to the nozzles used in the resin dispensing system. A nozzle comparison can be seen in Figure 9B.

[0170] The nozzle used in Test 1 resulted in overspraying in the spray gantry. The overspray remained inside the gantry throughout the panel processing. The overspray remaining in the gantry may have resulted in higher-than-normal losses because the resin was not sprayed onto the fabric and did not enter the press for curing. For Tests 2 and 3, nozzles using an application cleaner were used.

[0171] The three tests conducted resulted in a net VOC loss from the emission-reducing manufacturing process of this invention ranging from one to three percent, while the average gross loss of resin, based on the initial amount added to the system, was 2.52%. Taking carbon collection into account, the final average net loss of resin and / or volatiles entering the environment was 1.76%. The carbon filter system collected an average of 32% of the lost resin / volatiles, causing the difference between the initial and final weight of the resin added to the system. Compared to the first method, which resulted in a 6% loss entering the environment, the composite board production system and the improved method represent a 70.6% improvement. This figure would actually be higher if Test 1 were omitted from the data. Test 1 resulted in a higher loss value due to the nozzle design discussed above.

[0172] Embodiments of the systems and methods described herein provide a semi-continuous process for producing fabric-reinforced panels, wherein a programmable machine head operating on the fabric surface is used to spray resin onto the fabric. The resin system is primarily methyl methacrylate (MMA) / polymethyl methacrylate (PMMA), which can be considered as a thermoplastic polymer exhibiting, to some extent, the behavior of a thermosetting polymer. The substrate can be in the form of woven fabric, non-woven / non-pressed fabric, or various surface masks—all made of various types of fibers or combinations thereof.

[0173] For example, thermosetting resins involve chemical cross-linking reactions during exothermic reactions. However, according to embodiments of the resin system, heat and pressure can be used to thermoform the cured laminate into a 3-D shape.

[0174] According to exemplary embodiments of the disclosed method, the advantages of the present invention may include one or more of the following: • Reduced emissions of volatile organic compounds (VOCs) during the processing of methyl methacrylate (MMA) and / or polymethyl methacrylate (PMMA) to produce fiber / fabric reinforced composite panels / layers. • Reduced viscosity of the processed resin from ~20,000 - 30,000 centipoise (cps) to <500 cp when using the new method. • Reduced physical labor and manpower involved in the production of the aforementioned panels / layers. The present invention is also low-labor-intensive, requiring fewer operators and is more ergonomic. • Reduced waste of raw materials, thus increasing overall process yield. • Reduced number of process steps involved in the production of panels / layers. • Elimination of resin injection molding systems used for composite production, wherein such molds are made of metal (usually steel). In this case, the carrier film serves multiple roles within the closed-mold system, including acting as a carrier film, a closed system for limiting VOC release, a disposable tool and release paper for compound production, and a means of maintaining process continuity. • Improve the quality of the panel / layer to make it more uniform in terms of surface resin richness / quality and color, as well as thickness and / or resin content.

[0175] Thickness experiments were conducted to compare the thickness of the composite board produced according to the first method (Fig. 23) with that produced by the improved method according to the present invention. The experiments were conducted under the following conditions.

[0176] Referring to FIG. 24, five samples, each having a length of 10 inches L and a width of 10 inches W, are obtained from different locations on a composite panel having a length of 50 inches L and a width of 38 inches. This composite panel is produced according to the first method described above with reference to FIG. 23. Similarly, five samples, each having a length of 10 inches L and a width of 10 inches W, are obtained from different locations on a composite panel having a length of 50 inches L and a width of 38 inches W. This composite panel is produced using a modified method according to the present invention. As shown in FIG. 24, samples 1, 2, 4, and 5 of each panel are obtained at a distance of 6 inches from the edge of the panel forming one of the four corners. Sample 3 is obtained from approximately the center of each panel.

[0177] To determine the thickness measurements of each sample of the composite board produced according to the first method and the improved method of the present invention, five (5) samples, each 10" × 10", were cut from the large panel. Samples 1, 2, 4, and 5 (Fig. 24) were cut at a distance of 6" from the edge of the panel, and sample 3 was cut from the center of the panel. Twelve (12) thickness measurements were performed on each of the five (5) samples. The twelve (12) measurement points were randomly selected. A Mitutoyo 0-1" deep throat micrometer with ball / ball ends at the top and bottom was used for thickness measurement. More specifically, the steps listed above were followed.

[0178] 1. Place each sample on the frame and align it with the reference index mark to ensure consistent panel position each time a thickness measurement is calculated.

