A process and a system for producing a thermoplastic prepreg material

Abstract

Disclosed herein is a process and a system for producing a thermoplastic prepreg material, the thermoplastic prepreg material being a fibre-reinforced polymer composite material comprising a polymer matrix and a natural fibre material, the thermoplastic prepreg material is produced from a high viscosity thermoplastic biobased resin and a natural fibre material.

Description

[0001] A process and a system for producing a thermoplastic prepreg material

[0002] Technical Field

[0003] The invention relates to a process and a system for producing a thermoplastic prepreg material, the thermoplastic prepreg material being a fibre-reinforced polymer composite material comprising a polymer matrix and a natural fibre material, the thermoplastic prepreg material is produced from a high viscosity thermoplastic biobased resin and a natural fibre material.

[0004] Background art

[0005] Biodegradable plastics are plastics that can be decomposed by the action of living organisms, usually microbes, into water, carbon dioxide, and biomass. Biodegradable plastics are commonly produced with renewable raw materials, microorganisms, petrochemicals, or combinations of all three. While the words "bioplastic" and "biodegradable plastic" are similar, they are not synonymous. Not all bioplastics (plastics derived partly or entirely from biomass) are biodegradable, and some biodegradable plastics are fully petroleum based. As more companies are keen to be seen as having "Green" credentials, solutions such as using bioplastics are being investigated and implemented more.

[0006] However, many sceptics believe that bioplastics will not solve problems others expect. Many believe that biodegradable plastics (including compostable) cannot and must never be seen as a 100% replacement to traditional plastics, and reduction must come first. The reusable option must always be considered first, if suitable to the specific operational conditions.

[0007] Biodegradable plastics can therefore at present, e.g., be considered for the use in making compostable bags to optimise separate collection of organics, compostable tableware if and when reusable is not an option, disaster relief operations, coffee capsules and tea bags, absorbent hygiene products, etc. However, biodegradable plastics are at present not recommended for producing or replacing products, which are exposed to the climate.

[0008] Hence, in the above view of finding sustainable materials and environmental protection, there is a general need for materials that are based on renewable resources such as plant material and materials that can be discarded in an environmentally friendly manner.

[0009] Furthermore, through the last decades, the use of composite materials has grown significantly due to their high strength to weight ratio. Composite materials consist of at least two macroscopically different phases, commonly a fibrous material (a fibrous reinforcement) embedded in an organic polymer matrix. The fibrous reinforcement is commonly glass, carbon or aramid, but recently bio-based fibres such as hemp have become commercially available. The polymer matrix is in most cases epoxy, polyester, vinyl ester or polyurethane, which are all based on crude oil and non-biodegradable and in most cases non-recyclable.

[0010] Due to the commercial availability of bio-based fibres, composite materials with a sustainable reinforcement can be obtained whereas most available matrix materials are unsustainable. In addition to being non-biodegradable and only partly sustainable, composite materials made from a biological fibre and an oil-based polymer matrix has the drawback of a poor compatibility between the reinforcement and matrix due to differences in polarity and chemical groups between the fibres and the matrix. The poor compatibility has a negative impact on the mechanical properties of the composite material.

[0011] Composite materials have developed greatly since they were first introduced. However, before composite materials can be used as an alternative to conventional materials as part of a sustainable environment a number of needs remain. Among others are the need for availability of standardized durability characterization data for fibre-reinforced polymer composite materials, integration of durability data and methods for service life prediction of structural members utilizing fibre-reinforced polymer composites, development of methods and techniques for materials selection based on life cycle assessments of structural components and systems, and structurally and economically feasible.

[0012] Due to the above-mentioned high strength to weight ratio of fibre composite materials, it has become increasingly more popular to produce different kinds of items or constructions from such materials.

[0013] Such constructions made from fibre-reinforced composite materials are often manufactured by means of either resin transfer moulding (RTM) or vacuum assisted resin transfer moulding (VARTM) processes. Both processes involve two basic steps: first fabrication of a fibre preform inside a mould with the shape of the finished composite material, where the preform is comprised by a plurality of fibres in most cases present as fabric layers and second impregnation of the preform with a resin. During the process, full impregnation of the fibres is essential for the performance of the final composite material.

[0014] In RTM processes, the matrix resin is injected into the mould under pressure. In the VARTM process, the resin is drawn into the mould by applying a pressure inside the mould that is lower than the pressure outside the mould. If a thermoplastic resin is used, the resin is injected or drawn into the mould at a temperature above its melting point and upon impregnation of the preform, a temperature reduction will cause the resin to solidify and constitute the matrix of the composite material. For thermosetting resins, the resin is injected or drawn into the mould at a temperature where it is in a liquid state and upon impregnation of the preform, the resin is allowed to cure through polymerisation upon which the final composite material is obtained.

[0015] However, a problem with both these processes is that, in general, they are rather timeconsuming. Furthermore, components produced by these processes often need further processing such as milling or cutting to reach the desired shape.

[0016] Outer components made of biodegradable fibre and resins are so far only in use for motorsports, with no demand for lifetime durability. The parts are typically made using thermoset processing, which requires high pressure, vacuum and very long curing times. This is a blocking point for large-scale industrialization in terms of very high cost of the components. Further, thermoset components cannot be re-melted and reused like thermoplastic parts can.

[0017] One of the bottlenecks in the production of components made of biodegradable fibre and resins is the initial production of the prepreg material, if such is even produced in its own. Conventional thermoplastic composite sheets may e.g. be produced in a two-step process. In the first step, a fibre substrate, such as fabric or mat, is produced. Fibers in the fabric or mat are either mechanically or chemically bonded. In the second step, a thermoplastic resin is applied to the fibre substrate, followed by resin impregnation, where it is the step of impregnating with the resin that can cause a lot of problems, especially if dealing with a high viscosity thermoplastic resin, which many biobased resins are.

[0018] It is therefore an object of the present invention to provide a faster and more efficient method for producing thermoplastic prepreg materials than the ones known in the art.

[0019] Summary

[0020] The description herein of any aspect or embodiment of the invention using terms such as “comprising”, “having,” “including,” or “containing” with reference to an element or elements is intended to provide support for a similar aspect or embodiment of the invention that “consists of’, “consists essentially of’, or “substantially comprises” that particular element or elements, unless otherwise stated or clearly contradicted by context, e.g. a composition described herein as comprising a particular element should be understood as also describing a composition consisting of that element, unless otherwise stated or clearly contradicted by context. It will be further understood that the terms “comprises," "comprising," "includes" and / or "including," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0021] Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by those skilled in the art to which this invention pertains. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined in the present specification.

[0022] As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms, including “at least one,” unless the content clearly indicates otherwise. “At least one” is not to be construed as limiting “a” or “an.”

[0023] The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0024] The present invention solves the above problems via the herein disclosed aspects. Thus, disclosed herein in a first aspect is a process for producing a thermoplastic prepreg material, the thermoplastic prepreg material being a fibre-reinforced polymer composite material comprising a polymer matrix and a natural fibre material, the thermoplastic prepreg material is produced from a high viscosity thermoplastic biobased resin and a natural fibre material, the process comprising the steps of: providing the natural fibre material; drying the natural fibre material in an oven unit at a first predetermined temperature, hereby obtaining a dried natural fibre material; heating the dried natural fibre material in a heating system to a second predetermined temperature, hereby obtaining a heated natural fibre material; maintaining the heated natural fibre material at the second predetermined temperature while providing a first layer of the high viscosity thermoplastic biobased resin to a first side of the heated natural fibre material, the first layer of high viscosity thermoplastic biobased resin being provided using a first extruder apparatus, hereby obtaining a heated natural fibre material having a first resin layer; maintaining the heated natural fibre material having a first resin layer at the second predetermined temperature while impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated natural fibre material having a first resin layer using one or more first rollers, hereby obtaining a heated intermediate prepreg material; maintaining the heated intermediate prepreg material at the second predetermined temperature while providing a second layer of high viscosity thermoplastic biobased resin to a second side of the heated intermediate prepreg material, the second layer of high viscosity thermoplastic biobased resin being provided using a second extruder apparatus, hereby obtaining a heated intermediate prepreg material having a second resin layer; maintaining the heated intermediate prepreg material having a second resin layer at the second predetermined temperature while impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated intermediate prepreg material having a second resin layer using one or more second rollers, hereby obtaining a heated prepreg material; and cooling the heated prepreg material to a third predetermined temperature during a cooling down process, hereby obtaining the thermoplastic prepreg material.

