Method and system for continuous forming

Abstract

Disclosed herein are a continuous molding method and system for manufacturing a thermoplastic product (e.g., a continuous reinforced fiber thermoplastic product) from a feed material containing a thermoplastic component. The disclosed method and system include heating the feed material to a temperature above the glass transition temperature of the thermoplastic component, shaping a solidified material from the heated feed material, and cooling the solidified material to a temperature below the glass transition temperature. Further, the methods and systems of the present disclosure may include optional steps and / or units that further enable the production of thermoplastic products having any of a variety of shapes, structures, and / or forms.

Description

Background Art

[0001] Cross - References to Related Applications This application claims priority to U.S. Provisional Application No. 63 / 346,493, filed May 27, 2022, which is hereby incorporated by reference in its entirety.

[0002] Government Support The invention was made with government support under Army Contract Nos. W52P1J2093014, W912HZ219F003, and W912HZ229C005. The government has certain rights in the invention.

[0003] Background Conventional pultrusion methods and systems for manufacturing fiber - reinforced polymer products utilize thermosetting feed materials to produce exemplary products. Such methods and systems require the use of highly undesirable materials, such as volatile organic compounds (VOCs), which pose health and / or environmental risks during and / or after manufacturing.

Summary of the Invention

Means for Solving the Problems

[0004] Abstract The present disclosure provides, among other things, a continuous molding method and system for manufacturing thermoplastic products (e.g., fiber-reinforced thermoplastic products) that utilize a feed material comprising a thermoplastic material. As provided herein, the use of a feed material comprising a thermoplastic material provides advantages over conventional pultrusion methods and systems that utilize thermosetting materials. Such conventional methods and systems rely on pulling a fiber component through a resin saturation system, which is then cured within a die to produce a final product. Such methods and systems present significant health and / or environmental hazards, particularly due to high emissions of VOCs during processing. In many embodiments, the disclosed continuous molding method and system utilize a feed material comprising a thermoplastic component, such thermoplastic component being mixed with a fiber component. Such exemplary embodiments do not require the use of a resin saturation system, significantly reduce VOC emissions, and thus significantly reduce health and / or environmental risks. Additionally, the use of a feed material comprising a thermoplastic material in the disclosed method and system provides for reheating of the thermoplastic product and thus provides for remolding of the thermoplastic product, enabling increased recyclability and providing further environmental advantages over conventional methods and systems.

[0005] Furthermore, as provided herein, the disclosed methods and systems provide for manufacturing a broader range of exemplary products (e.g., fiber reinforced thermoplastic products) than conventional methods and systems. For example, the continuous forming methods and systems of the present disclosure provide for manufacturing products having geometries such as flat plates, round bars, pipe cross-sections, sandwich panels, and linear profiles with open and closed cross-sections. Such capabilities are at least partially due to the use of feed materials containing thermoplastic components and / or a wider selection of feed material forms that can be utilized, such as tapes, fibers, fabrics. Additionally, in a more efficient approach, some aspects of the disclosed methods and systems enable the creation of products with application-specific features (such as ridges or depressions). As a non-limiting example, roll forming enables the manufacture of products having a surface profile of ridges. While conventional methods and systems that utilize thermosetting materials can manufacture products with surface ridges or depressions, they require a post-manufacturing machining or a second, technically difficult and costly forming process.

[0006] The present disclosure encompasses the recognition of problems in the continuous forming of feed materials containing thermoplastic materials and provides methods for overcoming those problems. For example, thermoplastic materials have a viscosity approximately four times that of thermosetting materials during processing. One of ordinary skill in the art will understand that such processing characteristics lead to significant disadvantages in pulling out thermoplastic materials, such as low manufacturing speeds (e.g., pulling speeds on the order of mm / min) and / or the need for complex methods and systems (e.g., methods and systems involving evacuation), such as those reported in WO / 2017 / 219143 and WO 2020 / 237381. Accordingly, the present disclosure provides continuous forming methods and systems that overcome these processing problems and enable the manufacture of products at high production speeds (e.g., pulling speeds on the order of ft / min) without the need for complex systems.

[0007] In one aspect, the present disclosure is directed to a method for manufacturing a thermoplastic product (e.g., a continuous fiber thermoplastic composite part) from a feed material. In many embodiments, the method includes: i) providing a feed material; ii) heating the feed material to a first temperature to produce a heated feed material, wherein the first temperature is above the glass transition temperature of a first component of the feed material; iii) shaping a solidified material from the heated feed material; and iv) cooling the solidified material to a second temperature.

[0008] In some embodiments, providing the feed material includes: i) pulling each of the feed material, the heated feed material, and the solidified material through each of steps i), ii), iii), and iv), and / or ii) controlling the tension on the feed material (e.g., by providing tension to the feed material by a tensioning unit).

[0009] In some embodiments, the feed material is a continuous fiber thermoplastic composite material, which includes: i) a fiber component; ii) a thermoplastic component; iii) a functional component; or iv) any combination thereof. In some embodiments, the fiber component and the thermoplastic component are mixed.

[0010] In some embodiments, the fiber component includes fibers, which are selected from the group consisting of: i) glass fibers (e.g., E-glass); ii) carbon fibers; iii) aramid fibers; iv) basalt fibers; v) organic fibers (e.g., hemp fibers, wood fibers); and vi) any combination thereof.

[0011] In some embodiments, the thermoplastic component includes a thermoplastic polymer. For example, in some embodiments, the thermoplastic component is selected from the group consisting of polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETg), polycarbonate, polyethylene (e.g., high density polyethylene (HDPE), e.g., low density polyethylene (LDPE)), polypropylene, polyether ether ketone, polyaryl ether ketone (e.g., low melting point polyaryl ether ketone), polyamide (e.g., nylon 6, nylon 6 6, nylon 6 12, nylon 4, 6 nylon 12, etc.), acrylonitrile butadiene styrene, polylactic acid, polyvinyl chloride, or any combination thereof.

[0012] In some embodiments, the disclosed method further includes finishing the thermoplastic product. For example, in some embodiments, finishing includes i) finishing the surface (e.g., deforming the surface of the thermoplastic product), ii) winding the filament, iii) winding the tape, iv) bending, v) curving, vi) cutting, or vii) any combination thereof.

[0013] In some embodiments, the disclosed method does not include saturating the fiber component with the thermoplastic component.

[0014] In some embodiments, the thermoplastic product is selected from the group consisting of reinforcing bars (e.g., steel bars), plates (e.g., flat plates), I-beams, Pi preforms, structural angles, structural channels (e.g., C-channels), hollow structural sections, and pipes.

[0015] In some embodiments, heating the feed material includes exposing the feed material to at least one heat source. In some embodiments, the at least one heat source is selected from the group consisting of a) radiant heater, b) convection heater, c) induction heater, d) resistance heater, or e) any combination thereof.

[0016] In some embodiments, forming a solidified material from a heated feed material includes: i) collecting at least a portion of the heated feed material at a first temperature; ii) optionally heating the heated feed material to a third temperature; iii) optionally cooling the heated feed material to a fourth temperature; and iv) applying pressure to the heated feed material (e.g., by applying a solidification pressure).

[0017] In some embodiments, applying pressure to the heated feed material is carried out substantially simultaneously with at least one of i), ii), and / or iii).

[0018] In some embodiments, the third temperature is intermediate the first temperature and the second temperature.

[0019] In some embodiments, after forming a solidified material from a heated feed material, the solidified material has a cross-section (e.g., cross-sectional dimensions, e.g., cross-sectional shape) different from the cross-section of the heated feed material.

[0020] In some embodiments, cooling the solidified material includes: i) first, cooling the solidified material to a temperature that is (a) below the glass transition temperature of the feed material or (b) below the melting transition temperature of the feed material and / or ii) thereafter, cooling the solidified material to ambient temperature (e.g., room temperature).

[0021] In another aspect, the present disclosure is directed to a continuous forming machine for manufacturing a thermoplastic product from a feed material. In many embodiments, the continuous forming machine comprises: i) a loading unit; ii) a tension applying unit; iii) a heating unit; iv) a forming unit; v) a cooling unit; and vi) a pulling unit, and the continuous forming machine is capable of using a feed material comprising a thermoplastic material.

[0022] In some embodiments, the continuous forming machine does not include (i) a saturation unit and / or (ii) a vacuum unit. For example, in some embodiments, the continuous forming machine does not include a saturation unit selected from the group consisting of a resin bath saturation unit, a resin injection saturation unit, and combinations of both.

[0023] In some embodiments, the feed material is a continuous fiber thermoplastic composite material, and the continuous fiber thermoplastic composite material includes i) a fiber component, ii) a thermoplastic component, iii) a functional component, or iv) any combination thereof, and the fiber component and the thermoplastic component are mixed.

[0024] In some embodiments, the fiber component includes fibers selected from the group consisting of i) glass fibers (e.g., E-glass), ii) carbon fibers, iii) aramid fibers, iv) basalt fibers, v) organic fibers (e.g., hemp fibers, wood fibers), and vi) any combination thereof.

[0025] In some embodiments, the thermoplastic component includes a thermoplastic polymer, and the thermoplastic polymer is selected from the group consisting of polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETg), polycarbonate, polyethylene (e.g., high-density polyethylene (HDPE), e.g., low-density polyethylene (LDPE)), polypropylene, polyether ether ketone, polyaryl ether ketone (e.g., low melting point polyaryl ether ketone), polyamide (e.g., nylon 6, nylon 66, nylon 612, nylon 4, 6 nylon 12, etc.), acrylonitrile butadiene styrene, polylactic acid, polyvinyl chloride, or any combination thereof.

[0026] In some embodiments, the loading unit stores at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, or at least 50 feed material storage modules (e.g., spools, e.g., bobbins, e.g., reels, e.g., coils).

[0027] In some embodiments, the heating unit comprises at least one heat source. For example, in some embodiments, the at least one heat source is selected from the group consisting of radiant heaters, convection heaters, induction heaters, resistance heaters, or any combination thereof.

[0028] In some embodiments, the forming unit comprises a collection unit and at least one solidification die.

[0029] In some embodiments, the pulling unit is selected from the group consisting of a reciprocating pulling unit and a traction pulling unit.

[0030] In some embodiments, the pulling unit pulls the feed material at a speed in the range of about 0.1 ft / min to about 200 ft / min, at a speed in the range of about 0.1 ft / min to about 15 ft / min, or at a speed in the range of about 1 ft / min to about 10 ft / min.

[0031] In some embodiments, the continuous forming machine further comprises i) a thermoplastic injection unit, ii) a roll forming unit, iii) a surface finishing unit, iv) a tape / filament winding unit, v) a bending / curving unit, vi) a conveying unit, vii) a cutting unit, and viii) any combination thereof.

[0032] In some embodiments, the thermoplastic product is selected from the group consisting of reinforcing bars (e.g., steel bars), plates (e.g., flat plates), I-beams, Pi preforms, structural angles, structural channels (e.g., C-channels), hollow structural sections, and pipes.

Brief Description of the Drawings

[0033] The drawings are presented in this specification for illustrative purposes only and not by way of limitation. The foregoing and other objects, aspects, features, and advantages of the present disclosure will become more apparent and be more deeply understood by reference to the following description in conjunction with the accompanying drawings.

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[0068] Definitions In this application, unless the context clearly dictates otherwise or is otherwise specified, (i) the term "a" can be understood to mean "at least one", (ii) the term "or" can be understood to mean "and / or", (iii) the terms "comprising" and "including" can be understood to include the listed components or steps whether presented alone or together with one or more additional components or steps, (iv) the terms "about" and "approximately" can be understood to tolerate a standard deviation as would be understood by one of ordinary skill in the relevant art, and (v) when ranges are provided, endpoints are included. In some embodiments, the term "approximately" or "about" refers to values within 25%, 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, or less in either direction (greater than or less than) of the recited reference value, unless otherwise stated or otherwise apparent from the context (except where such number exceeds 100% of the possible value).

[0069] Comprising: A composition or method described herein as “comprising” one or more named elements or steps is open-ended, meaning that the named elements or steps are essential, but that other elements or steps may be added within the scope of the composition or method. To avoid redundancy, any composition or method described as “comprising” (or “comprises”) one or more named elements or steps also describes the corresponding more limited composition or method “consisting essentially of” (or “consists essentially of”) the same named elements or steps, meaning that the composition or method includes the named essential elements or steps and may also include additional elements or steps that do not substantially affect the basic and novel characteristics of the composition or method. It is also understood that any composition or method described herein as “comprising” or “consisting essentially of” one or more named elements or steps also describes the corresponding more limited closed-ended composition or method “consisting of” (or “consists of”) the named elements or steps, excluding any other unnamed elements or steps. In any composition or method disclosed herein, known or disclosed equivalents of any named essential element or step may replace that element or step.