[0179] 2. Simultaneously measure twelve (12) points randomly selected on each sample. There are a total of 24 thickness measurement probes or 12 pairs of corresponding probe tips. Each pair of probe tips is structurally designed so that at the start of measurement, each pair of probe tips moves toward each other until it makes physical contact with the panel.

[0180] 3. Before measuring the thickness of the panel, activate the probes so that the tips of each pair of probes are in contact with each other, and set the reading to the "zero" position.

[0181] 4. After setting the "zero" position, place the panel in the frame and restart the probes to move them toward each other, stopping when they contact the panel surface. At this point, measure and record the panel thickness at all 12 points (simultaneously).

[0182] 5. The probe used for thickness measurement is a Mitutoyo Absolute 0-1" deep throat micrometer with ball / ball ends at the top and bottom. The measurement value is determined using MeasureLink real-time software.

[0183] Calculate the average thickness (measured in mm), standard deviation, and coefficient of variation for each sample. Compared to the first method, the improved sample method according to the present invention provides an improvement in the resin thickness coated on the composite board. For example, as seen in Tables 6 and 7 below, the present invention results in a smaller range of resin thickness variation. In Table 8 below, the following characteristics are reported and defined as follows: "Average thickness" is the average thickness of all thickness measurements; specifically, it is the average of measurements 1 to 12 of samples 1 to 5. In other words, it is based on the average thickness of all 60 thickness measurements. "Standard deviation of thickness" is the standard deviation of all thickness measurements; specifically, it is the standard deviation of measurements 1 to 12 of samples 1 to 5. In other words, it is based on the standard deviation of all 60 thickness measurements. "Coefficient of variation of thickness" is the thickness standard deviation (as defined above) divided by the average thickness (as defined above) multiplied by 100. The standard deviation is standardized by dividing the standard deviation of thickness by the average thickness to demonstrate the various nominal thicknesses of the panel being evaluated. "Maximum Thickness" refers to the maximum thickness of measurements 1 through 12 of samples 1 through 5. In other words, it is the maximum thickness of all 60 measurements. "Minimum Thickness" refers to the minimum thickness of measurements 1 through 12 of samples 1 through 5. In other words, it is the minimum thickness of all 60 measurements. "Thickness Uniformity" is calculated by subtracting the difference between "Maximum Thickness" and "Minimum Thickness" from the numerical value, dividing by the "Average Thickness," and then multiplying by 100. The value is again standardized by dividing the difference by the average thickness to demonstrate the various nominal thicknesses of the panel being evaluated. The "Thickness Uniformity Index" is calculated by dividing "Thickness Uniformity" by "Thickness Variation." Table 6: First Method (Unless otherwise indicated, data is in mm). First Method Measurement number Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 1 0.879 0.780 1.029 0.942 0.801 2 0.893 0.916 0.831 0.744 0.733 3 0.992 0.902 0.965 0.848 0.914 4 0.964 0.940 0.893 1.049 0.940 5 0.841 0.862 0.856 0.923 1.052 6 0.955 0.937 0.818 0.838 0.982 7 0.806 0.852 0.781 0.820 0.923 8 0.941 0.928 0.933 0.951 0.927 9 0.906 0.918 0.876 0.994 0.944 10 0.922 0.888 0.983 0.859 0.903 11 0.897 0.885 0.900 1.096 0.931 12 0.850 0.850 0.917 0.842 0.853 average value 0.904 0.888 0.899 0.909 0.909 0.902 Standard deviation 0.055 0.046 0.072 0.103 0.082 0.072 number of variants 6.1% 5.2% 8.0% 11.3% 9.1% 8.0% Table 7: Improved Method (Unless otherwise indicated, data are in mm) Improved method Measurement number Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 1 1.001 1.062 0.987 0.953 0.999 2 1.002 1.017 1.012 1.074 0.941 3 1.081 1.013 0.933 0.881 0.861 4 1.041 0.993 0.937 0.908 0.921 5 1.063 1.026 1.043 0.980 1.041 6 1.043 1.130 0.899 0.940 0.959 7 1.074 0.979 0.912 1.019 0.953 8 0.954 1.044 1.033 1.027 0.902 9 1.001 1.082 1.027 1.054 0.953 10 0.919 0.923 1.026 0.931 0.988 11 0.987 0.892 1.034 1.053 1.039 12 1.034 1.015 0.926 1.022 1.050 average value 1.017 1.015 0.981 0.987 0.967 0.993 Standard deviation 0.049 0.065 0.055 0.063 0.059 0.060 number of variants 4.8% 6.4% 5.6% 6.4% 6.1% 6.0% Table 8: Comparison of the first method and the improved method Summary and comparison characteristic unit First Method Improved method average thickness mm 0.902 0.993 Thickness standard deviation mm 0.072 0.060 Thickness variation % 8.0 6.0 Maximum thickness mm 1.096 1.130 Minimum thickness mm 0.733 0.861 Thickness range mm 0.363 0.269 Thickness uniformity % 60 73 Thickness uniformity index NA 7.5 12.2