[0025] The present invention thereby solves the problem of providing a process for making a thermoplastic prepreg material. One of the advantages of the present disclosure is the complete impregnation of resins into the fibre material, which avoid any air being trapped inside the resin matrix, once the thermoplastic resins stiffens / cures.

[0026] As disclosed herein a prepreg material (short for "pre-impregnated material") is a composite material in which reinforcing fibres have been pre-impregnated with a resin matrix before it can be processed into the final composite structure (in another process than what is disclosed herein). The resin herein is a biobased resin, which is thermoplastic and the fibre material is a natural fibre material.

[0027] The process as disclosed herein ensures a uniform resin distributions and fibre impregnation, resulting in consistent mechanical properties and performance characteristics throughout the composite structure when being made.

[0028] As disclosed herein the thermoplastic biobased resin has a high viscosity, where the term high viscosity relates to the flowability of the thermoplastic resin, or in other words, the viscosity refers to the resin’s resistance to flow. High viscosity indicates that the resin is thick and resistant to flowing easily, while low viscosity means the resin flow more readily. In other words, high viscosity thermoplastic resins are more resistant to deformation or movement under an applied force compared to low viscosity thermoplastic resins. The viscosity can also be defined by the units Pacal-seconds (Pa*S) or centipoise (cP).

[0029] As disclosed herein the thermoplastic resin is a type of polymer that becomes pliable or mouldable when heated and solidifies upon cooling. This process can be repeated multiple times without significantly altering the material’s properties. A thermoset resin is a type of polymer that undergoes a chemical reaction during its initial processing and curing to form a three-dimensional network structure. Once this curing process is complete, the material hardens into a permanent and relatively infusible state. Unlike thermoplastics, thermosets cannot be melted and reprocessed once they have undergone the curing process.

[0030] The use of a thermoplastic resin makes the prepreg material formable and mouldable when heated and solidifies upon cooling, such that the prepreg material can be preheated, e.g., in an infrared oven, and then transferred to a forming tool, which may be heated as well, and the prepreg material can then be formed into the required or wanted shape. As disclosed herein the resin used is further a biobased resin. A biobased resin is a type of resin derived from renewable biological sources, such as plants, animals, or microorganisms. These resins are considered environmentally friendly alternatives to traditional petroleum-based resins because they are produced from renewable resources and typically have a lower carbon footprint. There are several types of biobased resins, each derived from different biological sources and manufacturing processes. Among these is worth mentioning plant-based resins, which are resins derived from various plant sources, including sugarcane, corn, soybeans, and wood pulp. For example, bio-based polyethylene (bio-PE) and bio-based polyethylene terephthalate (bio-PET) are produced from sugarcane ethanol. Further, animal-based resins also exist, which are resins derived from animal products, such as shellac, which is obtained from the secretions of the lac beetle. Other bio-based resins could be microbial resins, which are certain resins produced through microbial fermentation processes. For example, polylactic acid (PLA) is a biodegradable resin derived from fermented plant sugars. Algae-based resins and other biobased resins also exist.

[0031] The use of biobased resins offers several environmental benefits over petroleum-based resins, including but not limiting to reduced reliance on fossil fuels, lower greenhouse gas emissions, potential for biodegradability or compostability, and contribution to rural economies through agricultural and biomass production.

[0032] As disclosed herein a natural fibre material is used. Natural fibres are fibres derived from plants, animals, or minerals that occur in nature. Some common types of natural fibres include: Plant-based fibres: Derived from plants, these fibres are obtained from the stems, leaves, seeds, or fruits of various plant species. Examples include: o Cotton: Obtained from the seed hairs of the cotton plant, cotton is one of the most widely used natural fibres and is valued for its softness, breathability, and absorbency. o Flax: Also known as linen, flax fibres are obtained from the stem of the flax plant. Linen fibres are strong, durable, and known for their natural lustre. o Hemp: Hemp fibres are extracted from the stems of the hemp plant. They are strong, resilient, and increasingly used in textiles, composites, and construction materials. o Jute: Jute fibres are derived from the stem of the jute plant and are commonly used in the production of burlap, ropes, and carpets due to their strength and affordability. o Bamboo: Bamboo fibres are extracted from the pulp of bamboo plants. They are known for their softness, breathability, and antibacterial properties.

[0033] Animal-based fibres: These fibres are obtained from animals and include: o Wool: Wool is obtained from the fleece of sheep and other animals such as goats (cashmere, mohair), alpacas, and llamas. Wool fibres are known for their warmth, elasticity, and moisture-wicking properties. o Silk: Silk is produced by silkworms and is harvested from their cocoons. It is valued for its luxurious feel, smooth texture, and natural sheen.

[0034] Mineral fibres: These fibres are naturally occurring inorganic materials and include: o Asbestos: Although once widely used for its heat resistance and insulating properties, asbestos is now recognized as a health hazard and is strictly regulated or banned in many countries due to its carcinogenic effects.

[0035] Natural fibres are favoured for their sustainability and environmentally friendly properties, although they may have limitations compared to synthetic fibres in terms of uniformity, consistency, and processing requirements.

[0036] The process as disclosed herein start with providing the natural fibre material and then drying the natural fibre material in an oven unit at a first predetermined temperature, hereby obtaining a dried natural fibre material. The drying step is performed to ensure that the fibre material is dry prior to being impregnated with the resin.

[0037] Then the dried natural fibre material is heated to a second predetermined temperature, hereby obtaining a heated natural fibre material. The hearing is performed to ensure that the fibre material has the right temperature before impregnation with a resin, such that the resin is not being cured or stiffens when applied to the fibre material.

[0038] After heating, the temperature is maintained while providing a first layer of the high viscosity thermoplastic biobased resin to a first side of the heated natural fibre material, the first layer of high viscosity thermoplastic biobased resin being provided using a first extruder apparatus, hereby obtaining a heated natural fibre material having a first resin layer. Due to the high viscosity nature of the resins, the extruder is needed to apply a uniform layer onto the fibre material.

[0039] The material is then maintained at the second predetermined temperature while impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated natural fibre material having a first resin layer using one or more first rollers, hereby obtaining a heated intermediate prepreg material. It is in this step important that the fibre material has the right temperature to fulfil the impregnation. Further, the resin will in this step be massaged into the fibre material by passing it through a number of rollers, which will also apply a certain pressure. This means that after impregnation the fibre material and resin will go through several rolls to get the impregnation into the fibre material, and to get the right material thickness. Afterwards the intermediate prepreg material is then maintained at the second predetermined temperature while providing a second layer of high viscosity thermoplastic biobased resin to a second side of the heated intermediate prepreg material, the second layer of high viscosity thermoplastic biobased resin being provided using a second extruder apparatus, hereby obtaining a heated intermediate prepreg material having a second resin layer. The second layer of resin will be added to the top side or bottom side of the fibre material, depending on which side the first layer was added to. If the first layer was added to the bottom side of the fibre material, the second layer will be added to the top side, and vice versa. The fibre material at this point still needs to have the right temperature to fulfil the impregnation through the rolls and such that the material can obtain the right thickness needed.

[0040] Further, the heated intermediate prepreg material now having the second resin layer is maintained at the second predetermined temperature while impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated intermediate prepreg material having a second resin layer using one or more second rollers, hereby obtaining a heated prepreg material. It is in this step important that the fibre material has the right temperature to fulfil the impregnation. Further, the resin will in this step be massaged into the fibre material by passing it through a number of rollers, which will also apply a certain pressure. This means that after impregnation the fibre material and resin will go through several rolls to get the impregnation into the fibre material, and to get the right material thickness.

[0041] Lastly, the prepreg material is cooled to a third predetermined temperature during a cooling down process, hereby obtaining the thermoplastic prepreg material.

[0042] During the entire process it is essential that the thermoplastic resin to be added are added at the right temperature, hereby having the right viscosity. In general, the resins as disclosed herein has lower viscosities than for example epoxy resins known to the skilled person, and the temperature may therefore potentially be used to obtain a hight flow viscosity.