[0070] Glass transition: As used herein, "glass transition" is a gradual and reversible transition from a hard and relatively brittle "glass-like" state to a viscous or rubbery state in the amorphous regions within an amorphous material or a semi-crystalline material when the temperature is increased. The "glass transition" of a material is a phenomenon that spreads over a temperature range and is thus not always interpreted as occurring at a single temperature. As used herein, the "glass transition temperature" of a material refers to a temperature below which the material is characterized as hard and relatively brittle "glass-like". Thus, as the temperature of the material is increased above its "glass transition temperature", the material undergoes a transition to a rubbery and ductile state over the above temperature range. For example, various material property data references, databases, and / or handbooks such as Brandrup J et al. Polymer Handbook 4th Edition. 4th ed. Wiley 2004 can be used to identify the "glass transition" and / or "glass transition temperature" disclosed herein.

[0071] Melting transition: As used herein, "melting transition" is a thermodynamic transition from a structured crystalline state to a molten state in the crystalline regions within a crystalline material or a semi-crystalline material when the temperature is increased. Thus, as used herein, the "melting transition temperature", "melting temperature", or "melting point" of a material refers to the temperature at which the material exhibits its "melting transition". For example, various material property data references, databases, and / or handbooks such as s Brandrup J et al. Polymer Handbook 4th Edition. 4th ed. Wiley 2004 can be used to identify the "melting transition temperature" of the materials disclosed herein.

[0072] Detailed description of certain embodiments The systems, devices, methods, and processes of the present disclosure are expected to cover variations and adaptations developed using information from the embodiments described herein. Adaptations and / or modifications of the systems, devices, and processes described herein may be made by those skilled in the relevant art.

[0073] Throughout the description where articles, devices, and systems are described as having, comprising, or including certain components, or processes and methods are described as having, comprising, or including certain steps, there are additionally products, devices, and systems according to certain embodiments of the present disclosure consisting essentially of or consisting of the recited components, and there are additionally processes and methods according to certain embodiments of the present disclosure consisting essentially of or consisting of the recited process steps.

[0074] It should be understood that the order of steps or the order of execution of certain operations is not critical unless the feasibility is lost. Further, two or more steps or operations may be performed simultaneously. As understood by those skilled in the art, the terms "across," "under," "above," "below," "directly below," "on" are relative terms and may be replaced with respect to different directions of layers, elements, and substrates included in the present disclosure. For example, in some embodiments, a first layer on a second layer means a first layer that is in direct contact with the second layer directly above the second layer. In other embodiments, a first layer on a second layer may include another layer therebetween.

[0075] The headings are provided for the convenience of the reader and are not intended to limit the claimed subject matter.

[0076] I. Method for Manufacturing a Thermoplastic Product The present disclosure provides, among other things, methods and systems for manufacturing thermoplastic products (e.g., continuous fiber thermoplastic composite parts) from feed materials. By way of non-limiting example, manufacturing a thermoplastic product can include providing a feed material, heating the feed material to produce a heated feed material, shaping a solidified material from the heated feed material, and cooling the solidified material.

[0077] a. Exemplary feed material In accordance with various embodiments, the feed material of the present disclosure can be selected for any technique suitable for the application. By way of non-limiting example, the feed material can be a thermoplastic composite material. For example, in some embodiments, a continuous fiber thermoplastic composite material can include i) a fiber component, ii) a thermoplastic component, iii) a functional component, or iv) any combination thereof. In some embodiments, the fiber component and the thermoplastic component are mixed. For example, the feed material can be characterized as pre-impregnated (e.g., "pre-preg") or semi-impregnated (e.g., "semi-preg").

[0078] Furthermore, the feed material can be in any form suitable for the application. By way of non-limiting example, the feed material can be characterized as a tape (e.g., a unidirectional tape), a fiber (e.g., a mixed fiber), a cloth (e.g., a pre-impregnated cloth), or a towpreg (e.g., a pre-impregnated reinforcing fiber). Non-limiting embodiments of an exemplary tape of the feed material 210 are presented at least in FIGS. 2A-2C.

[0079] i. Fiber component According to various embodiments, the fiber component of the feedstock can be selected for any technique suitable for the application. By way of non-limiting example, the fiber component can be a naturally derived fiber material and / or a synthetically derived fiber material. In many embodiments, exemplary fiber components include, but are not limited to, glass fibers (e.g., E-glass), carbon fibers, aramid fibers, basalt fibers, organic fibers (e.g., hemp fibers, e.g., wood fibers), or any combination thereof.

[0080] ii. Thermoplastic component According to various embodiments, the thermoplastic component can be selected for any technique suitable for the application. By way of non-limiting example, the thermoplastic component is a thermoplastic polymer. In some embodiments, the thermoplastic polymer can be characterized as amorphous. In some embodiments, the thermoplastic polymer can be characterized as semi-crystalline, including both amorphous and crystalline components.

[0081] In many embodiments, exemplary thermoplastic polymers include, but are not limited to, polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETg), polycarbonate, polyethylene (e.g., high-density polyethylene (HDPE), e.g., low-density polyethylene (LDPE)), polypropylene, polyether ether ketone, polyaryl ether ketone (e.g., low melting point polyaryl ether ketone), polyamide (e.g., nylon 6, nylon 6 6, nylon 6 12, nylon 4, 6 nylon 12, etc.), acrylonitrile butadiene styrene, polylactic acid, polyvinyl chloride, or any combination thereof.

[0082] iii. Functional component In some embodiments, the feedstock may further include functional components that improve part functionality and / or performance. For example, the additional components may include inductive materials useful in bending exemplary continuous fiber thermoplastic composite parts after molding. Exemplary functional components may include susceptor materials (e.g., for use in inductive heating such as microwave or radio frequency heating), conductive materials (e.g., conductors or conductive meshes for use in resistive heating), thin metal films or foil materials (e.g., for use as EMI shields), surface materials such as, for example, dry fibers, cloth, and / or paper, filling or coating materials such as, for example, pure thermoplastic resins, foamed thermoplastic resins, or expanded foams, embedded sensors such as thermocouples or the like for detecting and transmitting conditions within the thermoplastic product, or any combination thereof.

[0083] b. Providing a feedstock According to various embodiments, methods and systems for manufacturing a thermoplastic product (e.g., a continuous fiber thermoplastic composite part) from a feedstock include providing one or more feedstocks. By way of non-limiting example, providing a feedstock includes i) pulling the feedstock, heated feedstock, and / or solidified material, and ii) controlling the tension on the feedstock.

[0084] i. Pulling In many embodiments, providing a feedstock includes i) pulling the feedstock, ii) the heated feedstock, and / or iii) the solidified material. One of ordinary skill in the art will understand that any of the feedstock, heated feedstock, and solidified material may actually be pushed through the particular steps and / or units of the provided system, because those steps and / or units are located after the pulling unit.

[0085] According to various embodiments, any of a variety of methods can be used to pull feed material, heated feed material, and / or solidified material within or through the provided system. For example, in some embodiments, an exemplary pulling unit 1400 provides the pulling force necessary to pull each of the feed material, heated feed material, solidified material, and thermoplastic product within and through the disclosed system. Such necessary pulling force can depend on the tension applied by an exemplary tension applying unit 300. In some embodiments, the exemplary pulling unit provides a pulling force of up to about 1 lb f up to about 10 lb f up to about 100 lb f up to about 1000 lb f up to about 10000 lb f up to about 100000 lb f up to about 1000000 lb f .

[0086] In some embodiments, each of the feed material, heated feed material, solidified material, and thermoplastic product moves substantially continuously (e.g., is pulled substantially continuously) through each step or unit of each material of the disclosed method and system. For example, each of the feed material, heated feed material, solidified material, and thermoplastic product moves substantially continuously (e.g., is pulled substantially continuously) at a speed within the range of about 0.1 ft / min to about 200 ft / min, within the range of about 0.1 ft / min to about 15 ft / min, or within the range of about 1 ft / min to about 10 ft / min.

[0087] In many embodiments, pulling is performed by a pulling unit 1400. For example, in some embodiments, the pulling unit 1400 may include a reciprocating pusher as illustrated in the non-limiting embodiment in FIG. 12. An exemplary reciprocating pusher may include two independent hydraulic grippers, and the two independent hydraulic grippers use hydraulic rams to sandwich a processed material (e.g., a solidified material and / or a thermoplastic product) and pull them forward, and each hydraulic gripper moves in an alternating direction such that one of them is always continuously pulling the processed material.

[0088] In some embodiments, the pulling unit 1400 may include a traction pusher 1410 as illustrated in the non-limiting embodiments in FIGS. 13 and 14A - 14E. In some embodiments, an exemplary traction pusher includes two opposing tracks that grip over a processed material (e.g., a solidified material, e.g., a thermoplastic product), and pulls each of the disclosed materials (e.g., a feed material, a heated feed material, a solidified material, and a thermoplastic product) at the exemplary speeds disclosed herein.

[0089] In many embodiments, providing a feed material further includes pulling a feed material from a loading unit 200 (e.g., a creel unit) as illustrated in the non-limiting embodiments in FIGS. 2A - 2C. An exemplary loading unit 200 provides storing an exemplary feed material 210 through the disclosed method and system and / or provides a uniform dispersion of the feed material.

[0090] Furthermore, the exemplary loading unit 200 provides design considerations suitable for the application. As a non-limiting example, the loading unit 200 can be appropriately sized and designed for thermoplastic product manufacturing requirements. For example, the design considerations can include the thermoplastic product shape (e.g., cross-sectional dimensions and / or shape) and / or thermoplastic product throughput needs (e.g., to provide ease in manufacturing scale-up requirements). One skilled in the art will understand that such design consideration capabilities enable beneficial scale-up of thermoplastic product manufacturing needs.

[0091] In some embodiments, the exemplary loading unit 200 enables storage and supply of at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50 storage modules (e.g., spools, e.g., bobbins, e.g., reels, e.g., coils) of the exemplary feed material 210.

[0092] In some embodiments, the exemplary loading unit 200 enables storage and supply of storage modules (e.g., spools, e.g., bobbins, e.g., reels, e.g., coils) of the exemplary feed material 210, and the exemplary storage modules (e.g., spools, e.g., bobbins, e.g., reels, e.g., coils) have a diameter of up to about 5 inches, up to about 10 inches, up to about 15 inches, up to about 20 inches, up to about 25 inches, up to about 30 inches, up to about 35 inches, up to about 40 inches, up to about 45 inches, or up to about 50 inches.

[0093] In some embodiments, an exemplary loading unit 200 enables storage and supply of a feed material 210 in a storage module (e.g., a spool, e.g., a bobbin, e.g., a reel, e.g., a coil), and the feed material 210 can have a width of up to about 1 inch, up to about 2 inches, up to about 5 inches, up to about 10 inches, up to about 15 inches, up to about 20 inches, up to about 25 inches, up to about 30 inches, up to about 35 inches, up to about 40 inches, up to about 45 inches, up to about 50 inches, or up to about 55 inches.

[0094] In some embodiments, an exemplary loading unit 200 enables storage of a feed material 210 in a storage module (e.g., a spool, e.g., a bobbin, e.g., a reel, e.g., a coil) in a vertical stacking method illustrated in FIG. 2A or a horizontal stacking method illustrated in FIG. 2B.

[0095] ii. Applying tension According to various embodiments, controlling the tension on the feed material can be performed in any manner suitable for the application. As a non-limiting example, controlling the tension includes applying tension to the feed material using an exemplary tensioning unit 300 illustrated in FIGS. 3A and 3B. For example, in some embodiments, an exemplary tensioning unit 300 can include a fixed cylinder and a compression cylinder having a linear rail and a spring system. In some embodiments, an exemplary tensioning unit 300 can include a brake system (e.g., a brake caliper of a storage module) that provides accurate and / or consistent tensioning via closed-loop control, or a brake system that provides minimal tensioning via passive control.

[0096] Additionally, or alternatively, the use of the exemplary tensioning unit 300 enables the placement of the feed material, which enables the production of thermoplastic products having various cross-sectional geometries and / or dimensions. In some embodiments, the repositioning of the feed material can be controlled by adjustable rollers included in the exemplary tensioning unit 300.

[0097] c. Heating According to various embodiments, any of a variety of methods can be used to heat the feed material. By way of non-limiting example, heating the feed material includes heating the feed material to a first temperature and producing the heated feed material. For processing the exemplary materials of the present disclosure, the thermoplastic components should not be in a hard, glassy state. Thus, the first temperature can be selected based on the inherent properties of the thermoplastic components of the exemplary feed material. For example, the first temperature can be determined based on the glass transition temperature inherent to the thermoplastic components of the exemplary feed material. Thus, in some embodiments, the first temperature is above the glass transition temperature of at least one component of the feed material (e.g., at least one thermoplastic component).

[0098] In many embodiments, the first temperature can be selected based on the range by which the glass transition temperature of the exemplary thermoplastic component can be exceeded. Considerations regarding the range by which the glass transition temperature can be exceeded include controlling the viscosity of the exemplary thermoplastic component to prevent processing and / or degradation of the exemplary feed material. For example, slightly exceeding the glass transition temperature of the thermoplastic component may not allow for sufficient viscosity for processing (e.g., if the viscosity is too low, it will not allow for proper material flow through the system). Instead, greatly exceeding the glass transition temperature of the thermoplastic component can cause the viscosity for processing to be too low and / or can cause degradation of any of the feed material components. One of ordinary skill in the art will understand that such considerations can vary among the thermoplastic components utilized according to the various embodiments of the present disclosure.