[0184] Referring generally to Figures 19A to 22B, these figures illustrate scanning electron micrographs of randomly selected cross-sections obtained from samples 3 (Figure 24) of panels produced according to the first method and panels produced according to the modified method. The images illustrate a planar weave fabric with glass fibers in the warp direction and carbon fibers in the weft direction used as a substrate. These images also illustrate a layer of polyester nonwoven material (one side of the planar weave fabric) combined with PMMA resin to produce a composite panel.

[0185] The present invention improves the uniformity of thickness. For example, as seen in Figures 19A (100× magnification, color), 20A (100× magnification), and 21A (200× magnification, color), unlike the fiberglass region of the panel produced by the first method as seen in Figures 19B (100× magnification, color), 20B (100× magnification), and 21B (200× magnification, color), the new method produces a panel characterized by a reduction in the thickness measurement value of the fiberglass region.

[0186] For example, referring specifically to Figures 21A and 21B, which show scanning electron microscopy (SEM) images of the cross-section of the composite panel (the panel is produced according to the first method in Figure 21A and the modified method in Figure 21B). A planar weave fabric with glass fibers in the warp direction and carbon fibers in the weft direction is used as the substrate. This substrate and a layer of polyester nonwoven material on one side of the planar weave fabric are combined with PMMA resin to produce the composite panel using the two methods (the first method and the modified method) for comparison. Thus, the composite panel produced according to the first method in Figure 21A shows a relatively thick glass fiber area. Conversely, the composite panel produced according to the modified method in Figure 21B shows a relatively thinner and more uniform glass fiber area.

[0187] Furthermore, as can be more clearly seen in Figures 22A (200× magnification, color) and 22B (200× magnification, color), the variability in the thickness measurements of the composite panels produced according to the present invention is reduced. SEM images show randomly selected areas of the composite panels shown in Figures 21A to 21B, these images being taken at a higher magnification from each of the two panels (the first method and the modified method). Different areas in the sample cross-sections (labeled 1, 2, and 3) highlight the variability in the thickness of the composite produced using the first method (on the left or in Figure 22A). Conversely, the composite produced by the modified method (on the right or in Figure 22B) shows a much more consistent thickness in the similar areas highlighted in the right-hand image—this consistency in thickness is also quantitatively demonstrated at a macroscopic level by the thickness measurements described above.

[0188] Referring, for example, to Figure 22A, it can be visually observed that the thickness measurements of the panels produced by the first method vary relative to each other, as obtained along lines 1, 2, and 3. However, referring to Figure 22B, it can be visually observed that the thickness measurements of the panels produced by the modified method show less variation relative to the variability illustrated in Figure 22A, as obtained along lines 1, 2, and 3 at similar locations. As noted above, this qualitative observation is consistent with the quantitative data illustrated in Tables 6 to 8 above.

[0189] The resin content was tested to compare the resin content of the composite panels produced according to the first method and the modified method. The first method, as described above, includes the following steps: coating, stacking, and cooling a pre-pressed portion of the material for subsequent unpacking and pressing.

[0190] The experiment was conducted under the following conditions. Referring to Figure 25, nine samples were obtained from different locations on a composite board having a 50-inch L and a 38-inch W, which was produced according to the first method described above with reference to Figure 23. Similarly, nine samples were obtained from different locations on a composite board having a 50-inch L and a 38-inch W, which was produced according to the present invention. The samples were 1 inch × 1 inch and were obtained according to positions (1-9) shown in Figure 25. To determine the resin content of each sample obtained from the composite board produced according to each of the first method and the modified method, the steps listed below were followed.

[0191] 1. The furnace used for burnout testing (to determine resin content) is a Thermo Scientific Thermolyne 1300 model. It is set to 550°C.

[0192] 2. Weigh the empty crucible and record the weight.

[0193] 3. Test samples (9) were obtained at various locations on the composite panel. The locations for sample collection are shown in Figure 25. Sample location #5 is located approximately at the center of the panel. Sample locations #1 to #4 and #6 to #9 are located 6 inches from each of the long and short edges of the panel.

[0194] 4. Place the test sample with dimensions of 1'' × 1'' in the crucible and record the new weight.

[0195] 5. Place the crucible and sample in the furnace for 60 minutes.

[0196] 6. Remove the crucible from the furnace and record the new weight of the crucible and its contents.