[0043] Some of the advantages of the above disclosed process is that a much better impregnation is obtained, without e.g. any air bubbles trapped in the cured polymer, such that a much stronger thermoplastic prepreg material is obtained. Other advantages could be that using the extrusion impregnation method as disclosed herein, the cost for the manufacturing of the film or powder before impregnation may be omitted, and hereby a less expensive process is obtained.

[0044] Disclosed herein in a second aspect is a system for producing a thermoplastic prepreg material from a natural fibre material and a high viscosity thermoplastic biobased resin, the system comprising: a feeding unit; an oven unit; a heating unit; a first extruder apparatus; one or more first rollers; a second extruder apparatus; and one or more second rollers.

[0045] Disclosed herein in a third aspect is a system for producing a thermoplastic prepreg material, the system comprising: a feeding unit configured for providing a natural fibre material; an oven unit configured for drying the provided natural fibre material at a first predetermined temperature, hereby obtaining a dried natural fibre material; a heating unit configured for heating the dried natural fibre material to a second predetermined temperature, hereby obtaining a heated natural fibre material; a first extruder apparatus configured for providing a first layer of a high viscosity thermoplastic biobased resin to a first side of the heated natural fibre material, hereby obtaining a heated natural fibre material having a first resin layer; one or more first rollers configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated natural fibre material having a first resin layer, hereby obtaining a heated intermediate prepreg material; a second extruder apparatus configured for providing a second layer of the high viscosity thermoplastic biobased resin to a second side of the heated intermediate prepreg material, hereby obtaining a heated intermediate prepreg material having a second resin layer; one or more second rollers configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated intermediate prepreg material having a second resin layer using, hereby obtaining a heated prepreg material; and a first cooling unit configured for cooling the heated prepreg material to a third predetermined temperature, hereby obtaining the thermoplastic prepreg material.

[0046] Disclosed herein in a fourth aspect is a process for producing a thermoplastic prepreg material, the thermoplastic prepreg material being a fibre-reinforced polymer composite material comprising a polymer matrix and a natural fibre material, the thermoplastic prepreg material is produced from a high viscosity thermoplastic biobased resin and a natural fibre material, the process comprising the steps of: providing the natural fibre material; drying the natural fibre material in an oven unit at a first predetermined temperature, hereby obtaining a dried natural fibre material; heating the dried natural fibre material in a heating system to a second predetermined temperature, hereby obtaining a heated natural fibre material; maintaining the heated natural fibre material at the second predetermined temperature while providing a first layer of the high viscosity thermoplastic biobased resin to a first side of the heated natural fibre material, the first layer of high viscosity thermoplastic biobased resin being provided using a first extruder apparatus, hereby obtaining a heated natural fibre material having a first resin layer; maintaining the heated natural fibre material having a first resin layer at the second predetermined temperature while impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated natural fibre material having a first resin layer using one or more first rollers, hereby obtaining a heated intermediate prepreg material; and cooling the heated intermediate prepreg material to a third predetermined temperature during a cooling down process, hereby obtaining the thermoplastic prepreg material.

[0047] In one or more embodiments according to the fourth aspect, the process further comprises the steps of maintaining the heated intermediate prepreg material at the second predetermined temperature while providing a second layer of high viscosity thermoplastic biobased resin to a second side of the heated intermediate prepreg material, the second layer of high viscosity thermoplastic biobased resin being provided using a second extruder apparatus, hereby obtaining a heated intermediate prepreg material having a second resin layer; and maintaining the heated intermediate prepreg material having a second resin layer at the second predetermined temperature while impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated intermediate prepreg material having a second resin layer using one or more second rollers, hereby obtaining a heated prepreg material.

[0048] Effects and features of the second, third, and fourth aspects are to a large extent analogous to those described above in connection with the first aspect. Embodiments mentioned in relation to the first aspect are largely compatible with the second, third, and fourth aspects.

[0049] Brief description of the drawings

[0050] Figure 1 discloses an overview of the system and process as disclosed herein in one or more embodiments.

[0051] Detailed description

[0052] The present disclosure will become apparent from the detailed description given below. The detailed description and specific examples disclose preferred embodiments of the disclosure by way of illustration only. Those skilled in the art understand from guidance in the detailed description that changes and modifications may be made within the scope of the disclosure.

[0053] This invention includes all modifications and equivalents of the subject matter recited in the claims and / or aspects appended hereto as permitted by applicable law.

[0054] As described above, disclosed herein is a process and a system for producing a thermoplastic prepreg material, the thermoplastic prepreg material being a fibre-reinforced polymer composite material comprising a polymer matrix and a natural fibre material, the thermoplastic prepreg material is produced from a high viscosity thermoplastic biobased resin and a natural fibre material.

[0055] In one or more embodiments, the thermoplastic prepreg material consist of fibres and one or more high viscosity thermoplastic biobased resin. In one or more embodiments, the one or more high viscosity thermoplastic biobased resin are biodegradable resins. In one or more embodiments, the biodegradable material / biodegradable resins is a material, which can be degraded completely into CO2 and water, or organic material by microorganisms and / or natural environmental factors. In one or more embodiments, the biodegradable material is a material, which degrades under biological action. In one or more embodiments, the biodegradable material is a material, which degrades under microbial action.

[0056] Biodegradable materials are materials, which can be decomposed by the action of living organisms, usually microbes, into water, carbon dioxide, and biomass. Biodegradable materials may be produced with renewable raw materials, microorganisms, petrochemicals, or combinations of all three, however, even though the words "bio-material" and "biodegradable material" are similar, they are not synonymous. Not all biomaterials (materials derived partly or entirely from biomass) are biodegradable, and some biodegradable materials are fully petroleum based.

[0057] Various biodegradable materials may be used, from biodegradable biomaterials to biodegradable petroleum-based materials.

[0058] The biodegradability of the herein disclosed materials may be measured and defined using ISO 14855 (Ultimate Biodegradation - CO2 Evolution). ISO 14855 is a standard biodegradation test method that determines ultimate aerobic biodegradability and disintegration of plastic materials under controlled composting conditions. To successfully compost a material or product, it must pass the phytotoxicity test to determine the quality of compost. This method predominantly measures ultimate aerobic biodegradation by the analysis of evolved carbon dioxide.

[0059] Ultimate aerobic biodegradation is when microorganisms fully consume a chemical compound or organic matter by in the presence of oxygen and produces carbon dioxide, water and mineral salts.

[0060] Test requirements for ISO 14855 include standard testing for a minimum of 90 days and then the biodegradation results are determined after an analysis of evolved CO2.

[0061] Solid aerobic biodegradation and disintegration of plastic materials under controlled composting conditions is generally the accepted form of testing to make product performance claims.

[0062] In one or more embodiments, the biodegradable materials are materials, which can pass the ISO 14855 test.

[0063] In one of more embodiments, the one or more resins are selected from thermoplastic resins. A thermoplastic resin is a type of polymer that becomes pliable or moldable when heated and solidifies upon cooling. This process can be repeated multiple times without significantly altering the material’s properties.

[0064] A thermoset resin is a type of polymer that undergoes a chemical reaction during its initial processing and curing to form a three-dimensional network structure. Once this curing process is complete, the material hardens into a permanent and relatively infusible state. Unlike thermoplastics, thermosets cannot be melted and reprocessed once they have undergone the curing process.

[0065] The polymer matrix as disclosed herein is synthesized / produced from resins, as disclosed herein, which preferably are resins as from natural origins, such as plants, animals, or microorganisms (bio-materials / bio-based). Such resins / polymer matrix could be, but not limited to: Polyhydroxyalkanoates (PHAs); Polylactic acid (PLA); Starch blends; Cellulose-based plastics; and / or Lignin-based polymer composites.

[0066] Polyhydroxyalkanoates (PHAs) are a class of biodegradable material, which is naturally produced by various microorganisms, such as Cuprividus necator. Specific types of PHAs include poly-3- hydroxybutyrate (PHB), polyhydroxyvalerate (PHV) and polyhydroxyhexanoate (PHH). PHA can be further classified into two types: scl-PHA and mcl-PHA. Scl-PHA from hydroxy fatty acids with short chain lengths including three to five carbon atoms, while mcl-PHA from hydroxy fatty acids with medium chain lengths including six to 14 carbon atoms.