[0099] In some embodiments, the first temperature is at least about 5°F, at least about 10°F, at least about 20°F, at least about 30°F, at least about 40°F, at least about 50°F, at least about 60°F, at least about 70°F, at least about 80°F, at least about 90°F, at least about 100°F, at least about 110°F, at least about 120°F, at least about 130°F, at least about 140°F, at least about 150°F, at least about 160°F, at least about 170°F, at least about 180°F, at least about 190°F, at least about 200°F, at least about 210°F, at least about 220°F, at least about 230°F, at least about 240°F, at least about 250°F, at least about 260°F, at least about 270°F, at least about 280°F, at least about 290°F, at least about 300°F, at least about 310°F, at least about 320°F, at least about 330°F, at least about 340°F, at least about 350°F, at least about 360°F, at least about 370°F, at least about 380°F, at least about 390°F, at least about 400°F, at least about 410°F, at least about 420°F, at least about 430°F, at least about 440°F, at least about 450°F, at least about 460°F, at least about 470°F, at least about 480°F, at least about 490°F, or at least about 500°F higher than the glass transition temperature of the thermoplastic component of the exemplary feed material.

[0100] In a non-limiting example according to various embodiments of the present disclosure, when PETg is utilized as the thermoplastic component of the exemplary feed material, the first temperature can be about 350°F, which is about 174°F higher than the glass transition temperature of PETg.

[0101] In accordance with various embodiments of the present disclosure, heating may be performed by any of a variety of heating units. As a non-limiting example, heating may be performed using an exemplary heating unit 400 (e.g., a preheater) to raise the bulk temperature of the feed material 410 from room temperature to a temperature close to or equal to a first temperature.

[0102] In some embodiments, the exemplary heating unit 400 includes at least one heat source. Utilizing at least one heat source enables the exemplary feed material to be heated uniformly and accurately. For example, the exemplary heating unit 400 may include three heat sources (e.g., three infrared heat sources) to assist in improving heating efficiency. Without wishing to be bound by any particular theory, in some embodiments, multiple heat sources allow heat to diffuse through the feed material between each heat source. Exemplary heat sources include any of a radiant heater, a convection heater, an induction heater, a resistance heater, or any combination thereof. Without wishing to adhere to a particular theory, in some embodiments, for example, using convection heating may be beneficial. This is because this mode of heating efficiently redistributes heat to portions of the feed material that may be hidden from a particular heating element or step (e.g., due to the distance between the heat source and the portion of the feed material).

[0103] In some embodiments, the heat source can be configured to provide rapid heating and / or accurate temperature control. Rapid heating enables high production throughput and / or a fast response to input changes. Accurate temperature control enables control of the heating rate, which is guaranteed with respect to quality control and some components of the feed material. Without wishing to be bound by any particular theory, in some embodiments, changes to the temperature control system can provide a trade-off between a rapid heating mode (which can overshoot or undershoot the target temperature) and a more accurate heating control that is slower in function (and thus relies on a more powerful previous stage) but more accurate and detailed at the target temperature. Exemplary input changes can include increasing or decreasing the feed material input rate (e.g., increasing or decreasing the feed material draw rate, e.g., increasing or decreasing the feed material mass rate, e.g., including additional feed material components). In some embodiments, such input changes can be useful or necessary for various needs, such as (i) studying the processing behavior and improving the overall performance during the development of a production line, (ii) enabling additional materials to be added during startup, (iv) enabling intermittent production functions such as bending and / or enabling the addition of materials at specific, non-linear locations for targeted reinforcement of specific areas, or (iv) enabling changes between exemplary feed materials (e.g., replenishing an existing spool of feed material, or changing the product architecture (e.g., changing the fiber direction, e.g., changing the fiber component, e.g., changing the thermoplastic component, e.g., including an exemplary functional component)).

[0104] In some embodiments, the radiant heater is an infrared heater, a laser heater, a microwave heater, a high-frequency heater, or other types of radiant heaters known in the art. Without wishing to be bound by any particular theory, infrared heaters are useful because they are efficient, provide immediate heating, and are compatible with the properties of exemplary feed materials. For example, infrared heaters are useful for feed materials that are flat tapes with a large surface area and / or translucent feed materials that transmit some of the infrared radiation from a layer of the feed material.

[0105] In some embodiments, convective heating is used to complement infrared heating to assist in providing a more uniform temperature distribution because it allows for additional means of distributing the heat accumulated by infrared radiation. Convective heating can be used as an independent heat source, and the properties of the feed material do not permit heating of the feed material by other heat sources (e.g., in large tapes or fiber bundles).

[0106] In some embodiments, induction heaters can be used when processing feed materials that include functional components such as, for example, stainless steel, carbon fiber, aluminum mesh, aluminum fiber, aluminum foil, susceptor materials (e.g., graphite or metal), or other conductive reinforcing materials.

[0107] In some embodiments, resistance heaters can be used when processing feed materials that include functional components such as, for example, stainless steel, carbon fiber, aluminum mesh, aluminum fiber, aluminum foil, susceptor materials (e.g., graphite or metal), nichrome, kanthal, or other conductive reinforcing materials. Without wishing to be bound by any particular theory, in some embodiments, resistance heaters may present unique advantages over other heat sources such as, for example, induction heaters. For example, resistance heaters can be beneficial for heating predetermined and targeted areas for additional forming steps.

[0108] In some embodiments, an exemplary heating unit 400 will include a heat reflective material for redirecting heat towards the feed material during heating to help minimize losses to the environment and provide a uniform heating pattern. For example, in some embodiments, an exemplary infrared heater may include a material that reflects infrared radiation wavelengths. In some embodiments, an exemplary radiant heater (e.g., a microwave and / or radio frequency heater) may include a waveguide that reflects the target wavelength and redirects and guides the radiation towards the feed material.

[0109] In some embodiments, a circulation fan may also be utilized to achieve a uniform temperature throughout the feed material.

[0110] d. Shaping According to various embodiments, any of a variety of methods may be used to shape the solidified material from the heated feed material. As a non-limiting example, shaping the solidified material from the heated feed material may include collecting at least a portion of the heated feed material and optionally heating the heated feed material to a third temperature and optionally cooling the heated feed material to a fourth temperature and applying pressure. In some embodiments, applying pressure (e.g., a solidification pressure) to the heated feed material is performed substantially simultaneously with collecting, optionally heating, and / or optionally cooling. In many embodiments, the heated feed material is collected at the first temperature.

[0111] In many embodiments, shaping may be performed using an exemplary shaping unit 500. For example, the shaping unit 500 may include a collection unit 510 and / or a solidification unit 520 (e.g., a solidification die), and the collection unit 510 transfers directly to the solidification unit 520 illustrated in FIG. 5.

[0112] i. Collecting In many embodiments, collecting at least a portion of the heated feed material at the first temperature is performed using an exemplary collection unit 510. For example, the exemplary collection unit 510 is a collection funnel that assists in providing the heated feed material into an exemplary solidification unit 520. The exemplary collection unit 510 is useful for removing excess matrix material. For example, in some embodiments, the exemplary collection unit 510 removes up to about 0.5 wt%, up to about 1 wt%, up to about 5 wt%, up to about 10 wt%, or up to about 15 wt% of the heated feed material before providing the heated feed material into the exemplary solidification unit 520.

[0113] ii. Applying pressure According to various embodiments, applying pressure can be performed by any of a variety of systems. By way of non-limiting example, in some embodiments, applying pressure is performed by using an exemplary solidification unit 520. For example, the exemplary solidification unit 520 can be a solidification die that applies pressure to the heated feed material by gradually narrowing the heated feed material to a final cross-sectional dimension that is smaller than the initial cross-sectional dimension, producing a solidified material. Thus, in some embodiments, the solidification unit 520 includes at least one portion that tapers to a final cross-sectional dimension that is smaller than the initial cross-sectional dimension.

[0114] In some embodiments, the exemplary solidification unit 520 includes a solidification unit 522 having a constant cross-sectional dimension as illustrated in FIG. 5B.

[0115] In addition, each of the at least one portion can be spaced apart by a spacer (e.g., a thin ceramic spacer). For example, the solidification die can include three portions, each with a constant taper in cross-sectional dimension, providing a continuous taper along the length of the exemplary solidification unit 520 illustrated in FIG. 5A.

[0116] iii. Optional heating step during forming During the shaping of the solidified material, in some embodiments, the feed material may require further heating to a temperature higher than the first temperature. Thus, in some embodiments, shaping the solidified material further includes heating the heated feed material to a third temperature. According to some embodiments, this optional additional heating of the heated feed material to the third temperature provides the bulk temperature of the feed material, which is the temperature required for shaping the feed material. Without wishing to be bound by any particular theory, heating the feed material to the third temperature may be more efficient than cooling the feed material to the third temperature, as the temperature measurement techniques used during heating may only provide some assurance of accuracy towards the bulk temperature of the feed material. Further, the intended third temperature is close to the degradation temperature of the thermoplastic component of the exemplary feed material, and it is safer to raise the material to the final temperature in the shaping process, as the temperature can be more accurately controlled in this range.

[0117] In some embodiments, the third temperature is at least about 5°F, at least about 10°F, at least about 20°F, at least about 30°F, at least about 40°F, at least about 50°F, at least about 60°F, at least about 70°F, at least about 80°F, at least about 90°F, at least about 100°F, at least about 110°F, at least about 120°F, at least about 130°F, at least about 140°F, at least about 150°F, at least about 160°F, at least about 170°F, at least about 180°F, at least about 190°F, at least about 200°F, at least about 210°F, at least about 220°F, at least about 230°F, at least about 240°F, at least about 250°F, at least about 260°F, at least about 270°F, at least about 280°F, at least about 290°F, at least about 300°F, at least about 310°F, at least about 320°F, at least about 330°F, at least about 340°F, at least about 350°F, at least about 360°F, at least about 370°F, at least about 380°F, at least about 390°F, at least about 400°F, at least about 410°F, at least about 420°F, at least about 430°F, at least about 440°F, at least about 450°F, at least about 460°F, at least about 470°F, at least about 480°F, at least about 490°F, or at least about 500°F higher than the glass transition temperature of at least one component (e.g., at least one thermoplastic component).

[0118] In some embodiments, the third temperature is at least about 10°F, at least about 20°F, at least about 30°F, at least about 40°F, at least about 50°F, at least about 60°F, at least about 70°F, at least about 80°F, at least about 90°F, at least about 100°F, at least about 110°F, at least about 120°F, at least about 130°F, at least about 140°F, or at least about 150°F higher than the first temperature.

[0119] In non-limiting examples according to various embodiments of the present disclosure, when PETg is utilized as the thermoplastic component of an exemplary feedstock, the first temperature can be about 350°F, the third temperature can be as high as about 400°F, the first temperature is about 174°F higher than the glass transition temperature of PETg, and about 50°F higher than the first temperature.

[0120] In certain embodiments, a feedstock comprising a semi-crystalline thermoplastic component may require molding at a third temperature equal to or higher than the melting temperature of at least one semi-crystalline thermoplastic component. Thus, in some embodiments, the third temperature is at least about 5°F, at least about 10°F, at least about 20°F, at least about 30°F, at least about 40°F, at least about 50°F, at least about 60°F, at least about 70°F, at least about 80°F, at least about 90°F, at least about 100°F, at least about 110°F, at least about 120°F, at least about 130°F, at least about 140°F, at least about 150°F, at least about 160°F, at least about 170°F, at least about 180°F, at least about 190°F, at least about 200°F, at least about 210°F, at least about 220°F, at least about 230°F, at least about 240°F, at least about 250°F, at least about 260°F, at least about 270°F, at least about 280°F, at least about 290°F, at least about 300°F, at least about 310°F, at least about 320°F, at least about 330°F, at least about 340°F, at least about 350°F, at least about 360°F, at least about 370°F, at least about 380°F, at least about 390°F, at least about 400°F, at least about 410°F, at least about 420°F, at least about 430°F, at least about 440°F, at least about 450°F, at least about 460°F, at least about 470°F, at least about 480°F, at least about 490°F, or at least about 500°F higher than the melting transition temperature of at least one component (e.g., at least one semi-crystalline thermoplastic component).

[0121] In non-limiting examples according to various embodiments of the present disclosure, when HDPE is utilized as the thermoplastic component of an exemplary feed material, the third temperature can be about 275°F, which is about 440°F higher than the glass transition temperature of HDPE and about 10°F higher than the melting temperature of HDPE.