[0197] 7. Calculate the resin content using the following formula: (Previous sample weight - Later sample weight) × 100 / Previous sample weight)

[0198] Calculate the average resin content (measured in wt%), standard deviation, and coefficient of variation for each sample. Compared to the first method, the present invention provides an improvement in the resin content coated on the composite board. For example, as seen in Tables 9 to 11 below, the present invention results in improved resin content uniformity based on the low level of variation indicated by the new method. In Table 11 below, the following characteristics are reported and defined as follows: "Average resin content" is the average resin content of all resin content measurements; specifically, it is the average of the resin content of samples 1 to 9. In other words, it is the average resin content based on all 9 resin content measurements. "Standard deviation of resin content" is the standard deviation of all resin content measurements; specifically, it is the standard deviation of the resin content of samples 1 to 9. In other words, it is based on the standard deviation of all 9 resin content measurements. "Variation of resin content" is the resin content standard deviation (defined above) divided by the average resin content (defined above) multiplied by 100. The standard deviation of resin content is standardized by dividing the standard deviation of resin content by the average resin content to demonstrate the various nominal resin contents of the panels being evaluated. "Maximum resin content" refers to the maximum resin content of samples 1 through 9. In other words, it is the maximum resin content of all nine measurements. "Minimum resin content" refers to the minimum resin content of samples 1 through 9. In other words, it is the minimum resin content of all nine measurements. "Resin content uniformity" is calculated by subtracting the difference between "maximum resin content" and "minimum resin content" from the numerical value, dividing it by the "average resin content," and then multiplying by 100. The value is again standardized by dividing the difference by the average resin content to demonstrate the various nominal resin contents of the panels being evaluated. The "resin content uniformity index" is calculated by dividing "resin content uniformity" by the "resin content variation." Table 9: First Method Sample location Cup weight (gm) before burning out Cup + Sample weight (gm) After burning Cup + Sample Weight (gm) % resin content 1 33.2 34.1 33.8 32.6 2 39.7 40.6 40.3 33.6 3 33.2 34.1 33.8 32.7 4 25.0 26.0 25.6 34.2 5 39.7 40.6 40.3 37.5 6 25.0 25.9 25.6 34.4 7 39.7 40.6 40.3 33.7 8 25.0 26.0 25.6 35.1 9 33.2 34.1 33.8 31.3 Table 10: Improved Method Sample location Cup weight (gm) before burning out Cup + Sample weight (gm) After burning Cup + Sample Weight (gm) % resin content 1 39.7 40.8 40.4 37.5 2 33.2 34.4 34.0 35.5 3 33.2 34.4 33.9 39.5 4 39.7 40.8 40.4 36.4 5 33.2 34.3 33.9 36.3 6 39.7 40.9 40.4 38.0 7 25.0 26.2 25.8 37.9 8 25.0 26.2 25.7 37.1 9 25.0 26.1 25.7 39.3 Table 11: Comparison of the first method and the improved method Summary and comparison characteristic unit First Method Improved method Average resin content wt.% 33.9 37.5 Standard deviation of resin content wt.% 1.7 1.3 Resin content variation % 5.2 3.6 Maximum resin content wt.% 37.5 39.5 Minimum resin content wt.% 31.3 35.5 scope wt.% 6.1 4.0 resin content uniformity % 82 89 Resin content uniformity index NA 15.8 24.7

[0199] Previous properties related to thickness uniformity and resin content uniformity have been enhanced by the improved method. It is believed that these enhanced properties are attributable to the conditions and steps of the improved method and their effect on the thickness uniformity and resin content uniformity of the produced panels. For example, and without being bound by any particular theory, when the resin viscosity is very high, such as measured in tens of thousands of cps, viscous forces dominate. The primary viscous force limits the resin's ability to achieve optimal wetting / impregnation of a given substrate material. This is especially true when the resin is allowed to impregnate the substrate under ambient / normal atmospheric pressure conditions. In the case of reactive systems, this problem is further exacerbated because the resin-coated substrate is stored under refrigeration / freezing conditions to increase the material's shelf life and prevent premature initiation of crosslinking reactions.

[0200] Since the degree of wetting / impregnation is a function of resin viscosity and substrate permeability, a lower viscosity and higher permeability are required for the resin system to wet / impregnate the substrate to the greatest extent. This relationship is based on the concept of flowing through porous media as explained by Darcy's law.