[0067] Polylactic acid (PLA) is thermoplastic aliphatic polyester synthesized from renewable biomass, typically from fermented plant starch such as from corn, cassava, sugarcane or sugar beet pulp. PLA is compostable, but may not be seen as non-biodegradable according to some American and European standards because it does not biodegrade outside of artificial composting conditions, however, as disclosed herein PLA is seen as being a biodegradable material.

[0068] Starch blends are thermoplastic polymers produced by blending starch with plasticizers. Because starch polymers on their own are brittle at room temperature, plasticizers are added in a process called starch gelatinization to augment its crystallization. While all starches are biodegradable, not all plasticizers are. Thus, the biodegradability of the plasticizer determines the biodegradability of the starch blend. Biodegradable starch blends include starch / polylactic acid, starch / polycaprolactone, and starch / polybutylene-adipate-co-terephthalate. Cellulose-based plastics are mainly the cellulose esters, (including cellulose acetate and nitrocellulose) and their derivatives, including celluloid. Cellulose can become thermoplastic when extensively modified. An example of this is cellulose acetate.

[0069] Lignin-based polymer composites are bio-renewable natural aromatic polymers with biodegradable properties. Lignin is found as a by-product of polysaccharide extraction from plant material through the production of paper, ethanol, and more. Lignin is useful due to its low weight material and the fact that it is more environmentally friendly than other alternatives. Lignin is neutral to CO2 release during the biodegradation process. Other biodegradable plastic processes such as polyethylene terephthalate (PET) have been found to release CO2 and water as waste products produced by the degrading microorganisms. Lignin contains comparable chemical properties in comparison to current plastic chemicals, which includes reactive functional groups, the ability to form into films, high carbon percentage, and it shows versatility in relation to various chemical mixtures used with plastics. Lignin is also stable, and contains aromatic rings. It is both elastic and viscous yet flows smoothly in the liquid phase. Most importantly, lignin can improve on the current standards of plastics because it is antimicrobial in nature.

[0070] The polymer matrix as disclosed herein may also be synthesized / produced from resins, as disclosed herein, which petroleum-based, i.e. derived from petrochemicals, which are obtained from fossil crude oil, coal, or natural gas. The most widely used petroleum-based plastics such as polyethylene terephthalate (PET), polyethylene (PE), polypropylene (PP), and polystyrene (PS) are not biodegradable. However, the following petroleum-based materials, which are biodegradable may be selected from: Polyglycolic acid (PGA); Polybutylene succinate (PBS); Polycaprolactone (PCL); Poly(vinyl alcohol) (PVA, PVOH); Polybutylene adipate terephthalate (PBAT).

[0071] Polyglycolic acid (PGA) is a thermoplastic polymer and an aliphatic polyester. PGA is often used in medical applications such as PGA sutures for its biodegradability. The ester linkage in the backbone of polyglycolic acid gives it hydrolytic instability. Thus, polyglycolic acid can degrade into its nontoxic monomer, glycolic acid, through hydrolysis. This process can be expedited with esterases. In the body, glycolic acid can enter the tricarboxylic acid cycle, after which can be excreted as water and carbon dioxide.

[0072] Polybutylene succinate (PBS) is a thermoplastic polymer resin that has properties comparable to propylene. It is used in packaging films for food and cosmetics. In the agricultural field, PBS is used as a biodegradable mulching film. PBS can be degraded by Amycolatopsis sp. HT-6 and Penicillium sp. Strain 14-3. In addition, Microbispora rosea, Excellospora japonica and E. viridilutea have been shown to consume samples of emulsified PBS. Polycaprolactone (PCL) is a material where the hydrolysis of its ester linkages offers its biodegradable properties. It has been shown that Bacillota and Pseudomonadota can degrade PCL. Penicillium sp. Strain 26-1 can degrade high density PCL; though not as quickly as thermotolerant Aspergillus sp. Strain ST-01. Species of Clostridium can degrade PCL under anaerobic conditions.

[0073] Poly(vinyl alcohol) (PVA, PVOH) is one of the few biodegradable vinyl polymers that is soluble in water. Due to its solubility in water (an inexpensive and harmless solvent), PVA has a wide range of applications including food packaging, textiles coating, paper coating, and healthcare products.

[0074] Polybutylene adipate terephthalate (PBAT) is a biodegradable random copolymer.

[0075] In one or more embodiments, the high viscosity thermoplastic biobased resin is selected from one or more bio-based and biodegradable resins, such that the thermoplastic prepreg material is a bio-based and biodegradable material.

[0076] In one or more embodiments, the high viscosity thermoplastic biobased resin is based on plant triglycerides, such as a poly lactic acid resin.

[0077] Plant triglycerides are triglycerides derived from plant (or animal) oil. By being based on plant triglycerides is meant that after deriving the triglyceride from the source it is functionalized with chemical groups that renders it polymerizable. These functional groups may be introduced through chemical reactions employing oil-based products to incorporate reactive groups such as epoxy, acrylate, and glycerol. The functionalisation by for instance epoxy groups can make the resin less environmentally safe as epoxy is sensitising to the human skin and it uses oil-based products. In addition, the resin based on functionalised triglycerides has elastic modulus and flexural modulus values lower than those of presently used composite matrix materials, even when the functionalised triglycerides are mixed with oil-based components. Examples of plant triglycerides are shown in e.g. WO 99 / 21900.

[0078] In one or more embodiments, the high viscosity thermoplastic biobased resin is a poly lactic acid resin.

[0079] Poly lactic acid is a polymer that can be amorphous or semi crystalline. Poly lactic acid can be produced from various plant sources such as maize, beans, peas, sugarcanes and wood. Poly lactic acid has an elastic modulus of 3.2-3.4 GPa which exceeds that of commonly used epoxy, polyester, and vinyl ester resins used as composite matrix material today. As used herein, the term poly lactic acid refers to any of the isomeric states of poly (L-lactic acid), poly (D-lactic acid) and poly (L, D-lactic acid) or mixtures hereof. In one or more embodiments, the resins may comprise at least 50% by weight of lactide or other cyclic diesters such as glycolide or poly lactic acid oligomers or other oligomers that can be synthesised from the aforementioned cyclic diesters such as poly glycolic acid oligomers with an average molecular mass between 200 and 6000 g / mol or at least 50% by weight of cyclic diester and oligomers synthesised from said diesters. As used herein, the term lactide refers to any of the isomeric states of L-lactide, D-lactide and meso-lactide or mixtures hereof.

[0080] The cyclic diester and oligomer may be selected from lactide and poly lactic acid oligomer, respectively. The lactide part of the resins may be polymerised to poly lactic acid or the poly lactic acid oligomers may be fully polymerised inside the mould containing the composite material by one or more catalysts suitable for the ring-opening polymerisation of lactide and other cyclic diesters or catalysis of polymerisation of poly lactic acid. Numerous catalysts are known to the skilled person, such as stannous octoate, zinc octoate, stannous alkoxides, aluminium isopropoxide, 4-(dimethylamino)pyridine and novozym 435 and their concentration can be varied as known. Common catalyst concentrations are 0.01 to 0.5 % by weight.

[0081] In one or more embodiments, the resins are at least 70% by weight of lactide or poly lactic acid oligomers with an average molecular mass between 200 and 6000 g / mol. In one or more embodiments, the resins is at least 70% by weight of lactide and poly lactic acid oligomers.

[0082] Full biodegradability may be achieved by employing biodegradable plant-based material as the resins in the composition or through addition of crude oil-based components capable of undergoing biodegradation.

[0083] In one of more embodiments, the thermoplastic prepreg material further comprises one or more components for increasing the fracture toughness of the resins when polymerized, such as poly olefins, poly hydroxyalkanoates, poly (ethylene glycole), and / or organo modified layered silicates such as montmorillonite.

[0084] In one of more embodiments, the thermoplastic prepreg material further comprises one or more components increasing the impact strength of the resins when polymerized, such as triacetin, poly (butylene succinate), glucose monoesters, and / or polyethylene.