[0122] iv. Optional cooling step during forming In some embodiments, forming the solidified material can further include cooling the heated material to a fourth temperature. For example, an exemplary feed material may require cooling to a temperature lower than the third temperature. In some embodiments, the fourth temperature can be at least about 5°F, at least about 10°F, at least about 20°F, at least about 30°F, at least about 40°F, at least about 50°F, at least about 60°F, at least about 70°F, at least about 80°F, at least about 90°F, at least about 100°F, at least about 110°F, at least about 120°F, at least about 130°F, at least about 140°F, at least about 150°F, at least about 160°F, at least about 170°F, at least about 180°F, at least about 190°F, at least about 200°F, at least about 210°F, at least about 220°F, at least about 230°F, at least about 240°F, or at least about 250°F lower than the third temperature.

[0123] As a non-limiting example, according to various embodiments of the present disclosure, when polyethylene terephthalate glycol (PETg) is utilized as the thermoplastic component of an exemplary feed material, the third temperature can be 400°F and the fourth temperature can be 325°F.

[0124] As an additional non-limiting example according to various embodiments of the present disclosure, when high-density polyethylene (HDPE) is utilized as the thermoplastic component of an exemplary feed material, the third temperature can be approximately 275°F and the fourth temperature can be approximately 175°F.

[0125] According to various embodiments, optional cooling can be implemented by any of a variety of methods. As a non-limiting example, optional cooling can be implemented using the exhaust heat unit 530 included in the exemplary solidification unit 500. In some embodiments, the exemplary exhaust heat unit can be a liquid immersion cooling unit, a fan cooling unit, an immersion cooling unit, a liquid injection cooling unit (e.g., a coolant, either gas or liquid, is injected into the annular space within the exemplary cooling unit 530), a solid state cooling unit (e.g., a Peltier or other similar thermoelectric device), an internal cooling channel unit (e.g., including a coolant, either gas or liquid, flowing through channels within the exemplary cooling unit 530).

[0126] In some embodiments, the exhaust heat unit is associated with (e.g., disposed at at least one terminal portion of the solidification unit 520). The exemplary exhaust heat unit 530 can include at least one exhaust fan combined with a fan shroud, and circulate heated gas above and away from the solidification unit 520 through the at least one exhaust fan. For example, the exemplary exhaust heat unit 530 includes six exhaust fans combined with the fan shroud illustrated in FIG. 6. In some embodiments, the exemplary exhaust heat unit 530 can include a heat sink (e.g., heat sink fins) disposed on the exemplary solidification die 500.

[0127] e. Cooling According to various embodiments, any of a variety of methods can be used to cool the solidified material to a second temperature. In some embodiments, the second temperature is equal to or lower than the glass transition temperature of at least one component of the exemplary solidified material (e.g., at least one thermoplastic component). For example, cooling can include first cooling the solidified material to a temperature that is at least about 5°F, at least about 10°F, at least about 20°F, at least about 30°F, at least about 40°F, at least about 50°F, at least about 60°F, at least about 70°F, at least about 80°F, at least about 90°F, at least about 100°F, at least about 110°F, at least about 120°F, at least about 130°F, at least about 140°F, at least about 150°F, at least about 160°F, at least about 170°F, at least about 180°F, at least about 190°F, at least about 200°F, at least about 210°F, at least about 220°F, at least about 230°F, at least about 240°F, or at least about 250°F lower than the glass transition temperature of at least one component of the feed material.

[0128] In a non-limiting example according to various embodiments of the present disclosure, when PETg is utilized as the thermoplastic component of an exemplary feed material, the second temperature can be 120°F, which is about 56°F lower than the glass transition temperature of PETg.

[0129] In some embodiments, the second temperature is equal to or lower than the melting transition temperature of at least one component of the exemplary solidified material (e.g., at least one semi-crystalline thermoplastic component). For example, cooling can include first cooling the solidified material to a temperature that is at least about 5°F, at least about 10°F, at least about 20°F, at least about 30°F, at least about 40°F, at least about 50°F, at least about 60°F, at least about 70°F, at least about 80°F, at least about 90°F, at least about 100°F, at least about 110°F, at least about 120°F, at least about 130°F, at least about 140°F, at least about 150°F, at least about 160°F, at least about 170°F, at least about 180°F, at least about 190°F, at least about 200°F, at least about 210°F, at least about 220°F, at least about 230°F, at least about 240°F, or at least about 250°F lower than the melting transition temperature of at least one component of the exemplary solidified material (e.g., at least one semi-crystalline thermoplastic component).

[0130] In a non-limiting example according to various embodiments of the present disclosure, when HDPE is utilized as the thermoplastic component of the exemplary feed material, the second temperature can be approximately 120°F, which is about 155°F lower than the melting transition temperature of HDPE.

[0131] In some embodiments, first cooling the solidified material can be performed using the exemplary cooling die 700 illustrated in FIG. 7. The exemplary cooling die 700 operates by circulating a coolant (e.g., cooling water) through the cooling die 700 to transfer heat from the solidified material.

[0132] In some embodiments, cooling further includes subsequently cooling the solidified material to an ambient temperature (e.g., room temperature). For example, subsequently cooling the solidified material can be performed using an exemplary cooling unit 800 for subsequently cooling the solidified material to an ambient temperature. For example, in some embodiments, the ambient temperature can be room temperature and / or a temperature that is safe for operation.

[0133] In some embodiments, exemplary cooling unit 800 includes a liquid immersion cooling unit, a fan cooling unit, an immersion cooling unit, a compressed air (e.g., air blow) cooling unit, a quasi-ambient cooling unit (e.g., utilizing a quasi-ambient gas or liquid cooling medium).

[0134] The exemplary liquid immersion cooling unit 800 illustrated in FIG. 8 operates by directly passing a flow of coolant (e.g., cooling water) over the solidified material. In some embodiments, the exemplary liquid immersion cooling unit 800 provides cooling water at a rate of at least about 0.5 gallons per minute, at least 1 gallon per minute, at least 5 gallons per minute, at least 10 gallons per minute, at least 15 gallons per minute, at least 20 gallons per minute, at least 25 gallons per minute, at least 30 gallons per minute, or at least 35 gallons per minute.

[0135] f. Optional Steps and Units In some embodiments, the methods and systems of the present disclosure can further include optional steps and units. For example, such optional steps can include, among other things, injecting a thermoplastic component, roll forming, reshaping a surface, winding a tape / filament, bending / curving, transporting, and cutting.

[0136] i. Injecting a thermoplastic component When presented in this specification, injecting a thermoplastic component should not be seen in a context similar to injecting in conventional drawing methods and systems. In contrast to conventional drawing methods and systems, injecting a thermoplastic component is not used to combine components of exemplary feed materials. For example, in accordance with this disclosure, injecting a thermoplastic component is not useful for saturating a thermoplastic component with a fiber component.

[0137] One of ordinary skill in the art will understand that the disclosed methods and systems enable the production of thermoplastic products with complex shapes. Such complex shapes can lead to issues such as material voids in the thermoplastic product during manufacturing. Thus, injecting a thermoplastic component can enable void reduction with respect to any of the disclosed thermoplastic products. For example, void reduction can be useful for the production of complex thermoplastic product shapes by filling voids at material intersections of exemplary shapes and profiles (e.g., I-beams, T-profiles, Pi preforms, etc.). In some embodiments, injecting a thermoplastic component can enable the production of products having a linear surface shape that does not require a fiber component. Additionally, or alternatively, injecting a thermoplastic component can enable the production of overmolded thermoplastic products such as, among other things, pipes and tubes.

[0138] In accordance with various embodiments, any of a variety of methods can be used for injecting a thermoplastic component. By way of non-limiting example, injecting a thermoplastic component can be performed by a screw-type thermoplastic injection system that melts and pressurizes the thermoplastic component for injection. In some embodiments, injecting occurs during or after molding.

[0139] In some embodiments, injecting is performed by injecting the thermoplastic component into an exemplary molding unit 500. For example, injecting the thermoplastic component may include injecting the thermoplastic component into an exemplary solidification unit 520 to fill unwanted voids such as voids that occur at material intersections.

[0140] In some embodiments, injecting is performed by injecting the thermoplastic component into an annular region of an exemplary solidification unit 520 that produces a product (e.g., a pipe, a pressure vessel, etc.) characterized as "overmolded".

[0141] In some embodiments, injecting is performed by injecting the thermoplastic component into a manufactured void in an exemplary solidification unit 520 to create longitudinal features on the surface of the thermoplastic product.

[0142] In some embodiments, injecting the thermoplastic component to produce an "overmolded" product may be performed by a mandrel or other similar device for injecting the thermoplastic component into the interior of a hollow profile (e.g., on the inner surface of a pipe, for example).

[0143] ii. Roll forming In some embodiments, the disclosed methods and systems may further include roll forming. For example, the solidified material is roll formed after being formed from a heated feed material. Exemplary methods and units for roll forming enable the production of thermoplastic products having complex cross-sections from the solidified material.

[0144] Any of a variety of methods and systems may be used for roll forming. As a non-limiting example, roll forming includes passing a compression roller over the solidified material to produce the roll formed material.

[0145] In some embodiments, roll forming can occur first by cooling (e.g., between when the material exits the exemplary cooling die 700 and before subsequent cooling (e.g., before entering the immersion cooling unit 800)).

[0146] In some embodiments, the solidified material enters the roll forming unit 1500 at the glass transition temperature of the thermoplastic component of the feed material, enabling overall manufacturing efficiency by utilizing the energy added during manufacturing.

[0147] In some embodiments, the exemplary roll forming unit 1500 includes mechanical or actuating rollers that help enable the production of thermoplastic products having non-linear shapes.

[0148] In some embodiments, additional heating units or cooling units can be implemented before or during roll forming to optimize the roll forming process. In some embodiments, heating before or during roll forming can be performed by infrared heating, induction heating (e.g., where an exemplary susceptor material is placed in the area of the thermoplastic product intended to be roll formed), and / or hot air heating.

[0149] As a non-limiting example, FIGS. 15A and 15B depict roll forming in which a solidified material having an 8-inch flat plate shape is passed through an exemplary roll forming unit 1500 to produce a C-channel thermoplastic product.

[0150] iii. Reforming the surface In some embodiments, the disclosed methods and systems can further include reforming the surface. Exemplary methods and units for reforming the surface enable the production of thermoplastic products having non-linear and pattern-driven surface profiles.

[0151] According to various embodiments, any of a variety of methods and systems for reshaping a surface may be used. By way of non-limiting example, an exemplary surface reshaping unit includes a continuous rolling mold for producing a thermoplastic product having a non-linear surface profile. For example, such a profile may include ridges and / or depressions on the surface of an exemplary thermoplastic product.

[0152] By way of non-limiting example, reshaping a surface includes passing a solidified material through a continuous rolling mold as illustrated in FIG. 16C to produce a reshaped material surface as illustrated in FIG. 16B from a material having a smooth linear surface profile as illustrated in FIG. 16A. Without wishing to be bound by any particular theory, such surface deformation can be significant for thermoplastic products in applications where a mechanical bond between the thermoplastic product and cast concrete is essential, such as for concrete reinforcement bars (e.g., rebar).

[0153] In some embodiments, the solidified material is reshaped after being formed from a heated feed material. For example, reshaping the surface can occur between first cooling (e.g., after the material exits the exemplary cooling die 700) and subsequent cooling (e.g., before entering the immersion cooling unit 800).

[0154] In some embodiments, an exemplary surface reforming unit includes heating and / or applying pressure to enable the production of a thermoplastic product having a non-linear surface profile. In some embodiments, heat can be utilized from recycled thermal energy added during manufacture. In some embodiments, heat can be utilized by an in-line heating element to reheat the surface and cross-section of the material undergoing surface reforming. In some embodiments, applying pressure is effected by rollers to effect the desired deformation. In some instances, surface reforming occurs by locally yielding the surface of the material, for example if no additional heat is applied.

[0155] In some embodiments, a mechanical or actuated tool enables the production of a thermoplastic product having a non-linear surface profile. The tool can operate on the profile through a method in which either pressure or displacement is restricted. For example, if deformation is desired to be applied using a given pressure, the tool can be actuated by pneumatic, fluidic, or other pressure-controlled means. If deformation is desired to be applied using a given tool displacement, the tool can be mechanically configured using a screw-type or similar connection. In some embodiments, the tool method can utilize multiple forming stages to gradually form the cross-section into the desired non-linear surface profile. This can reduce the required force and limit any damage to the feed material.

[0156] In some embodiments, reshaping the surface includes depositing additional material onto the solidified material. In some embodiments, the additional material may provide a bulk for strengthening the reshaping of the surface, provide solidified material with different component properties, or provide a specific surface finish to the solidified material. By way of non-limiting example, a surface reshaping unit may be used to apply additional material such as a pure thermoplastic component, which may then be more easily deformed or provide a strengthened surface finish. In some embodiments, this may proceed by feeding a continuous sheet of the thermoplastic component into the area where the rolling tool contacts the exemplary feed material.

[0157] iv. Winding the tape / filament In some embodiments, the disclosed methods and systems may further include winding the tape / filament. Winding the tape / filament enables the strengthening and / or surface modification of the thermoplastic product by externally wrapping the flexing material onto a pattern on the surface of the thermoplastic product. For example, the disclosed tape / filament winding methods may provide for profiling of the surface, creation of hollow pipes and rods, or creation of a skin fiber orientation for a particular application.