[0201] When a substrate impregnated with high-viscosity resin is introduced into the press of the first method to produce a composite laminate / component, the resin is pushed out / flashed across the periphery of the substrate. The substrate needs to be impregnated with resin in an ideal or optimal manner, but the possibility of extruding a relatively excessive amount of resin along the periphery is higher when using high-viscosity resin. Furthermore, the resin can be pushed out and flattened in the central area of ​​the substrate, but depending on the size of the substrate, and for relatively large substrates, the resin can be highly concentrated in the central portion of the material system relative to the peripheral area described in the first method above. This can result in a resin content gradient in the composite board with a higher amount of resin in the central or core area compared to the peripheral area where the resin is pushed out.

[0202] Therefore, material systems with high-viscosity resins can have disadvantages in some cases, including the fact that composites produced by the first method can lead to greater variability in specific composite board properties such as thickness and fiber / resin content. Such variability in properties can further affect variability in other material, mechanical, and potential properties.

[0203] Conversely, the improved method is expected to use resins with reduced viscosity (e.g., as low as ~100 cp), making capillary forces more dominant than viscous forces. Therefore, the resin wets / impregnates the substrate more quickly, and the resin is uniformly driven by the concepts of capillary action and wicking effect. When the resin-coated substrate is introduced into the press to produce composite laminates / components, the amount of resin ejected / flashed around the substrate periphery is relatively low because the low-viscosity resin is more easily incorporated into the substrate and moves within it to fill any voids or areas where resin may be needed. Therefore, material systems with lower-viscosity resins have the advantages of producing composites with more uniform thickness and resin / fiber content, and thus are expected to have better consistency in mechanical and other properties.

[0204] As illustrated in Figures 20A and 20B, the present invention improves the uniformity of resin content. For example, as seen in Figure 20A (100× magnification), compared to the panel produced by the improved method as seen in Figure 20B (100× magnification), the panel produced by the first method has a darker discoloration area. Reduced discoloration indicates a more uniform fiber-resin distribution, because compared to areas without discoloration, the discoloration indicates a higher degree of variability in the uniformity of the fiber-resin distribution. This qualitative observation is consistent with the quantitative data illustrated in Tables 9 to 11 above.

[0205] Apart from the viscosity of the resin used in the process, the improved method differs from the first method in other aspects that are believed to affect the uniformity of thickness and / or the uniformity of resin content. For example, the improved method embodiment described herein employs the following: spraying resin onto a substrate, such that a resin-substrate assembly is situated or "sandwiched" between two elongated film layers to form a continuous or semi-continuous mold, using a shell in which resin is coated in a controlled manner, and employing a press positioned to press the resin-substrate assembly via film layers, having the continuous or semi-continuous characteristics of a method for pushing the resin-substrate assembly from the resin coating station to the press and to the film removal station.

[0206] These features of the improved method by Xianxin, alone or in combination, promote the improvement of the uniformity of the produced panels. This uniformity is particularly beneficial to thickness and resin content.

[0207] Thickness can be quantified in terms of thickness variation, thickness uniformity, and thickness uniformity index to indicate the improved thickness uniformity of the manufactured panel. Specifically, when thickness uniformity and thickness uniformity index are improved, thickness variation needs to be reduced.

[0208] The thickness uniformity index of the reinforced composite product is preferably 8 or greater, or more preferably 10 or greater. The thickness variation of the reinforced composite product is preferably 7% or less, or more preferably 6% or less. The thickness uniformity of the reinforced composite product is preferably 61% or greater, or more preferably 70% or greater. The reinforced composite product may have at least one of the following: a thickness uniformity index of 8 or greater, a thickness variation of 7% or less, and / or a thickness uniformity of 61% or greater, or any combination thereof.

[0209] The improved resin content uniformity of the produced panel can be quantified in terms of resin content variation, resin content uniformity, and resin content uniformity index. Specifically, when resin content uniformity and resin content uniformity index are improved, it is necessary to reduce the resin content variation.

[0210] The resin content uniformity index of the reinforced composite product is preferably 16 or greater, or more preferably 20 or greater. The resin content variation of the reinforced composite product is preferably 5% or less, or more preferably 4% or less. The resin content uniformity of the reinforced composite product is preferably 83% or greater, or more preferably 85% or greater. The reinforced composite product may have at least one of the following: a resin content uniformity index of 16 or greater, a resin content variation of 5% or less, and / or a resin content uniformity of 83% or greater, or any combination thereof.