[0085] In one of more embodiments, the thermoplastic prepreg material further comprises one or more cross-linking agents. By adding cross-linking agents, the polymer matrix when formed may be able to form interconnecting bonds between polymer chains, which can increase the glass transition temperature and strength of the polymer matrix. One example of cross-linking agent is a molecule with at least two amine groups within the entire molecule. Preferably, the cross-linking agent has at least three primary amine groups as this increases the probability of cross-linking and the primary amine groups are more reactive than the secondary ones. The amine groups can undergo reaction with the ester group in e.g. a poly lactic acid chain or other structures within the polymer matrix that contain ester bonds to yield an amide. With multiple reactive groups within the molecule, the amine molecule can be connected to different polymer chains containing ester bonds and thereby establish a cross-linked structure. Other suitable cross-linking agents are molecules containing at least two carboxylic acids groups or at least two hydroxy groups. Exemplified is e.g. the terminal groups of poly lactic acid chains, which are hydroxyl groups. Such groups can undergo reaction with a carboxylic acid group to yield a linkage of the two molecules through an ester bond under the displacement of water. Other suitable cross-linking agents could be molecules comprising multiple groups able to undergo reaction with ester bonds, hydroxyl groups or other functional groups present in the resins of the composite material. Alternative, the cross-linking agent can comprise chemical groups with a functionality to bind as described above in addition to one or more other functional groups that can bind to another cross-linking agent. This can be chemical groups such as carbon-carbon double or triple bonds, epoxy, and / or hydroxyl groups.

[0086] In one of more embodiments, the thermoplastic prepreg material is dyed with one or more molecules. This enables tailoring of the colour of the polymer matrix after polymerization of the resins to a specific application, where a certain colour may be required. Commercial dyes are known to the skilled person.

[0087] In one of more embodiments, the thermoplastic prepreg material further comprises one or more flame retarding molecules or compounds. This may be used to increase the fire safety of the formed material. Flame retarders are known to the skilled person, such as spirocyclic pentaerythritol bisphosphorate disphosphoryl melamine, organomodified silicates, triazine phosphamide, ethyl phosphorodichloridate, and / or aryl polyphenylphosphonates.

[0088] Additives to the thermoplastic prepreg material may be either comprised in the provided natural fibre material or added during the process, such as e.g. mixed with the resin in the extruder.

[0089] In one of more embodiments, the natural fibre material has a fabric weight of at least 250 grams for every square meter of material, such as at least 300 grams for every square meter of material.

[0090] In one of more embodiments, the natural fibre material has a fabric weight of less than or equal to 600 grams for every square meter of material, such as less than or equal to 500 grams for every square meter of material. In one of more embodiments, the natural fibre material has a weight between 200 and 1400 g / m2, such as between 200 and 1300 g / m2, such as between 400 and 1200 g / m2, such as between 500 and 1100 g / m2, such as between 600 and 1000 g / m2, such as between 700 and 900 g / m2, such as substantially 400 g / m2, such as substantially 500 g / m2, such as substantially 600 g / m2, such as substantially 700 g / m2, such as substantially 800 g / m2, or such as substantially 900 g / m2.

[0091] In one of more embodiments, the natural fibre material has is selected from one or more woven sheets of fibrous material, such as one woven sheet of fibrous material, such as at least two woven sheets of fibrous material, such as two woven sheets of fibrous material, or such as at least three woven sheets of fibrous material.

[0092] In one of more embodiments, the ratio between the polymer matrix and the natural fibre material in the fibre-reinforced composite polymer is between 30:70 and 70:30 wt. / wt.%, such as between 40:60 and 60:40 wt. / wt.%, or such as between 45:55 and 55:45 wt. / wt.%.

[0093] In one of more embodiments, the thermoplastic prepreg material comprises at last 40 wt.% natural fibre material, such as at least 45 wt.%, such as at least 50 wt.%, such as at least 55 wt.%, such as at least 60 wt.%, such as at least 65 wt.%, or such as at least 70 wt.% natural fibre material.

[0094] In one of more embodiments, the thermoplastic prepreg material comprises less than or equal to 70 wt.% resin, such as less than or equal to 65 wt.%, such as less than or equal to 60 wt.%, such as less than or equal to 55 wt.%, such as less than or equal to 50 wt.%, such as less than or equal to 45 wt.%, or such as less than or equal to 40 wt.% resin.

[0095] In one of more embodiments, the thermoplastic prepreg material comprises between 40 and 70 wt.% resin and between 40 and 70 wt.% natural fibre material.

[0096] In one of more embodiments, the thermoplastic prepreg material consists of resin and natural fibre material.

[0097] In one of more embodiments, the natural fibre material is selected from sisal, hemp, coconut, flax, jute, kenaf, bamboo, sphagnum, hay or combinations thereof.

[0098] In one of more embodiments, the natural fibre material at least comprises a flax material.

[0099] In one of more embodiments, the natural fibre material is selected from sisal, hemp, jute, flax, hay or combinations thereof. In one of more embodiments, the natural fibre material is selected from jute, hemp, flax, or combinations thereof.

[0100] In one of more embodiments, the natural fibre material is selected from hemp, flax, or combinations thereof.

[0101] In one of more embodiments, the natural fibre material is hemp fibrous material.

[0102] In one of more embodiments, the natural fibre material is jute fibrous material.

[0103] In one of more embodiments, the natural fibre material is flax fibrous material.

[0104] In one of more embodiments, the natural fibre material comprises continuous fibres or discontinuous fibres.

[0105] In one of more embodiments, the natural fibre material comprises a plurality of fibres, which are woven and / or bonded together.

[0106] In one of more embodiments, the diagonal lines in the natural fibre material cross at least two warp threads and two weft threads consecutively before moving on to a next set of two, such as the diagonal lines in the natural fibre material cross at least four warp threads and four weft threads consecutively before moving on to the next set of four.

[0107] In one or more embodiments, the natural fibre material has a weaving such that the natural fibre material is a very open structure, whereby the step of providing a second layer of high viscosity thermoplastic biobased resin to a second side of the heated intermediate prepreg material may be omitted as the resin material is able to go through the natural fibre material and hereby be applied on both sides.

[0108] In one of more embodiments, the thermoplastic prepreg material comprises at least two sheets of natural fibre material and resins, wherein the resins and the at least two sheets are composed as a sandwich structure with alternating layers of resins and sheets of fibrous material, such as resin-sheet-resin-sheet-resin.

[0109] In one of more embodiments, the polymer matrix comprises one or more resins selected from thermoset resins, thermoplastic resins, or combinations thereof. In one of more embodiments, the polymer matrix comprises one or more resins selected from thermoplastic resins. In one of more embodiments, the polymer matrix consist of one or more resins selected from thermoplastic resins. In one or more embodiments, the polymer matrix comprises one or more resins selected from one or more biodegradable resins, such that the polymer matrix is biodegradable.

[0110] In one or more embodiments, the polymer matrix comprises one or more resins selected from one or more bio-based / bio-material and biodegradable resins such that the polymer matrix is a bio-based and biodegradable material.

[0111] In one or more embodiments, the thermoplastic prepreg material comprises a continuous polymer matrix reinforced with the one or more fibrous materials.

[0112] In one or more embodiments, the polymer matrix is based on plant triglycerides.

[0113] In one or more embodiments, the polymer matrix comprises at least one or more poly lactic acid resins.

[0114] In one or more embodiments, the high viscosity thermoplastic biobased resin is a 100% biobased resin. As disclosed herein when the resin is a 100% biobased resin, it means that 100% of the resin used in the production is derived from renewable biological sources, as disclosed herein, such as e.g. plant sources. In one or more embodiments, a biobased resin is a resin obtained from 100% natural material, such as natural plant material. In one or more embodiments, the biobased resin is not obtained from fossil fuels.

[0115] In one of more embodiments, the thermoplastic prepreg material has a surface roughness of less than 120 RMS, such as less than 100 RMS, such as less than 80 RMS. In one or more embodiments, the composite lightweight construction has a surface roughness of more than 20 RMS. In one or more embodiments, the composite lightweight construction has a surface roughness of between 20 RMS and 120 RMS, such as between 20 RMS and 100 RMS, such as between 20 RMS and 80 RMS, or such as between 20 RMS and 60 RMS.

[0116] RMS is the root mean square average of the profile height deviations from the mean line, recorded within the evaluation length. RMS can be measured using ASME B46.1.

[0117] It is advantageous that the material after being obtained by the method has a low RMS value, however not to low, as this ensures the protective film or foil to have a stronger binding to the material, hereby better protecting the biodegradable material from environmental degradation. However, the surface roughness can be modified with a postprocess and when the prepreg material is processed into the final material. The surface roughness can e.g. be controlled using the method, by controlling the pressing step, in which the light weight construction is pressed into the desired three-dimensional shape.