[0158] According to various embodiments, any of a variety of tape / filament winding methods and systems may be used. By way of non-limiting example, an exemplary tape / filament winding unit 1700 is presented in FIGS. 17A and 17B. In many embodiments, the exemplary tape / filament winding unit 1700 operates by rotating around a non-rotating but linearly moving solidified material and depositing the exemplary winding material onto the solidified material.

[0159] In some embodiments, exemplary winding materials include, among other things, unidirectional (UD) tapes (for use, e.g., in tape winding) and biocomponent filaments (for use, e.g., in filament winding). In some embodiments, exemplary winding materials can be or include the thermoplastic components disclosed herein. In some embodiments, the winding material can be characterized as pre-impregnated (e.g., “pre-preg”) or semi-impregnated (e.g., “semi-preg”). In some embodiments, the winding material can be or include the functional components disclosed herein.

[0160] In some embodiments, after being formed from the heated feed material, the solidified material undergoes winding of the tape / filament. For example, winding of the tape / filament can occur after cooling. Additionally, an exemplary tape / filament winding unit 1700 can be positioned downstream of the exemplary tension unit 1400.

[0161] As illustrated in FIGS. 17A and 17B, an exemplary tape / filament winding unit 1700 includes a rotating wheel with an exemplary winding material 1710 (e.g., a spool with continuous fiber reinforced thermoplastic (CFRTP) tape attached) and winds the tape in a specific direction around an exemplary thermoplastic product (with a maximum 6” outer diameter). In some embodiments, the direction will be determined based on the relationship between the manufacturing speed (e.g., the pulling speed) and the tape / filament packing speed. In some embodiments, prior to tape / filament winding, the exemplary winding material is heated to improve the accumulation with the thermoplastic product and / or previously accumulated winding material. In some embodiments, a constant tension is applied to the winding material to ensure consistent alignment and density during winding.

[0162] v. To bend / To curve In some embodiments, the disclosed methods and systems may further include bending / curving. Bending / curving enables the production of thermoplastic products having a bent / curved profile as opposed to a linear, linear profile in methods and systems that do not include bending / curving. For example, bending / curving may be useful for producing thermoplastic products that conform to the curvature of a hull. As another example, bending / curving may be useful for producing thermoplastic products or thermoplastic products that are bent into helical coils for use as concrete restraint and shear reinforcement.

[0163] In accordance with various embodiments, any of a variety of bending / curving methods and systems may be used. As a non-limiting example, an exemplary bending / curving unit 1800 is presented in FIGS. 18A and 18B. In many embodiments, the exemplary bending / curving unit 1800 is located downstream of the exemplary tension unit 1400.

[0164] In some embodiments, the exemplary bending / curving unit includes at least one roller for producing thermoplastic products having curvatures of varying complexity (e.g., ranging from simple curved products to helical products). In some embodiments, the roller is powered. In some embodiments, the roller may have heating and / or cooling elements. FIGS. 18A and 18B present an exemplary bending / curving unit 1800 that is capable of producing a curved C-channel thermoplastic product by utilizing heat and offset rollers to produce the desired curvature.

[0165] In some embodiments, the exemplary bending / curving unit includes robotics and / or other actuation techniques for producing thermoplastic products having curvatures of varying complexity (e.g., ranging from simple curved products to helical products).

[0166] vi. transporting In some embodiments, manufacturing the thermoplastic product further includes transporting the thermoplastic product. According to various embodiments, any of a variety of methods and units may be utilized for transporting. As a non-limiting example, a roller conveyor may be utilized for transporting. Transporting enables the temperature of the thermoplastic product to equilibrate before entering an exemplary tension unit.

[0167] vii. Cutting In some embodiments, manufacturing the thermoplastic product further includes cutting the thermoplastic product. According to various embodiments, any of a variety of methods or units may be utilized for cutting. As a non-limiting example, an exemplary cutting unit may be utilized for cutting the thermoplastic product. In some embodiments, the exemplary cutting unit may include an automatic flying saw unit or an automatic shearing unit.

[0168] g. Thermoplastic product According to various embodiments, any of a variety of thermoplastic products may be made using the provided methods and systems. As a non-limiting example, the thermoplastic product is a structural part (e.g., a structural member). In some embodiments, the structural part may include, among other things, reinforcing bars (e.g., rebars), plates (e.g., flat plates), I-beams, Pi preforms, structural angles, structural channels (e.g., C-channels), hollow structural sections, or pipes.

[0169] II. Exemplary advantages of the present disclosure Without being bound by any particular theory, after reading the present disclosure, one of ordinary skill in the art will understand that the disclosed drawing methods and systems provide advantages over conventional drawing methods and systems.

[0170] a. Saturating the fiber component As presented herein, exemplary methods and systems utilize an exemplary feed material that includes a fiber component and a thermoplastic component that can be characterized as being mixed. Thus, in many embodiments, the disclosed methods and systems for manufacturing thermoplastic products from the exemplary feed material do not require saturating the fiber component with the thermoplastic component during manufacturing and thus do not require a saturation unit. Thus, utilizing the disclosed methods and systems provides reduced VOC emissions and a reduced risk in environmental and / or health hazards. In contrast, conventional drawing methods and systems utilize a feed material that includes a fiber component and a thermosetting component. In such systems, the fiber component and the thermosetting component require saturating the fiber component with the thermosetting component during manufacturing (i.e., the fiber component and the thermosetting component are impregnated during manufacturing). Thus, conventional methods and systems require the use of a saturation unit. The use of such systems and units results in environmental and / or health hazards, particularly due to VOC emissions. Exemplary saturation units include, among others, a resin saturation bath unit, a resin injection saturation unit (e.g., a resin injection unit that impregnates the fiber component with a thermosetting component).

[0171] b. Making it vacuum As presented herein, some methods and systems attempt to overcome challenges in continuous molding for manufacturing thermoplastic products, such as challenges in reducing voids. However, such methods and systems rely on complex techniques, such as making it vacuum, to overcome exemplary challenges. Thus, the disclosed methods and systems do not require or include vacuum methods and / or units and are thus advantageous over known methods and systems.

[0172] Exemplification Example 1: Manufacturing a thermoplastic product including PETg and E glass The thermoplastic drawing machine consists of multiple different parts. At the head of the machine, a creel unit holds the required tape reels in position and is used for storage and arrangement. As the tapes are pulled out from the creel, they pass through a tensioning system. The tensioning mechanism removes slack from the tape line and prevents the tape from sagging and contacting the machine walls and each other as the tape moves into the preheater.

[0173] After exiting the creel and tensioning units, the tape moves into a preheater, which is an enclosed space where the tape is heated by an array of infrared process heaters. It is in the preheater that the tape is raised to the required curing temperature. Tensioning of the tape in this section is also required to provide the alignment needed to help heat the tape uniformly.

[0174] Once heated to the desired curing temperature, the tape enters a collector, which is a wide - open heated funnel designed to advance the tape into the heated die opening. It is also in the collector that excess material supplied to the system is removed. This excess matrix material, aided by the heating of the curing die, is removed from the system by gravity. This prevents the build - up of material within the system.

[0175] The curing die is divided into at least three sections. Each section tapers at a constant rate, starting at the mouth of the first section and narrowing to the diameter of the final portion at the exit of the last section. The section temperatures are monitored and heated by built - in cartridge heaters. Each section is spaced apart from the others by ceramic spacers, allowing for more precise temperature control. This arrangement should be adaptable to most possible temperature profiles.

[0176] Similar to how the ceramic spacer separates sections of the solidification die, the ceramic spacer separates the solidification die from the cooled die. After the desired cross-section is reached, the material moves into the cooled die. The material is cooled to approximately the glass transition temperature within the cooled die, and simultaneously, the die tapers outward to facilitate removal. This die section is actively cooled by cooling water flowing through channels on the outside of the die.

[0177] The partially cooled and solidified material exits the cooled die and enters directly into a post-cooler section to complete the cooling process. The post-cooler cools the core of the drawn part and prevents any warping in the system. This is achieved by spraying a large flow of cooling water over that part.

[0178] The drawing process is driven by a pulling device located immediately after the post-cooler. In most industrial processes, the pulling section consists of a set of reciprocating fluid-driven linear pullers. Due to the scale of the system and technical constraints, a continuous track solution is implemented instead. This type of puller is also common in industry, and while it cannot generate a tensile force as strong as a conventional fluid system, it has the advantage of being more controllable. Each track of the puller is independently driven by a motor and planetary gear set. The required compressive force between the tracks is provided by a compressed air cylinder.

[0179] Due to the speed at which the material is moving through the system, an automated method for cutting the produced thermoplastic rebar will be required. This can be achieved by using a circular saw arrangement mounted on guide rails. This allows the saw to cut the rebar as it moves along with the draw for straight cuts.

[0180] a. Major System Assumptions A number of assumptions were made throughout the process of designing this system. Where possible, design choices were made to accommodate a range of possible values. Detailed assumptions and design considerations are included within each relevant section. Listed below are some of the major assumptions made.

[0181] 1. Steady-state operation: Although some functions must be considered with respect to startup and shutdown sequences, system attributes are considered with respect to steady-state operation. This includes power levels throughout the heating / cooling system and forces and speeds within the tensioning system.

[0182] 2. Constant material properties: All of the heat capacity, thermal conductivity, and density are functions of varying temperature intensities. They are considered constant to simplify calculations, and appropriate margins will be included to accommodate variations in these properties.

[0183] 3. A constant die pressure of 100 psi. The true die pressure is unknown, however, it is expected that the true die pressure can be varied by changing operating parameters such as, for example, the number of tapes supplied and the draw speed.

[0184] 4. Negligible friction in the movement of the tape outside of the die section and creels

[0185] 5. The tape fibers are arranged in a laterally isotropic manner around the draw axis.

[0186] 6. Negligible heat loss except where intentionally designed or explicitly described

[0187] b. System characteristics overview Overall system parameters and material properties are defined in this section and referenced throughout all further sections for calculations.

[0188] i. Material properties The material properties of the PETg-E glass composite are extremely important for the design calculations included in this document. The following information was collected regarding the known characteristics of the system.

[0189]

Table 1

[0190] Using the rule of mixtures for the composite material, the properties of the composite material can be calculated. From the glass composite density and weight fraction, the volume fraction of glass is calculated.

[0191]

Equation

[0192] From the volume fraction of glass, the composite density can be calculated.

[0193]

Equation

[0194] The composite heat capacity is a function of the heat capacity of each component in the composite and the weight (mass) fraction. The composite heat capacity is calculated as follows.

[0195]

Equation

[0196] The thermal conductivity of the composite material is extremely important for the behavior of the parts withdrawn in the heating and cooling dies. The thermal conductivity is maximized along the fiber length and minimized across their width. This can be explained again by the rule of mixtures.

[0197] The thermal conductivity along the fiber length can be calculated as follows.

[0198]

Equation

[0199] The heat conductivity across the fiber width can be calculated as follows.

[0200]

Number

[0201] ii Operating parameters The overall expected operating parameters of this machine are defined here and referenced in all further sections.

[0202]

Table 2

[0203] Although it is not expected that this system will be further developed to produce reinforcing bars with diameters greater than 1 / 2", the drawing speed can vary up to a speed of about 10 ft / min. This consideration must be borne in mind during the design of all sections of the machine.

[0204] From the manufacturer's data, it is known that the tape is 2" wide with a thickness of 0.012. This gives the cross-sectional area of the individual composite tape as follows.

[0205] Cross-sectional area of each tape:

Number

[0206] Useful in most sections of the machine is the mass flow rate of the composite. Four different mass flow rates must be calculated: the flow through the preheater and the flow through the rest of the system calculated for an expected drawing speed of 5 ft / min and a maximum speed of 10 ft / min. These mass flow rates will be referenced in all system calculations.

[0207]

Table 3

[0208] Finally, the expected temperatures in each section are listed here for reference. These temperatures are referenced in all system calculations.

[0209]

Table 4

[0210] c. Creel and Tensioning Device iii. Overview The purpose of the creel system is to provide a framework on which rolls of composite tape can be stored and uniformly distributed into the preheater. Design considerations include the size of the creel, the direction of the tape as it enters the withdrawal system, a modular approach for potential design upgrades, and easy access for changing empty spools.

[0211] This force directly contributes to the tensile force required in the tension section. A separate device between the creel and the preheater is constructed to provide additional tension in the tape. This tensioning system consists of two fixed cylinders and a compression cylinder with linear rails and a spring system.

[0212] iv. Assumptions 1. The system operates in a steady state with no change in draw speed.

[0213] 2. Constant material properties.

[0214] 3. The composite tape rotates freely.

[0215] v. Design The tape being used is known to be 2” wide with a thickness of 0.012. A taper is formed in the heated die to allow excess material to be fed into the system to ensure the entire die is filled. The diameter of this tapered opening is 0.55. The number of tapes required to fill this diameter can be calculated as follows.