[0211] While preferred embodiments of the invention have been shown and described herein, it should be understood that such embodiments are provided by way of example only. Many variations, modifications, and substitutions will arise to those skilled in the art without departing from the spirit of the invention. Therefore, it is intended that the appended claims cover all such variations falling within the spirit and scope of the invention. [Simplified Explanation of the Diagram]

[0012] The foregoing invention and the following description will be better understood and appreciated in conjunction with the non-limiting examples illustrated in the accompanying drawings, in which: FIG1 schematically illustrates a process path for manufacturing a reinforced composite panel according to an exemplary embodiment of the present invention; FIG2 is a perspective view of an embodiment of a production assembly for producing a composite product, such as a panel, comprising a substrate and resin integrated into the substrate; FIG3A is a side view of an embodiment of a system for producing a composite product comprising a substrate and resin integrated into the substrate; FIG3B is a side view of the system of FIG3A, showing a process path for producing a composite product comprising a substrate and resin integrated into the substrate; FIG3C is a schematic side view of the system of FIG3A; FIG3D is a side view of a variant of the system of FIG3C, showing a process path for producing a composite product comprising a substrate and resin integrated into the substrate; FIG4A is a top view of the system of FIG3A; Figure 4B is a top view of a variant of the system in Figure 3A, showing a system for capturing volatile organic compounds (VOCs) during the production of a composite product including a substrate and a resin integrated into the substrate; Figure 4C is a top view of the system in Figure 3C.Figure 5A is a perspective view of one embodiment of the press of the system of Figure 3C; Figure 5B is a schematic side view of the press of Figure 5A; Figure 6 is a side view of one embodiment of the lower film supply of the system of Figure 3C; Figure 7 is a side view of one embodiment of the upper film supply of the system of Figure 3C; Figure 8 is a side view of one embodiment of the substrate supply of the system of Figure 3C; Figure 9A is a top view of one embodiment of a resin dispenser according to the present invention; Figure 9B is a perspective view of an embodiment of a nozzle having an eye-like structure or a square structure; Figure 9C is a top view of the resin dispenser of Figure 9A, showing the coating of resin along a predetermined pattern of xy coordinates at least in part based on the shape of the substrate; Figure 9D illustrates the pattern of xy coordinates of Figure 9C, according to another embodiment of the present invention, the dimensions shown may vary from the dimensions indicated therein and only one possible embodiment is illustrated; Figure 10 is a side view of one embodiment of a film removal station according to the present invention; Figure 11 is a side view of a mold according to one embodiment of the present invention; Figure 12A is a flowchart summarizing the process path for producing a composite product including a substrate and resin integrated with the substrate. Figure 12B is a flowchart illustrating a process path according to an exemplary embodiment of the present invention; Figure 12C is a flowchart illustrating a process path of Figure 12A according to an exemplary embodiment of the present invention, showing the start-up production mode for filling and moving with the press closed; Figure 12D is a flowchart illustrating a process path of Figure 12A according to an exemplary embodiment of the present invention, showing the complete production mode for filling and moving with the press open; Figure 13 is a flowchart illustrating a system for capturing volatile organic compounds (VOCs) according to an embodiment of the present invention; Figure 14 is a schematic diagram of an embodiment of a system for capturing volatile organic compounds (VOCs); Figure 15 is a flowchart illustrating a process path for capturing VOCs while simultaneously producing a composite product including a substrate and a resin integrated with the substrate to form a resin-substrate assembly; Figure 16 is a reinforced composite product according to an exemplary embodiment of the present invention, having a length L, a width W, and a thickness T; Figure 17 illustrates a system for a mass balance test method, which is used to determine the reduction of VOC emissions during the production of the composite product according to an exemplary embodiment of the present invention. Figure 18 shows a bar graph illustrating the results of the experiment performed using the system of Figure 17. Figures 19A and 19B show scanning electron micrographs (100× magnification, color) of cross-sectional samples from composite plates produced according to the first method (Figure 19A) and composite plates produced according to the second, modified method according to the present invention. Figures 20A and 20B show scanning electron micrographs (100× magnification) of cross-sectional samples from composite plates produced according to the first method and composite plates produced according to the modified method.Figures 21A and 21B show scanning electron micrographs (200× magnification, color) of cross-sectional samples from composite panels produced according to the first method and composite panels produced according to the modified method. Figures 22A and 22B show scanning electron micrographs (200× magnification, color) of cross-sectional samples from composite panels produced according to the first method and composite panels produced according to the modified method. Figure 23 shows a flowchart illustrating the first method. Figure 24 shows the location of a sample obtained for measuring the thickness of the composite panel. Figure 25 shows the location of a sample obtained for measuring the resin content of the composite panel.