[0118] In one or more embodiments, the thermoplastic prepreg material has a surface roughness of less than 120 RMS, such as less than 100 RMS, such as less than 80 RMS. In one or more embodiments, the fibre-reinforced polymer composite material has a surface roughness of more than 20 RMS. In one or more embodiments, the fibre-reinforced polymer composite material has a surface roughness of between 20 RMS and 120 RMS, such as between 20 RMS and 100 RMS, such as between 20 RMS and 80 RMS, or such as between 20 RMS and 60 RMS.

[0119] In one of more embodiments, the thermoplastic prepreg material comprises at least two sheets of natural fibre material and a polymer matrix, wherein the polymer matrix and the at least two sheets are composed as a sandwich structure with alternating layers of polymer matrix and sheets of fibrous material.

[0120] The thermoplastic prepreg material can be seen as a fibre-reinforced polymer composition. Fbre- reinforced polymer (FRP) composites are increasingly being considered as an enhancement to and / or substitute for infrastructure components or systems that are constructed of traditional civil engineering materials, namely concrete and steel. Fibre-reinforced polymer composites are lightweight, non-corrosive, exhibit high specific strength and specific stiffness, are easily constructed, and can be tailored to satisfy performance requirements.

[0121] Fibre-reinforced polymer reinforcements offer a number of advantages such as corrosion resistance, non-magnetic properties, high tensile strength, lightweight and ease of handling. However, they generally have a linear elastic response in tension up to failure (described as a brittle failure) and a relatively poor transverse or shear resistance. They also have poor resistance to fire and when exposed to high temperatures. They lose significant strength upon bending, and they are sensitive to stress-rupture effects. Moreover, their cost, whether considered per unit weight or based on force carrying capacity, is high in comparison to conventional steel reinforcing bars or prestressing tendons.

[0122] The polymers of a fibre-reinforced polymer composite may be combined with various agents to enhance or in any way alter the material properties of polymers, and the result may be referred to as a plastic. The composite plastics can be of homogeneous or heterogeneous mix. Composite plastics refer to those types of plastics that result from bonding two or more homogeneous materials with different material properties to derive a final product with certain desired material and mechanical properties. The fibre-reinforced plastics (or fibre-reinforced polymers) are a category of composite plastics that specifically use fibre materials (not mix with polymer) to mechanically enhance the strength and elasticity of plastics. The original plastic material without fibre reinforcement is known as the matrix. The matrix is a tough but relatively weak plastic that is reinforced by stronger stiffer reinforcing filaments or fibres. The extent that strength and elasticity are enhanced in a fibre-reinforced plastic depends on the mechanical properties of the fibre and matrix, their volume relative to one another, and the fibre length and orientation within the matrix. Reinforcement of the matrix occurs by definition when the fibre-reinforced polymer material exhibits increased strength or elasticity relative to the strength and elasticity of the matrix alone.

[0123] The linking of small molecules (monomers) to make larger molecules is a polymer.

[0124] Polymerization requires that each small molecule have at least two reaction points or functional groups. There are two distinct major types of polymerization processes, condensation polymerization, in which the chain growth is accompanied by elimination of small molecules such as H2O or CH3OH, and in addition polymerization, in which the polymer is formed without the loss of other materials. There are many variants and subclasses of polymerization reactions.

[0125] The fibre-reinforced composites are materials in which a fibre made of one material is embedded in another material (the matrix). The polymer composites are any of the combinations or compositions that comprise two or more materials as separate phases, at least one of which is a polymer. By combining a polymer with another material, such as glass, carbon, or another polymer, it is often possible to obtain unique combinations or levels of properties. Typical examples of synthetic polymeric composites include glass-, carbon-, or polymer-fibre-reinforced.

[0126] Typically, the goal is to improve strength, stiffness, toughness, or dimensional stability by embedding particles or fibres in a matrix or binding phase. A second goal may be to use inexpensive, readily available fillers to extend a more expensive or scarce resin; this goal is increasingly important as petroleum supplies become costlier and less reliable.

[0127] Today, the most commonly used fibre-reinforced polymer composites are based on glass fibres, cloth, mat, or roving embedded in a matrix of an epoxy or polyester resin.

[0128] The material as disclosed herein is usually made of two components, a fibre and matrix. The fibre is selected from a biodegradable fibre, and the matrix is selected from a biodegradable polymer, preferable a thermoplastic polymer. The fibre is embedded in the polymer matrix in order to make the matrix stronger. Fibre-reinforced composites are strong and light. They are often stronger than steel, but weigh much less. This means that composites can be used to make automobiles lighter, and thus much more fuel-efficient.

[0129] By having both the fibres and the polymer being selected from materials being biodegradable waste products that would traditionally cost money for disposal, now become a beneficial resource, allowing recycling to be both profitable and environmentally conscious. Further, the normally posed challenge with plastics in recycling processes, especially for fibre-reinforced plastics where the fibres themselves are difficult to remove from the matrix and preserve for reuse is also alleviated by using environmentally friendly matrices and fibrous material.

[0130] The thermoplastic prepreg material may further comprise additional added layers or components, which can have added benefits. This can e.g. be components assisting in wear-, scratch-, and / or UV-resistance.

[0131] Wear resistance is the ability of a material to resist the progressive loss of volume from its surface through mechanical actions such as repeated rubbing, sliding, or scraping. Wear-resistant materials can be improved by using additives such as glass and carbon. Additionally, solid lubricants can be used to eliminate the need for extra lubrication, offering advantages such as reduced wear, better operating characteristics, and greatly reduced maintenance efforts.

[0132] Scratch-resistant essentially means that the product is able to withstand minor scratches. Scratch-resistance can be improved by implementing anti-scratch coating, which is a type of protective coating or film applied to an object's surface for mitigation against scratches. Scratches are small surface-level cuts left on a surface following interaction with a sharper object. Antiscratch coatings provide scratch resistances by containing tiny microscopic materials with scratch-resistant properties. Scratch resistance materials come in the form of additives, filters, and binders. Besides materials, scratch resistances is impacted by coating formation techniques. Scratch resistance is measured using the Scratch-hardness test.

[0133] UV resistance refers to a material’s ability to avoid degradation caused by the absorption of UV radiation. The sun’s UV rays break down chemical bonds in polymers, causing plastics to wear down and disintegrate over time. This is known as photodegradation. Photodegradation can cause discoloration (especially yellowing or whitening known as “chalking”), contributing to loss of impact and tensile strength and making plastics brittle and prone to cracking or breaking. UV damage also negatively impacts elongation, which is the ability of a material to resist changes before irreversible deformation. UV resistance may be achieved by the use of additives such as UV stabilizers, black coloration (typically using carbon black) or protective surface coatings (such as paint, or metallization). The addition of carbon black is a low cost and typically very effective way of creating UV resistant plastics.

[0134] Further disclosed herein is a three-dimensional shaped structure formed by positioning a sheet of thermoplastic prepreg material in a mould and heating and pressing the sheet of thermoplastic prepreg material into the three-dimensional shaped structure. The use of natural fibres and a biodegradable resin in the composite material accommodates the increasing request for using natural and sustainable materials wherever it is possible.

[0135] In one or more embodiments, the process further comprises the step of cutting the thermoplastic prepreg material into sheets having a predetermined dimension.

[0136] In one or more embodiments, the step of cutting the thermoplastic prepreg material into sheets is performed using computer-controlled cutting equipment, such as using laser cutting, cold or warm knife cutting, water cutting or air cutting.

[0137] These types of cutting have proven to be suitable for cutting the thermoplastic prepreg material both sharply and fast.

[0138] In one or more embodiments, the predetermined dimension is a dimension having a length of at least 800 mm, such as at least 900 mm, such as at least 1000 mm, such as at least 1100 mm, or such as a length of at least 1200 mm.

[0139] In one or more embodiments, the process further comprises the step of rolling the thermoplastic prepreg material onto rolls.

[0140] In one or more embodiments, the natural fibre material is provided having a width of at least 500 mm, such as at least 600 mm, such as at least 700 mm, such as at least 800 mm, such as at least 900 mm, such as at least 1000 mm, or such as at least 1270 mm.