[0216]

Number

[0217] To provide sufficient material to the system, the number of tapes is rounded up to 10 tapes. The creel system is designed to hold 16 tapes to account for possible design production upgrades. This ensures that sufficient material is fed into the system to fill the die.

[0218] The second function of the creel section is to provide tension in the tape to keep the tape taught as it passes through the preheater section and into the mouth of the consolidator. This tension helps prevent the tapes from contacting each other and maintains the proper spacing required for effective heating in the preheater. The desired tension in each tape is currently estimated to be 10 lb. Considering this and the number of tapes, the force required to draw the tape out of the creel can be calculated.

[0219]

Number

[0220] d. Preheater vi. Overview The preheater has the role of raising the bulk temperature of the tape from room temperature to the desired curing temperature (or to near the desired curing temperature). This is expected to be accomplished through the use of infrared heaters within the enclosed volume. The tape passes through the perforated front plate and enters the heating chamber. Inside the preheater body, the tape is heated by an array of infrared heaters. The heating chamber consists of three sections to improve the efficiency of the heating system. To assist the heating process, the inner surface of the body is made of a suitably reflective material to redirect infrared radiation towards the tape bundle. This helps to minimize losses to the environment and provide an even heating pattern. A circulation fan may be provided to assist in creating a uniform temperature throughout the tape.

[0221] The downstream end of the preheater is attached to an outflow drain and an outflow heater. This allows any excess PETg supplied to the system to be removed as it is taken away by the openings in the curing section. The outflow heater ensures that the material retains sufficient thermoplasticity for it to flow by gravity from the preheater through the small lower opening. The excess matrix material can be collected in a waste container under the machine.

[0222] vii. Assumptions 1. The preheater is in a steady state and there are no changes in the heating rate.

[0223] 2. Constant material properties.

[0224] 3. The infrared heating system produces a uniform temperature profile across the tape.

[0225] viii. Design The total mass flow rate of the composite through the system can be calculated as a function of the draw speed, cross-sectional area, and number of tapes supplied, as well as the composite density, as calculated in the overall system characteristics section.

[0226] The required heater power can be calculated from the mass flow. The material enters at the ambient temperature and exits at the preheater temperature as defined in the system parameters section.

[0227]

Number

[0228] Fraction of heat used to heat the tape:

Number

[0229] Fraction of power converted to useful heat:

Number

[0230] These efficiencies can be used to convert the required power to the nominal power.

[0231]

Number

[0232] To account for the possibility of operating this system at the maximum potential drawdown rate of the system, these calculations should be repeated using a speed of 10 ft / min.

[0233]

Number

[0234]

Number

[0235] Note that in the preheater, it is unknown whether the tape configuration significantly affects the performance of the infrared heating process. The preheater is insulated, but there will be some heat loss to the surroundings. Efficiency

Number

[0236] e. Collector and consolidation die ix. Overview The collection funnel is located at the end of the preheater body and assists in guiding the tape bundle into the heated die. The collector funnel transitions directly to a heated die section that tapers gently to the final material diameter.

[0237] The consolidation die consists of three separate 1 ft split hollow aluminum die sections, each with a certain taper to improve consolidation. The die sections are separated by thin ceramic spacers to allow for finer temperature control between each section and are heated by integrated cartridge heaters.

[0238] The role of the collector and consolidation die sections is to provide sufficient consolidation pressure, complete heating of the matrix to its peak required temperature, and then initiate cooling of the material to a lower temperature, perhaps in the range of 300 - 325 °. The pressure should be maintained over the length of the consolidation die. The consolidator funnel also has the role of removing any excess matrix material and bringing the cross-section to the required size.

[0239] x. Assumptions 1. It is assumed that the material is always in contact with the inside of the die.

[0240] 2. Viscous flow in the matrix is negligible as it is long drawn by the fibers.

[0241] 3. The system operates in a steady state and there are no changes in the heating rate.

[0242] 4. Constant material properties.

[0243] xi. Design The material enters the consolidator at the preheater outlet temperature and exits at the maximum material temperature as defined in the overview section. The total mass flow rate of the composite through the system can be calculated as a function of the draw rate, the cross-sectional area of the composite reinforcement, and the composite density. This is also defined in the overview section.

[0244] T preheat to T max The total energy required to heat the composite from T

[0245] To accommodate potential inaccuracies in material properties, variations in mass flow rate, and fluctuations in other properties, the heater will be rated for a wide range of power up to the power required for the maximum draw rate.

[0246]

Number

[0247]

Number

[0248] The power determined in the previous equation determines the heater rating required to raise the material temperature after the die has reached its operating temperature. This does not take into account the energy required to heat the die to the temperature required in a timely manner at startup. The energy required to heat an aluminum alloy die material from room temperature to the operating temperature is determined by applying the equation for specific heat with no heat loss under ideal conditions. The die is heated from the ambient temperature to the operating temperature as defined in the overview section.

[0249] The approximate die mass was calculated using Solidworks mass evaluation for a 3” x 3” x 3’ aluminum die with a 0.5” diameter hole over its length.

[0250]

Number

[0251] Approximate heat capacity of aluminum alloy:

[0252]

Number

[0253] The total energy requirement to raise the die to the operating temperature can now be calculated. Additionally, an approximate time frame of 30 minutes can be applied as the reference startup time.

[0254]

Number

[0255]

Number

[0256] This gives an estimate for the power required to heat the die to the operating temperature. From this power, the final heater specifications can be determined.

[0257] To initiate cooling the material in the heated dissection towards 300 - 325°F, the dissection is covered by an exhaust heat system where cooling fans and shrouds direct the airflow over and away from the die system. Simulation of the draw process in the dissection may be sufficient to lower the temperature to the range of 325°F with natural convection alone, but if the die system exceeds the expected operating temperature, a cooling fan system is implemented. For specific information regarding power levels and temperatures in the heated dissection, refer to the "Simulation" section of this report below.

[0258] f. Exhaust Heat System: Solidified Die The exhaust heat system is equipped with six exhaust fans combined with fan shrouds that surround the die. This system advances the heated air away from the system, over, and through the exhaust fans.

[0259] This system is designed to have a response time of 30 minutes, like that of the reference startup time. The exhaust heat system uses a combination of forced and free convection, and thus the heat transfer rate was calculated for each case to determine the overall heat transfer coefficient of the system. The forced heat transfer rate is the product of the relationship between the Nusselt number for laminar flow, the thermal conductivity of the die, and the representative length of the die. These values are listed below.

[0260]

Table 5

[0261] Using the above values, the forced convection heat transfer rate was calculated.

[0262]

Equation

[0263] The free convection heat transfer coefficient was calculated using the following equation.

[0264] [Number]

[0265] This relationship was defined using the phase curves for free convection between various shapes and fluids. (From “The Basic Laws and Data of Heat Transmission III - Free Convection” by W. J. King.)

[0266] By using these heat transfer coefficients, the total heat transfer rate can be calculated.

[0267] [Number]

[0268] This results in a cooling time of 30.9 minutes.

[0269] [Number]

[0270] g. Cooling die section xii. Overview The role of the cooling die is to reduce the temperature of the heated composite material to the glass transition temperature with respect to the matrix. When the material reaches the glass transition temperature, the material can be withdrawn without the risk of deformation due to the non-uniform cooling rate from the cooled die. This glass transition temperature is listed in the overall material properties section.

[0271] As the composite cools, the matrix becomes stiffer and loses its ability to flow as a viscous plastic. In addition, the material itself shrinks as it cools as a function of the coefficient of thermal expansion for the matrix and fibers. Both of these factors reduce the efficiency of heat transfer from the material to the cooling die. Because of the difficulty in predicting the overall effect of these variations on heat transfer, the process is assumed to be ideal. Further information on this process is available in the heat simulation section of this report.

[0272] xiii. Assumptions 1. It is assumed that the material is always in contact with the inside of the die.

[0273] 2. Viscous flow in the matrix can be ignored because the matrix is pulled by the fibers.

[0274] 3. The system operates in a steady state and there are no changes in the cooling rate.

[0275] 4. Constant material properties.

[0276] 5. The resistance to heat transfer from the die to the cooling water can be ignored.

[0277] xiv. Design The mass flow rate through the cooling die is given by the die flow rate in the overview section for the expected maximum draw speed. The cooling die takes in the material at the die exit temperature and reduces the bulk temperature to the glass transition temperature, as defined in the overview section. Using these flow rates, the heat capacity of the composite, and the expected cooling difference in the die, the total rate of heat rejection can be calculated.

[0278]

Number

[0279]

Number

[0280] It is important to note the assumptions made in determining these power levels. As noted above, the assumption that the composite has sufficient contact with the die surface is most likely the least certain assumption. The assumption that viscous flow in the matrix can be ignored implies the implicit assumption that the heat generated by viscous losses can also be ignored.

[0281] h. Post-cooling section xv. Overview The role of the post-cooler is to further cool the composite rebar from the glass transition temperature to near room temperature. Due to the fact that the efficiency of cooling the material using the solid die surface deteriorates as the material cools (as explained in the cooled die section), the post-cooler operates by passing a direct flow of cooling water across the part as the part is withdrawn.

[0282] xvi. Assumptions 1. Constant wetting area.

[0283] 2. The system is operating in a steady state and there is no change in the cooling rate.

[0284] 3. Constant material properties.

[0285] 4. The bulk rebar temperature is reduced just above the temperature of the cooling water.

[0286] 5. The rebar skin temperature is the cooling water temperature everywhere.

[0287] 6. The cooling water temperature rise can be ignored.

[0288] xvii. Design The post cooler reduces the bulk temperature of the composite from the glass transition temperature to approximately the temperature of the cooling water. As with many problems in fluid mechanics, the solution process relies on a number of assumptions. The values calculated for heat transfer in this section are only estimates. The following equations can be used to calculate the power delivery required from the rebar to the cooling water for both the expected and maximum draw speeds.

[0289]

Number

[0290]

Number

[0291] The potential rate of heat rejection can be found by using this equation.

[0292]

Number

[0293] Here, A T is the total surface area of the rebar exposed to water, h is the calculated heat transfer coefficient,

Number

[0294] A T can be found using the surface area of a cylinder.

[0295]

Number

[0296] D is the diameter of the rebar, L is the length of the rebar in the post cooler, and is approximately 1 ft.

[0297] The calculated heat transfer coefficient was found using the following equation.

[0298]

Number

[0299]

Number

Table 6

[0300] From the above data, the required dimensionless groups can be calculated.

Number

[0301] For these conditions and the geometric conditions of a cylinder submerged in water with an axis of the cylinder perpendicular to the flow direction, a Nusselt number correlation can be constructed. Note that this correlation is based on experimental data for geometrically similar systems and provides an estimate for the Nusselt number.

Number

[0302] Considering this estimated Nusselt number, the overall heat transfer coefficient between the cooling water and the reinforcing bars can now be calculated.

Number

[0303] The remaining required information is the log mean temperature difference between the cooling water and the reinforcing bars. The calculation of this value is based on Assumptions 4 and 5 for this section, namely that the bulk reinforcing bar temperature is reduced to just above the temperature of the cooling water, and that the bar skin is at the cooling water temperature anywhere in the post-cooling section. It is assumed that the bulk reinforcing bar temperature falls within 1°F of the cooling water temperature.

Number

[0304] Finally, the estimated heat transfer rate for these conditions can be calculated.

Number

[0305] This calculated power value far exceeds even the maximum required rate of heat rejection in the post-cooling section. This indicates that the bulk temperature of the reinforcing bars can be reduced even closer to the temperature of the cooling water.

[0306] The validity of Assumption 6 can now be confirmed. This is achieved by applying the energy balance across the cooling water flow. The physical properties of water listed above are used in this determination. The mass flow rate of water is based on the assumed volumetric flow rate of 4 GPM in the post-cooling section.

Number

[0307] With a maximum temperature rise of just over 1 / 2°F, Assumption 6 would appear to be reasonable. Again, these calculations should not be considered as exact calculations of the expected operating conditions. Rather, they should be interpreted as providing confirmation that the proposed system will function as intended. The high heat transfer capacity of the rebar - liquid interface is illustrated by a calculated cooling capacity that far exceeds what is required. This should ensure that the system should be able to remove the heat necessary to adequately cool the rebar, even under non - ideal conditions.

[0308] i. Heat rejection system: Post - cooling system xviii. Overview To save cost and reduce system complexity, the cooled die and the post - cooling section share one cooling fluid system. This system serves to circulate cooling water for both sections and reject heat to the air.

[0309] The heat rejection system draws fluid from the reservoir and pumps it in parallel to the post - cooler and the cooled die. The flow passing through the post - cooler returns directly to the reservoir after flowing through the extraction. The flow passing through the cooled die channel first passes through the radiator before returning to the reservoir.

[0310] xix. Assumptions 1. The system operates in a steady state and there are no changes in the cooling rate.

[0311] 2. The heat transfer rate between the cooling water and the radiator far exceeds the heat transfer rate between the air and the radiator.

[0312] 3. Hydraulically smooth pipes.