Claims

1. A system for producing a composite product including a substrate and a resin integrated with the substrate, the system comprising: a press located between an upstream end of a system configured to incorporate the substrate into the system and a downstream end of a system configured to convey the composite product from the system; a lower film supply located at the upstream end of the system and configured to introduce the lower film into the system in a direction downstream of the press; a substrate supply located at the upstream end of the system and configured to introduce the substrate onto the lower film in the system in a direction downstream of the press; and a resin dispenser located upstream of the press and downstream of the substrate supply and configured to apply the resin onto the substrate to form a resin-substrate assembly. An upper membrane supply, located downstream of the resin dispenser and structurally designed to introduce the upper membrane into the system in a downstream direction toward the press and onto the resin-substrate assembly; and a membrane removal station, located at the downstream end of the system and structurally designed to remove the lower membrane and the upper membrane from the resin-substrate assembly; and a press, located downstream of the upper membrane supply and upstream of the membrane removal station, positioned to apply pressure to the resin-substrate assembly via the upper and lower membranes when the resin-substrate assembly and the press are in the same position.

2. The system for producing composite products as claimed in claim 1, further comprising a heater designed to heat the resin-substrate assembly to a high temperature above ambient temperature, the high temperature being selected to accelerate the curing or polymerization of the resin in the resin-substrate assembly.

3. The system for producing composite products as described in claim 1, which is structurally designed to receive substrates cut using CNC or nesting operations.

4. As in claim 1, the system for producing composite products has a substrate with a thickness of not more than about 5 mm.

5. The system for producing composite products as claimed in claim 1, wherein the resin dispenser is structurally designed to coat resin, including thermoplastic or thermosetting polymers having a viscosity of up to 5000 cp.

6. The system for producing composite products as claimed in claim 5, wherein the resin dispenser is structurally designed to coat resin, including thermoplastic or thermosetting polymers having a viscosity of up to 500 cp.

7. The system for producing composite products as claimed in claim 5, wherein the resin dispenser is structurally designed to coat resin, including thermoplastic or thermosetting polymers having a viscosity of up to 250 cp.

8. The system for producing composite products as claimed in claim 5, wherein the resin dispenser is structurally designed to coat resin, including thermoplastic or thermosetting polymers having a viscosity of up to 100 cp.

9. The system for producing composite products as claimed in claim 1, wherein the resin dispenser is structurally designed to coat resin, the resin comprising crosslinkable polymers, monomers, or combinations thereof.

10. The system for producing composite products as claimed in claim 1, wherein the resin dispenser is structurally designed to coat a resin comprising one or more of the following: colored packaging, reaction initiator, reaction inhibitor, shock modifier, flame retardant, lubricant, light stabilizer, conductive or thermally conductive additive, and antioxidant.

11. The system for producing composite products as claimed in claim 1, wherein the resin dispenser is structurally designed to coat resin, the resin comprising a thermoplastic polymer soluble in a solvent to change viscosity.

12. The system for producing composite products as claimed in claim 1, wherein the resin dispenser is structurally designed to coat the resin by spraying.

13. The system for producing composite products as claimed in claim 1, wherein the resin dispenser includes a reservoir for containing the resin and a nozzle coupled to receive the resin from the reservoir and for spraying the resin onto the substrate.

14. The system for producing composite products as described in claim 13, wherein the resin dispenser is structurally designed to spray the resin onto the substrate in a pattern.

15. The system for producing composite products as claimed in claim 13, wherein the nozzle is structurally designed to spray the resin formulation onto the substrate in a predetermined pattern.

16. The system for producing composite products as claimed in claim 1, wherein the film removal station includes a winding machine configured to wind the lower film and the upper film onto separate rolls of the lower film and the upper film.

17. The system for producing composite products as claimed in claim 1, wherein the press includes a top platen and a bottom platen mounted to move relative to each other, such that when the top platen and the bottom platen are moved toward each other by moving at least one of the top platen and the bottom platen, the press is structurally designed to close on the lower film and the upper film when the resin-substrate assembly is between the lower film and the upper film, until a seal is formed to seal at least a portion of the lower film, the upper film and the resin-substrate assembly; and when the top platen and the bottom platen are moved apart by moving at least one of the top platen and the bottom platen, the press opens and the seal disengages.

18. The system for producing composite products as claimed in claim 1, further comprising a stretching station structurally designed to stretch the lower and upper films in a downstream direction when the resin-substrate assembly is located between the lower and upper films.

19. As in claim 18, in a system for producing composite products, the traction station is located downstream of the press.

20. As in claim 18, in a system for producing composite products, the traction station is located upstream of the membrane removal station.

21. The system for producing composite products as claimed in claim 1, further comprising at least one wetting station, which is structurally designed to facilitate the integration of the resin into the substrate of the resin-substrate assembly.

22. The system for producing composite products as claimed in claim 21, wherein the at least one wetting station is located downstream of the resin distributor.

23. As in claim 21, in a system for producing composite products, the at least one wetting station is located upstream of the press.