[0141] The thermoplastic prepreg material may be cut out into a piece having a predetermined size and shape depending on the construction to be produced using the thermoplastic prepreg material. In one or more embodiments, cutting the thermoplastic prepreg material into sheets having a predetermined dimension may be performed using a cutting unit / cutting equipment. In one or more embodiments, cutting the thermoplastic prepreg material into sheets having a predetermined dimension may be performed using a laser cutter. In one or more embodiments, cutting the thermoplastic prepreg material into sheets having a predetermined dimension may be performed using a rotary cutter. In one or more embodiments cutting the thermoplastic prepreg material into sheets having a predetermined dimension may be performed using ultrasonic cutting equipment. In one or more embodiments, cutting the thermoplastic prepreg material into sheets having a predetermined dimension may be performed using oscilliating knife cutting equipment. In one or more embodiments, cutting the thermoplastic prepreg material into sheets having a predetermined dimension may be performed using universal knife cutting equipment. In one or more embodiments, cutting the thermoplastic prepreg material into sheets having a predetermined dimension may be performed using laser cutting equipment. In one or more embodiments, the piece that is cut out of the sheet is slightly oversized. In one or more embodiments, the piece that is cut out of the sheet is cut out to net shape.

[0142] Net shape refers to the concept in manufacturing where a component or product is manufactured to its final shape with minimal or no additional machining or processing. The goal is to produce a finished part directly from the manufacturing process, reducing the need for secondary operations.

[0143] In traditional manufacturing, many parts are initially produced in a rough or near-net shape and then undergo additional processes such as machining or finishing to achieve their final dimensions and surface characteristics. This can involve removing excess material or refining the shape through various machining operations.

[0144] Net shape manufacturing aims to minimize or eliminate these secondary processes. The benefits of net shape manufacturing include reduced material waste, lower production costs, and often faster production cycles.

[0145] In one or more embodiments, the applied pressure from the one or more first rollers and / or the one or more second rollers is controlled using an air pressure, such as a pneumatic system.

[0146] In one or more embodiments, the first predetermined temperature is a temperature between 60 °C and 130 °C, such as between 70 °C and 120 °C, such as between 75 °C and 115 °C, or such as between 80 °C and 110 °C.

[0147] In one or more embodiments, the second predetermined temperature is a temperature between 130 °C and 210 °C, such as between 140 °C and 200 °C, such as between 150 °C and 190 °C, or such as between 160 °C and 180 °C.

[0148] In one or more embodiments, the second predetermined temperature is a temperature between 130 °C and 260 °C, such as between 145 °C and 250 °C, such as between 160 °C and 230 °C, such as between 170 °C and 210 °C, or such as between 180 °C and 200 °C.

[0149] In one or more embodiments, the process further comprises the step of subjecting the heated prepreg material to a fourth predetermined temperature prior to cooling the heated prepreg material to a third predetermined temperature, wherein the fourth predetermined temperature is a temperature between 90 °C and 130 °C, such as a temperature between 100 °C and 120 °C, such as a temperature around 110 °C. In one or more embodiments, the process further comprises the step of applying a pressure to the first side and / or the second side of the heated prepreg material by means of one or more massage rollers. A massage roller is a tool used for applying a massage like pressure to the material. It typically consists of a cylindrical or elongated-shaped roller made from materials like foam, rubber, plastic, metal, or wood. In one or more embodiments, the applied pressure from the one or more massage rollers is controlled using an air pressure, such as a pneumatic system.

[0150] In one or more embodiments, the step of applying a pressure to the first side and / or the second side of the heated prepreg material by means of one or more massage rollers is performed while subjecting the heated prepreg material to the fourth predetermined temperature.

[0151] In one or more embodiments, the first extruder apparatus applies 50% or more of the high viscosity thermoplastic biobased resin compared to the amount of high viscosity thermoplastic biobased resin in the thermoplastic prepreg material, and wherein the second extruder apparatus applies 50% or less of the high viscosity thermoplastic biobased resin compared to the amount of high viscosity thermoplastic biobased resin in the thermoplastic prepreg material.

[0152] As disclosed herein an extruder is a machine that works by forcing a material, preferably a thermoplastic, through a shaped opening known as a die. The material is pushed through the die under high pressure, causing it to take on the shape of the die opening. The extruder process begins with raw plastic material in the form of pellets or granules being fed into the extruder's hopper. Inside the extruder, the material is heated and softened until it reaches a molten state. The molten plastic is then forced through a specially designed die, which gives the plastic its desired shape. Once the plastic exits the die, it is applied to the natural fibre material.

[0153] In one or more embodiments, the first extruder apparatus applies between 50% and 75% of the high viscosity thermoplastic biobased resin compared to the amount of high viscosity thermoplastic biobased resin in the thermoplastic prepreg material.

[0154] In one or more embodiments, the second extruder apparatus applies between 25% and 50% of the high viscosity thermoplastic biobased resin compared to the amount of high viscosity thermoplastic biobased resin in the thermoplastic prepreg material.

[0155] In one or more embodiments, the first layer of high viscosity thermoplastic biobased resin is being provided using a first extruder apparatus having a first extruder process, the first extruder process having the following steps: providing a first extruder apparatus; introducing the high viscosity thermoplastic biobased resin into the first extruder apparatus; subjecting the high viscosity thermoplastic biobased resin to controlled pressure and temperature within the first extruder apparatus; and extruding the high viscosity thermoplastic biobased resin through a die of predetermined shape, thereby forming a first layer of the high viscosity thermoplastic biobased resin to the first side of the heated natural fibre material.

[0156] In one or more embodiments, the second layer of high viscosity thermoplastic biobased resin is being provided using a second extruder apparatus having a second extruder process, the second extruder process having the following steps: providing a second extruder apparatus; introducing the high viscosity thermoplastic biobased resin into the second extruder apparatus; subjecting the high viscosity thermoplastic biobased resin to controlled pressure and temperature within the second extruder apparatus; and extruding the high viscosity thermoplastic biobased resin through a die of predetermined shape, thereby forming a second layer of the high viscosity thermoplastic biobased resin to the second side of the heated intermediate prepreg material.

[0157] In one or more embodiments, the process further comprising the step of drying the high viscosity thermoplastic biobased resin prior to introducing the high viscosity thermoplastic biobased resin into the first and / or second extruder apparatus.

[0158] In one or more embodiments, the first and / or second extruder apparatus is a twin-screw extruder apparatus. The twin screw extrusion shall support the compounding of the resin together with the different additives that is need for the resin.

[0159] The twin-screw extruder as disclosed herein is a type of extrusion machine that utilizes two intermeshing screws to process materials. It is widely used in the plastics industry for compounding, mixing, and shaping thermoplastic materials. The twin-screw extruder is highly versatile and offers advantages such as improved mixing capabilities, enhanced process control, and the ability to process a wide range of materials. A twin-screw extruder process typically works as follows:

[0160] The raw materials, typically in the form of pellets, powders, or liquids, are fed into the extruder through a hopper;

[0161] The materials are then conveyed along the length of the extruder barrel by the rotation of the screws. As the screws turn, they intermesh and create a kneading and mixing action, which helps blend the materials uniformly. This mixing action is especially beneficial for compounding applications where additives, fillers, or colorants need to be dispersed evenly throughout the polymer matrix;

[0162] Along the length of the extruder barrel, the material is subjected to heating elements or external heating sources to melt thermoplastic materials. The combination of heat and mechanical energy from the screws facilitates melting and homogenization of the material; As the material progresses along the barrel, it reaches the die at the end of the extruder. The die shapes the molten material into the desired cross-sectional profile, and in this case applies it to the natural fibre material.

[0163] Twin-screw extruders come in various configurations, including co-rotating and counter-rotating designs. Co-rotating twin-screw extruders, where the screws rotate in the same direction, are the most common. They offer high throughput rates, efficient mixing, and excellent self-cleaning capabilities. Counter-rotating twin-screw extruders, where the screws rotate in opposite directions, are suitable for applications requiring higher shear and elongational mixing.

[0164] Overall, twin-screw extruders are indispensable in the plastics industry for their ability to efficiently process a wide range of materials and produce complex formulations with consistent quality.