[0313] xx. Flow design The cooling material pump can be described by the required flow rate and the head loss of the system. The pipes used are assumed to be hydraulically smooth and permit the use of the Blasius equation in calculating the friction factor for fluid flow. Two in-line valves are used to control the fluid flow to each branch, enabling the system to be defined by the required flow rate. Estimates regarding these flow rates, pipe parameters, and water properties are listed below.

[0314]

Table 7

[0315] To calculate the Reynolds number, the bulk fluid velocity must first be calculated for each section.

[0316]

Equation

[0317]

Equation

[0318]

Equation

[0319] Now that the fluid velocity is available, the Reynolds number for each section can be calculated.

[0320]

Equation

[0321]

Equation

[0322]

Equation

[0323] The corresponding friction coefficient can be determined for each section using Blasius' equation.

[0324]

Number

[0325]

Number

[0326]

Number

[0327] Finally, considering the flow rate and friction coefficient for each section, the overall pressure loss can be calculated and summed over the system.

[0328]

Number

[0329]

Number

[0330]

Number

[0331]

Number

[0332] This pressure loss can be converted to the head loss to assist in determining the pump specifications.

[0333] [Number]

[0334] xxi. Thermal Design The selected radiator must be capable of removing the combined heat of the cooling die and the post cooler. To accommodate the possibility that the cooling die may tolerate hotter materials, the power is rated based on reducing the material temperature from the system maximum temperature to the assumed temperature of the cooling water. This combined rated power can be calculated as follows.

[0335] [Number]

[0336] [Number]

[0337] The selected radiator must be able to accommodate these cooling requirements at a flow rate of 2 GPM. Currently, the radiators to be cooled (whose tubing characteristics are listed in the flow design section of this section) are rated to operate at these power levels.

[0338] j. Thermal Simulation Most of the thermal considerations in the curing and cooling die sections were operated using simulations of the system using COMSOL Multiphysics. It is important to note that the thermal simulations in this section do not include the waste heat system for the curing die. This is because the die system is designed such that the system operates without a waste heat system.

[0339] xxii. Materials The composite material was represented using the thermoplastic plug flow mode. This was achieved by allowing slippage at the mold boundaries and imparting a large shear strength to the material. This enables a uniform velocity profile in the die being simulated. The remaining material properties were given using the values calculated above.

[0340] To the composite flow region, a custom composite material was given. To the coolant fluid region, a comprehensive water material was given. To the die, an aluminum material was given, and to the ceramic spacer, a "brick-like" material was chosen for its high thermal resistance similar to that of the proposed ceramic spacer.

[0341] xxiii. Geometric shape Solidworks models of the die and the fluid regions were created and imported into COMSOL. This included three heated die sections and their corresponding ceramic spacers, a cooling die with its fluid channels, and a cooling die channel cover plate. Solid objects were created with respect to the composite region and the cooling fluid region to assist in defining the fluid regions in COMSOL. The heated die and the cooling die included their appropriate bolt holes, similar to the holes for the cartridge heaters in the heated die.

[0342] xxiv. Boundary conditions The boundary conditions were defined using parameters similar to those expected for the final machine.

[0343] xxv. Composite boundaries At the inlet of the system, two boundary conditions were given to the cross-section of the composite.

[0344] 1. Inlet velocity set at 5 ft / min

[0345] 2. Inlet temperature set at the expected outlet temperature of the preheater (350°F)

[0346] Along the length of the die, boundary conditions are set to allow for fluid slip, which is a feature that enables the expected plug flow.

[0347] At the outlet of the system, two boundary conditions were given for the cross-section of the composite.

[0348] 1. Outlet velocity, normal flow ignoring edge effects

[0349] 2. Outlet heat condition allowing heat flow outside the system

[0350] xxvi. Cooling water boundary The cooling water region utilized a set of boundary conditions similar to those for the composite material. At the inlet, two boundary conditions were given for the cross-section of the water flow.

[0351] 1. Inlet velocity set to the velocity required to allow a 2 GPM flow rate

[0352] 2. Inlet temperature set to an estimated 110°F.

[0353] Unlike the composite material, no-slip conditions were given for the walls of the cooling die for the water. This more accurately models the flow in the cooling channels.

[0354] At the outlet, two boundary conditions were given for the cross-section of the water.

[0355] 1. Outlet velocity, normal flow ignoring edge effects

[0356] 2. Outlet heat condition allowing heat flow outside the system

[0357] xxvii. Solid boundary conditions The following boundary conditions were applied to the solid objects of the die.

[0358] Heated die section:

[0359] 1. Thermal insulation on the bottom surface to represent the ceramic attachment solution

[0360] 2. Natural convection on the exposed side surface and to that side surface. This is to enable more delicate control over the composite temperature as it moves through the system.

[0361] 3. Heat flux through the surface of the cartridge heater attachment holes. The net power for each section was set independently. The power in each section is low to allow the material to begin to cool gently towards 325°F.

[0362] a. Section 1: Total 125W

[0363] b. Section 2: Total 40W

[0364] c. Section 3: Total 5W

[0365] Cooled die:

[0366] 1. Thermal insulation on the bottom surface to represent the ceramic mounting solution

[0367] 2. Natural convection on the exposed side surface and to that side surface. The cooled die is not thermally insulated as any heat lost to the surroundings in this section aids the cooling process.

[0368] xxviii. Meshing A user-defined mesh was implemented for this mode. Special attention was paid to the boundary mesh elements for the fluid regions, similar to those for the surfaces cooled by natural convection. 1,986,000 elements were used. The solution showed good convergence over different meshing conditions. An exemplary die meshing is presented in Figure 9.

[0369] xxix. Results Considering the above conditions, the simulation yielded promising data. The temperature distribution was approximately as expected. The composite entered at 350°F and remained as such for most of the first die section. Between the second and third die sections, the material began to cool due to natural convection at the outer die surface and dropped to approximately 340°F in the second die and approximately 325°F in the third die. The ceramic spacers between the four die sections were proven to be effective in protecting the temperature control in each zone.

[0370] Upon transfer to the cooling die, the material was rapidly cooled to the cooling water temperature and reached a core temperature of approximately 113°F before exiting the system. In fact, the effectiveness of this cooling section can decrease as the material cools and loses firm contact with the die wall. This may not pose a substantial problem as long as the material is further cooled to approximately the glass transition temperature before exiting into the post-cooling solution. If a higher rate of heat removal is required throughout the die system, a heat removal system for the solidification die is implemented.

[0371] There are numerous interesting features to note in the generated simulation data. The rapid cooling rate during the cooling die transfer can be reduced by moving the cooling channels further from the upstream die end. The heated die can also be maintained near the required temperature using minimal heat input as only the convective heat loss is countered. Exemplary die temperature profiles are presented in Figures 10 and 11.

[0372] k. Conveyor section If required, the purchase of a roller conveyor will be made from McMaster-Car. The potential role of the conveyor section is to enable the temperature within the rebar to be equal across its width before it enters the puller.

[0373] l. Puller section All of the tensile forces are generated by the puller and required to move the composite through the die from the creel into the cutting section. Typical industrial solutions for draw pullers fall into two main categories.

[0374] Dual reciprocating hydraulic pullers. These systems consist of two independent hydraulic grippers that use hydraulic rams to grip the part and pull it forward, moving in alternating directions so that one is always pulling the part.

[0375] Exemplary advantages of using a hydraulic puller

[0376] 1. Fewer moving parts compared to other solutions

[0377] 2. High tensile forces resulting from the use of a hydraulic system.

[0378] Disadvantages of using a hydraulic puller

[0379] 1. Higher technical requirements both for the required hydraulic power and the control to operate the system

[0380] 2. Larger space requirements for the hydraulic cylinders and controls

[0381] Opposing track pullers. These systems consist of two opposing tracks attached to suitable gripping materials. One track is allowed to move vertically and the track grips the part and pulls it through the die as the track rotates. Exemplary track pullers are shown in FIGS. 13, 14A - 14E.

[0382] Advantages of using an opposing track puller

[0383] 1. Can operate using an electric motor and aerodynamics, simplifying the control and power delivery methods.

[0384] 2. As the spatial requirements are reduced as the length is largely determined by the designed grip length.

[0385] Disadvantages of using opposing track pullers

[0386] 1. A larger number of moving parts compared to a reciprocating puller.

[0387] 2. Difficulty of operating in a small system as the required motor size quickly increases due to increasing torque requirements.

[0388] To keep the cost as low as possible and limit the required control considerations, an opposing track system was chosen for this machine. The approximate design consists of two tracks, each of which is independently driven by an electric gear motor. For simplicity, the system can accommodate two motors, but only one is attached to the star. If it is found that additional driving force is required, a second motor and gearbox are attached.

[0389] One track is mounted on a linear rail, allowing it to be raised and lowered by a set of pneumatic cylinders. The track is made from each of two parallel series of roller chains and connected by a steel bar to which the gripping material is fixed. A VFD (Variable Frequency Drive) unit enables the motor to be driven at the desired withdrawal speed.

[0390] The following Figures 13 and 14A - 14E show the current design regarding the puller section. Figure 14A presents an overview of all sections including a pneumatic cylinder that serves to compress the carriage, an outer tubular frame, and a geared drive motor. Figure 14B provides a side view of the machine, showing more clearly the form of the linear shaft on which the upper carriage moves and the carriage frame. Figure 14C gives a front view, showing how the two tracks contact. Figures 14D and 14E show the carriage and their internal structure.

[0391] There are two parameters that are very important for the design of the puller section, namely the required pulling speed and the required pulling force. The drive speed is defined by the overall system parameters and comes with a maximum speed of 10 ft / min. The required pulling force is calculated from the sum of the contributions from the creel, the heated die and the cooled die, and the cutting section.

[0392]

Number

[0393]

Number

[0394]

Number

[0395] The ordered current motor and drive sprocket combination for use in the puller has the following characteristics.

[0396] Rated speed:

Number

[0397] Constant torque:

Number

[0398] Sprocket pitch diameter:

Number

[0399] It is difficult to know what the coefficient of friction is between the pulley grip and the pulled-out part, and there is little data to explain the coefficient of friction regarding the matrix. However, it can be safely assumed that the coefficient of friction is 0.25 or more.

[0400] Coefficient of static friction:

Number

[0401] The approximate driving speed can be calculated from the rated motor speed and the sprocket pitch diameter.

[0402]

Number

[0403] The approximate boundaries for VFD speed control range from 20% to 125% of the rated motor speed. This range results in a corresponding range of possible driving speeds.

[0404]

Number

[0405]

Number

[0406] Similarly, the driving force obtained from one motor can be calculated from the continuous torque and the sprocket pitch diameter.

[0407]

Number

[0408] Compared to the approximately required tensile force, this system will provide a design margin of nearly 2.2. This has obvious benefits and may allow for a higher tensile force, subjecting the motor to a smaller load. This reduces wear and heat within the motor and gearbox.

[0409] The required compressive force between the tracks can be calculated from the estimated coefficient of friction and the required driving force.

[0410]

Number

[0411] The choice to use independent drive units is accompanied by important considerations. If the two drives are allowed to rotate at slightly different speeds, the resulting difference in track speed can cause damage to the parts being pulled out or to the pulley section itself. There are only a handful of solutions to this problem.

[0412] First, the problem can be completely avoided by instead specifying a motor and gearbox that can provide the required torque and rotational speed using one unit instead of two. The drawback of this solution is that the corresponding components of the pulley must be designed to handle this higher load in one carriage instead of two. This includes the roller chain, drive and idler shafts, and torque arm assembly. In addition, the cost of the gearbox increases rapidly and non-linearly with the increased torque requirements. Implementing a single gearbox system can be more expensive than a dual gearbox solution.

[0413] The tracks can be made to rotate at the same speed by one of a few different possible methods. First, by using encoder feedback, the motor speeds can be tightly adjusted to each other's tracks. This will result in small speed mismatches that may not be significant enough to affect mechanical performance. Second, depending on the selection of the VFD unit, the motors can be set to operate in a torque-limited manner. This will prevent one motor from exerting more force than the other during extraction. Finally, a single large VFD can be selected to drive both motors and provide the same drive signal to each motor.

[0414] It is also worth noting that the selection of the grip material can affect the significance of the speed differences on the system. Softer and thicker pads can help to compensate for small speed differences.

[0415] m. Cutting section At the expected operating speed of 5 ft / min, the rebar produced needs to be cut regularly as it is produced, and new sections are cut approximately once per minute. This level of cutting activity is not the role of the operator, especially considering the dust, gas, and fibers generated by cutting the composite material. Instead, the material is cut by an automated system that forms the cutting section.

[0416] As the extracted part leaves the puller, it moves directly into the cutting section. At this time, the machine already in the ASCC is expected to handle this task. The initial deployment of this extraction line may be lacking this cutting machine, which is added later after the space requirements and machine performance are better known.

[0417] The correct parameters regarding the required force and cutting speed are currently unknown. The system can follow best practices for cutting the composite material in terms of cutting speed, blade, and force.