24. The system for producing composite products as described in claim 1, wherein: The lower membrane is structurally designed to move relative to the press in a downstream direction extending from the upstream end of the press toward the downstream end of the press. The lower membrane has an upper surface positioned to support the combination of the substrate and the resin. The lower membrane has a continuous length selected to extend beyond the upstream end of the press in the upstream direction and beyond the downstream end of the press in the downstream direction. The upper film is structurally designed to move relative to the press in a downstream direction extending from the upstream end of the press toward the downstream end of the press. The upper film has a lower surface disposed to contact the combination of the substrate and the resin. The upper film also has a continuous length selectively extended beyond the upstream end of the press in the upstream direction and beyond the downstream end of the press in the downstream direction. An encapsulation is formed by contact between the upper surface of the lower film and the lower surface of the upper film. The encapsulation is disposed to at least partially surround the substrate. The encapsulation extends along a portion of the continuous length of the lower and upper films and extends transversely to the continuous length of the lower and upper films. The lower film, the upper film, and the encapsulation together define a mold designed to be sealed into the combination of the substrate and the resin.

25. The system for producing composite products as claimed in claim 24, wherein the encapsulation forms a periphery to at least partially surround the substrate, the periphery having a shape that substantially corresponds to the shape of the substrate, thereby reducing the amount of resin extruded from the substrate when pressure is applied.

26. The system for producing composite products as described in claim 24, wherein the lower membrane comprises polyethylene terephthalate or polycarbonate.

27. The system for producing composite products as claimed in claim 24, wherein the upper membrane comprises polyethylene terephthalate or polycarbonate.

28. The system for producing a composite product as claimed in claim 1, further structurally designed to capture volatile organic compounds (VOCs) during the production of the composite product including the substrate and the resin integrated with the substrate, the system further comprising: a housing into which the substrate can be introduced when the housing is opened. The housing is structurally designed to contain VOCs emitted into the housing when the housing is closed; a filter coupled to receive VOCs from the housing of the resin distributor; and an exhaust device structurally designed to reduce the pressure inside the housing and positioned to drive the VOCs from the housing and into the filter, the exhaust device being operable when the housing is opened to allow the substrate to enter the housing and the resin-substrate assembly to exit the housing.

29. The system for producing composite products as claimed in claim 28, wherein the resin dispenser includes a nozzle and the housing includes a spray box having an upstream gate that opens to allow the substrate to enter the housing and a downstream gate that opens to allow the resin-substrate assembly to exit the housing.

30. The system for producing composite products as claimed in claim 29 further includes an upper membrane supply located upstream of the downstream gate of the housing and structurally designed to introduce the upper membrane into the system in a downstream direction toward the downstream gate of the housing and onto the resin-substrate assembly, wherein the upper membrane provides a barrier to prevent VOCs from escaping from the resin-substrate assembly when the resin-substrate assembly exits the downstream gate of the housing.

31. The system for producing composite products as claimed in claim 30, wherein the housing of the resin dispenser includes an upper membrane gate disposed to allow the upper membrane to enter the housing.

32. The system for producing composite products as claimed in claim 31, wherein the upper membrane gate is positioned at the top of the housing to move the upper membrane toward the upper surface of the substrate.

33. The system for producing composite products as claimed in claim 11, wherein the resin comprises methyl methacrylate (MMA), polymethyl methacrylate (PMMA), or a combination thereof.

34. A method for producing a composite product comprising a substrate and a resin integrated with the substrate, the method comprising: supplying a lower film to introduce the lower film in a downstream direction; supplying a substrate to introduce the substrate in the downstream direction and onto the lower film; dispensing resin to coat the resin onto the substrate to form a resin-substrate assembly; supplying an upper film to introduce the upper film onto the resin-substrate assembly; applying pressure to the resin-substrate assembly via the upper film and the lower film; and removing the lower film and the upper film from the resin-substrate assembly.

35. The method of claim 34, further comprising heating the resin-substrate assembly to a high temperature above ambient temperature, the high temperature being selected to accelerate the curing or polymerization of the resin in the resin-substrate assembly.

36. The method of claim 34 further comprises sealing the periphery of the lower film and the upper film to at least partially surround the substrate, the periphery having a shape that substantially corresponds to the shape of the substrate, thereby reducing the amount of resin extruded from the substrate when pressure is applied.

37. The method of claim 34, further comprising: opening an upstream gate of the housing; activating an exhaust device to reduce the pressure inside the housing when the upstream gate of the housing is open; receiving the substrate into the housing via the upstream gate of the housing; closing the upstream gate of the housing; applying the resin onto the substrate to form the resin-substrate assembly in the housing; and emitting VOCs from the housing and into a filter.

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