[0418] n. Frame section The frame is a support structure that holds the preheater, the solidification die, and the cooling die. It is designed to support the puller structure and transfer any forces from the puller into the compression section of the structure.

[0419] Given the uncertainties in the final design, the frame design is based on the following requirements.

[0420] Requirements:

[0421] The resistance transmitted from the puller as the reaction force of friction forms the maximum case that balances the resultant force of the puller.

[0422] The frame resists the maximum force from the puller as a moment and as compression. The moment is caused by the offset between the extraction line of the center point of the die and the highest point along the surface of the frame in contact with the puller system. The compression force is caused by the tensile force and is parallel to i. This force is resisted by the contact between the frame surface and the surface of the puller system.

[0423] The frame design resists that moment by an opposing moment and forms the weight of the system. The compression force is resisted by the material properties of the structural material and the contact area through which the force is transmitted.

[0424] The frame design also requires panels and doors for easy access and storage throughout the machine.

[0425] o. Control section A robust control system is required due to a significant number of conditions that must be monitored during the operation of this machine and the corresponding operating parameters to be adjusted. This system must be able to measure all the required operating conditions and, based on that information, make corresponding adjustments to the relevant systems. These operations must occur quickly and be open to operator control. In addition, the system should be able to respond very rapidly to conditions that require a process stop, such as overheating, material depletion, emergency stop, or other conditions that can pose a threat to the machine, extraction, or operator.

[0426] The current control system concept has three different physical layers.

[0427] 1. Main Controller: The master device on the network. It could be a Raspberry Pi or a similar microcomputer solution.

[0428] 2. Sub - controller Network: A network of slave controller devices. It is connected to the main controller via a standard communication protocol (which could be UART, I2C, or a similar serial bus). These devices could be Arduino microcontrollers.

[0429] 3. Sensors and Outputs: All sensors and digital outputs from the system are connected to the sub - controllers.

[0430] A full - spreadsheet detailing the location, function, and type of sensors expected to be used is available on the network in the control folder of many current system designs. The general gist of the sensor and network layout is detailed below.

[0431] xxx. Sensors by Area As it currently stands, there are a total of seven different sections of machinery. The associated sensors for each section are as follows.

[0432] 1. Creel a. Material break detection operated by an optical break beam sensor

[0433] 2. Preheater a. Material outlet temperature measured by an infrared temperature sensor directed at the tape bundle at the end of the preheater section.

[0434] b. Effluent material temperature. To prevent excess material removed from building up inside the machine, the outlet surface must be heated. A thermocouple measures the temperature of the effluent surface.

[0435] 3. Heated die / consolidator a. Section temperature. Thermocouples probably measure the temperature of the three die sections, perhaps at the inlet and outlet of each section.

[0436] b. Consolidator temperature measured by a thermocouple.

[0437] 4. Cooled die a. Die temperature probably measured by a thermocouple at the die inlet and outlet.

[0438] b. Coolant temperature measured by a thermocouple.

[0439] 5. Post cooler a. Coolant temperature measured by a thermocouple.

[0440] 6. Puller a. Track speed measured by an encoder for some purpose. This measures the speed of each puller track to provide feedback for closed-loop speed control.

[0441] a. The material speed measured by an encoder wheel in contact with the material. This confirms that the material is being pulled out at the same speed as the track and warns the system if the material is slipping in the puller.

[0442] b. The vertical position of the track determined by a slide potentiometer fixed between the tracks.

[0443] 7. Cutting section a. The cutting completion state determined by a contact switch triggered by a saw arm after the composite has been cut through.

[0444] b. The retraction state determined by a second contact switch triggered when the saw arm returns to its vertical position.

[0445] c. The carriage return state determined by a third contact switch triggered when the saw carriage returns to its original position to start the next cut.

[0446] xxxi. Possible additional considerations Due to the lack of data on the operating parameters of the thermoplastic drawing, it may be beneficial to obtain as much data as possible on the system and process to assist future design and production. In this regard, there are a number of sensors that can be placed in the system to record more useful data.

[0447] 1. Die pressure. This can be measured in a number of ways. The most promising method may utilize a split die in service. A short die section will be introduced into the process at several points in the heated die. This section is on the order of 2” - 4” and is closed by two bolts. These bolts are fitted with bolt load cells to measure the compression load. During operation, the load cell then measures the reduction in compression load that correlates to the pressure within the die.

[0448] 2. Pulling force. Knowing the pulling speed, die pressure, and pulling force enables a much more general characteristic evaluation of the drawing process. This can be measured by introducing a load cell into the load-bearing connection between the puller and the die frame.

[0449] Reference www.sd3d.com / wp-content / uploads / 2017 / 06 / MaterialTDS-PETG_01.pdf - Thermal conductivity of PETg and Heat Capacity of PETg

[0450] www.matweb.com / search / datasheet_print.aspx?matguid=4de1c85bb946406a86c52b688e3810d0 - Density of PETg

[0451] www.matweb.com / search / DataSheet.aspx?MatGUID=d9c18047c49147a2a7c0b0bb1743e812 - Density of E-glass

[0452] www.sd3d.com / wp-content / uploads / 2017 / 06 / MaterialTDS-PETG_01.pdf - Heat Capacity of PETg

[0453] www.azom.com / properties.aspx?ArticleID=764 - Thermal Conductivity of E-glass and PETg

[0454] J. Sucec, Heat Transfer. Mumbai: Jaico Publishing House, 2005.

[0455] Equivalents One of ordinary skill in the art can recognize, or can identify, many equivalents to the specific embodiments of the invention described herein using only routine experimentation. The scope of the invention is not intended to be limited to the above description, but rather is intended to be as set forth in the following claims.

Claims

Claim 1 A method for manufacturing a thermoplastic product (e.g., a continuous fiber thermoplastic composite part) from a feed material, the method comprising: i) providing the feed material; ii) heating the feed material to a first temperature to produce a heated feed material, the first temperature being above the glass transition temperature of at least one component of the feed material; iii) shaping a solidified material from the heated feed material; iv) cooling the solidified material to a second temperature and including. Claim 2 Providing the feed material comprises: i) pulling each of the feed material, the heated feed material, and the solidified material through each of steps i), ii), iii), and iv) and / or ii) controlling the tension on the feed material (e.g., by applying tension to the feed material by a tension applying unit) The method according to claim 1, including. Claim 3 The feed material is a continuous fiber thermoplastic composite material, and the continuous fiber thermoplastic composite material comprises: i) a fiber component; ii) a thermoplastic component; iii) a functional component; or iv) any combination thereof Including, The fiber component and the thermoplastic component are mixed. The method according to any one of the preceding claims. Claim 4 The fiber component includes fibers, and the fibers are selected from the group consisting of: i) glass fibers (e.g., E glass), ii) carbon fibers, iii) aramid fibers, iv) basalt fibers, v) organic fibers (e.g., hemp fibers, wood fibers), and vi) any combination thereof. The method according to claim 3. Claim 5 The thermoplastic component includes a thermoplastic polymer, and the thermoplastic polymer is selected from the group consisting of polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETg), polycarbonate, polyethylene (e.g., high-density polyethylene (HDPE), e.g., low-density polyethylene (LDPE)), polypropylene, polyether ether ketone, polyaryl ether ketone (e.g., low melting point polyaryl ether ketone), polyamide (e.g., nylon 6, nylon 66, nylon 612, nylon 4, 6 nylon 12, etc.), acrylonitrile butadiene styrene, polylactic acid, polyvinyl chloride, or any combination thereof, according to the method of claim 3 or claim 4.

6. Further including finishing the thermoplastic product, and finishing includes: i) finishing the surface (e.g., deforming the surface of the thermoplastic product), ii) winding the filament, iii) winding the tape, iv) bending, v) curving, vi) cutting, or vii) any combination thereof, according to the method of any one of the preceding claims.

7. The method does not include saturating the fiber component with the thermoplastic component, according to the method of any one of the preceding claims.

8. The thermoplastic product is selected from the group consisting of reinforcing bars (e.g., steel bars), plates (e.g., flat plates), I-beams, Pi preforms, structural angles, structural channels (e.g., C-channels), hollow structural cross-sections, and pipes, according to the method of any one of the preceding claims.

9. Heating the feed material includes exposing the feed material to at least one heat source, according to the method of any one of the preceding claims.

10. The heat source is selected from the group consisting of: a) radiant heater, b) convection heater, c) induction heater, d) resistance heater, or e) any combination thereof, according to the method of claim 9.

11. Forming the solidified material from the heated feed material includes i) collecting at least a portion of the heated feed material at the first temperature; and ii) optionally heating the heated feed material to a third temperature; and iii) optionally cooling the heated feed material to a fourth temperature; iv) applying pressure to the heated feed material (e.g., by applying a solidification pressure) The method according to any one of the preceding claims, comprising. **Claim 12** The method according to claim 11, wherein applying pressure to the heated feed material is carried out substantially simultaneously with at least one of i), ii), and / or iii). **Claim 13** The method according to claim 11 or claim 12, wherein the third temperature is intermediate between the first temperature and the second temperature. **Claim 14** After forming the solidified material from the heated feed material, the solidified material has a cross-section different from the cross-section of the heated feed material (e.g., cross-sectional dimensions, e.g., cross-sectional shape). The method according to any one of claims 11 to 13. **Claim 15** Cooling the solidified material comprises i) first, cooling the solidified material to a temperature below (a) the glass transition temperature of the feed material or (b) the melting transition temperature of the feed material and / or ii) then, cooling the solidified material to ambient temperature (e.g., room temperature). The method according to any one of the preceding claims, comprising. **Claim 16** A continuous molding machine for manufacturing a thermoplastic product from a feed material, the continuous molding machine comprising: i) a loading unit, ii) a tension applying unit, iii) a heating unit, iv) a molding unit, v) a cooling unit, and vi) a pulling unit, and the continuous molding machine being capable of using a feed material containing a thermoplastic material. **Claim 17** The continuous molding machine according to claim 16, not comprising (i) a saturation unit and / or (ii) a vacuum unit. **Claim 18** The continuous molding machine according to claim 17, wherein the saturation unit is selected from the group consisting of a resin bath saturation unit, a resin injection saturation unit, and a combination of both. **Claim 19** The feed material is a continuous fiber thermoplastic composite material, the continuous fiber thermoplastic composite material comprising i) a fiber component, ii) a thermoplastic component, iii) a functional component, or iv) any combination thereof, and the fiber component and the thermoplastic component being mixed. The continuous molding machine according to any one of claims 16 to 18. **Claim 20** The fiber component includes fibers selected from the group consisting of i) glass fibers (e.g., E-glass), ii) carbon fibers, iii) aramid fibers, iv) basalt fibers, v) organic fibers (e.g., hemp fibers, wood fibers), and vi) any combination thereof, the continuous forming machine according to claim 19.

21. The thermoplastic component includes a thermoplastic polymer, and the thermoplastic polymer is selected from the group consisting of polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETg), polycarbonate, polyethylene (e.g., high-density polyethylene (HDPE), e.g., low-density polyethylene (LDPE)), polypropylene, polyether ether ketone, polyaryl ether ketone (e.g., low melting point polyaryl ether ketone), polyamide (e.g., nylon 6, nylon 6 6, nylon 6 12, nylon 4, 6 nylon 12, etc.), acrylonitrile butadiene styrene, polylactic acid, polyvinyl chloride, or any combination thereof, the continuous forming machine according to claim 19 or claim 20.

22. The loading unit stores at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50 storage modules (e.g., spools, e.g., bobbins, e.g., reels, e.g., coils) of the feed material, the continuous forming machine according to any one of claims 16 to 21.

23. The heating unit includes at least one heat source, the continuous forming machine according to any one of claims 16 to 22.

24. The at least one heat source is selected from the group consisting of a radiation heater, a convection heater, an induction heater, a resistance heater, or any combination thereof, the continuous forming machine according to claim 23.

25. The forming unit includes a collection unit and at least one solidification die, the continuous forming machine according to any one of claims 16 to 24.

26. The pulling unit is selected from the group consisting of a reciprocating pulling unit and a traction pulling unit, the continuous forming machine according to any one of claims 16 to 25.

27. The continuous forming machine according to claim 26, wherein the pulling unit pulls the feed material at a speed within the range of from about 0.1 ft / min to about 200 ft / min, at a speed within the range of from about 0.1 ft / min to about 15 ft / min, or at a speed within the range of from about 1 ft / min to about 10 ft / min.

28. The continuous forming machine according to any one of claims 16 to 27, further comprising: i) a thermoplastic injection unit; ii) a roll forming unit; iii) a surface finishing unit; iv) a tape / filament winding unit; v) a bending / curving unit; vi) a conveying unit; vii) a cutting unit; and viii) any combination thereof.

29. The continuous forming machine according to any one of claims 16 to 28, wherein the thermoplastic product is selected from the group consisting of reinforcing bars (e.g., steel bars), plates (e.g., flat plates), I-beams, Pi preforms, structural angles, structural channels (e.g., C-channels), hollow structural cross-sections, and pipes.

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