[0165] In one or more embodiments, the process is configured such that the thermoplastic prepreg material has a thickness of at least 0.2 mm, such as at least 0.3 mm, or such that the thermoplastic prepreg material has a thickness of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm. The thickness of the thermoplastic prepreg material is defined by the gap between the rolls after first and second extruder. Alternatively, or additionally, the thickness can be defined by the gap between the belt press unit.

[0166] In one or more embodiments, the one or more first and / or second rollers are at least two rollers positioned one on top of the other hereby crating a gap between them, wherein the natural fibre material with the resin layer is fed into the gap and pulled through the at least two rollers. The movement of the natural fibre material through the process will be supported by the rollers that will pull the prepreg material through the equipment. Additionally, a belt unit may be included, which will further assist in moving / pulling the material through the extrusion and into the rollers. Even further, the belt may be part of a belt press unit which additionally assist in this movement of material.

[0167] In one or more embodiments, the one or more first and / or second rollers are at least four rollers positioned in pairs parallel to each other, wherein the rollers in each pair are positioned one on top of the other hereby crating a gap between them, wherein the natural fibre material with the resin layer is fed into the gap and pulled through by rotation of the at least four rolls.

[0168] In one or more embodiments, the gap has a size of at least 0.2 mm, such as at least 0.3 mm, or such as a size of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm. In one or more embodiments, the third predetermined temperature is a temperature below 60 °C, such as below 55 °C, such as below 50 °C, such as below 40 °C, or such as below 30 °C. In one or more embodiments the third predetermined temperature is room temperature.

[0169] In one or more embodiments, the process further comprising a step of subjecting one or more of the intermediate products to ultra-sonic vibration. Ultra-sonic vibration refers to mechanical vibrations that occur at frequencies above the range of human hearing, typically above 20,000 hertz (Hz). These vibrations are produced by ultrasonic transducers, which convert electrical energy into high-frequency mechanical oscillations.

[0170] In one or more embodiments, the heated natural fibre material having a first resin layer is subjected to ultra-sonic vibration. In one or more embodiments, the heated intermediate prepreg material is subjected to ultra-sonic vibration. In one or more embodiments, the heated intermediate prepreg material having a second resin layer is subjected to ultra-sonic vibration. In one or more embodiments, the heated prepreg material is subjected to ultra-sonic vibration.

[0171] In one or more embodiments, the second side of the heated intermediate prepreg material is the side corresponding to the side opposite of the first side of the heated natural fibre material to which the first layer of the high viscosity thermoplastic biobased resin is applied. In one or more embodiments, the first side of the heated natural fibre material is the bottom side of the heated natural fibre material. In one or more embodiments, the second side of the heated intermediate prepreg material is the top side of the heated intermediate prepreg material.

[0172] In one or more embodiments, the cooling down process is a temperature drop zone. As disclosed herein "Temperature drop zone" refers to a specific area within the system or process where a significant decrease in temperature occurs.

[0173] In one or more embodiments, the natural fibre material is provided on a continues roll of natural fibre material.

[0174] As discussed herein the thermoplastic biobased resin has a high viscosity, where the term high viscosity relates to the flowability of the thermoplastic resin, or in other words, the viscosity refers to the resin’s resistance to flow. High viscosity indicates that the resin is thick and resistant to flowing easily, while low viscosity means the resin flow more readily. In other words, high viscosity thermoplastic resins are more resistant to deformation or movement under an applied force compared to low viscosity thermoplastic resins. The viscosity can also be defined by the units Pacal-seconds (Pa*S) or centipoise (cP). In one or more embodiments, the high viscosity thermoplastic biobased resin is a resin having a viscosity of at least 400 Pacal-seconds (Pa*S), such as at least at least 425 Pacal-seconds, such as at least 450 Pacal-seconds, or such as at least 475 Pacal-seconds. In one or more embodiments, the high viscosity thermoplastic biobased resin is a resin having a viscosity of at least 400.000 centipoise, such as at least at least 425.000 centipoise, such as at least 450.000 centipoise, or such as at least 475.000 centipoise.

[0175] Pascal-second (symbol: Pa s) is the SI unit of viscosity, equivalent to newton-second per square metre. It is sometimes referred to as the “poiseuille” (PI). One poise is exactly 0.1 Pa s. One poiseuille is 10 poise or 1000 cP, while 1 cP = 1 mPa s.

[0176] In one or more embodiments, the feeding unit is configured for providing the natural fibre material to the oven unit. In one or more embodiments, the oven unit is positioned downstream of the feeding unit.

[0177] In one or more embodiments, the oven unit is configured for drying the natural fibre material at a first predetermined temperature. In one or more embodiments, the first predetermined temperature is a temperature between 60 °C and 130 °C, such as between 70 °C and 120 °C, such as between 75 °C and 115 °C, or such as between 80 °C and 110 °C.

[0178] In one or more embodiments, the heating unit is positioned downstream of the oven unit. In one or more embodiments, the heating unit is configured for heating the natural fibre material to a second predetermined temperature. In one or more embodiments, the second predetermined temperature is a temperature between 130 °C and 210 °C, such as between 140 °C and 200 °C, such as between 150 °C and 190 °C, or such as between 160 °C and 180 °C.

[0179] In one or more embodiments, the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the first extruder apparatus. In one or more embodiments, the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the one or more first rollers. In one or more embodiments, the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the second extruder apparatus. In one or more embodiments, the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the one or more second rollers.

[0180] In one or more embodiments, the heating unit is configured to maintain the second predetermined temperature of: the natural fibre material at the first extruder apparatus; the natural fibre material at the one or more first rollers; the natural fibre material at the second extruder apparatus; and the natural fibre material at the one or more second rollers. In one or more embodiments, the first extruder apparatus is configured for providing a first layer of a high viscosity thermoplastic biobased resin to a first side of the natural fibre material. In one or more embodiments, the first extruder apparatus is positioned downstream of the oven unit.

[0181] In one or more embodiments, the one or more first rollers are positioned downstream of the first extruder apparatus. In one or more embodiments, the one or more first rollers are configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the natural fibre material comprising the first layer of a high viscosity thermoplastic biobased resin. In one or more embodiments, the applied pressure from the one or more first rollers is controlled using an air pressure, such as a pneumatic system.

[0182] In one or more embodiments, the second extruder apparatus is positioned downstream of the one or more first rollers. In one or more embodiments, the second extruder apparatus is configured for providing a second layer of a high viscosity thermoplastic biobased resin to a second side of the natural fibre material.

[0183] In one or more embodiments, the one or more second rollers are positioned downstream of the second extruder apparatus. In one or more embodiments, the one or more second rollers are configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the natural fibre material comprising the second layer of a high viscosity thermoplastic biobased resin. In one or more embodiments, the applied pressure from the one or more second rollers is controlled using an air pressure, such as a pneumatic system.

[0184] In one or more embodiments, the system further comprises a first cooling unit, wherein the first cooling unit is configured for cooling the natural fibre material to a third predetermined temperature. In one or more embodiments, the first cooling unit is positioned downstream of the one or more second rollers. In one or more embodiments, the third predetermined temperature is a temperature below 60 °C, such as below 55 °C, such as below 50 °C, such as below 40 °C, or such as below 30 °C.

[0185] In one or more embodiments, the system further comprises a second cooling unit, wherein the second cooling unit is configured for cooling the natural fibre material to a fourth predetermined temperature. In one or more embodiments, the second cooling unit is positioned downstream of the one or more second rollers and upstream of the first cooling unit. In one or more embodiments, the fourth predetermined temperature is a temperature between 90 °C and 130 °C, such as a temperature between 100 °C and 120 °C, such as a temperature around 110 °C.

[0186] In one or more embodiments, the system further comprises a double belt compression unit comprising an upper belt and a lower belt. As disclosed herein a double belt compression unit is a mechanical device. The unit comprises two parallel belts, often made of rubber or other suitable materials, which are positioned horizontally with a small gap between them. The material to be compressed, the natural fibre material with layers of resin, is fed into the gap between the belts. As the belts move, they compress the material between them, exerting pressure to form it into the desired shape.

[0187] The use of a double belt compression units offer several advantages for the manufacturing process, such as: precise control over the compression process, allowing to achieve consistent results in terms of product quality and characteristics; high Efficiency: as the unit can be operate at high speed, making it suitable for high-volume production; the process can be easily adjusted to accommodate different types of materials and product specifications, if a change is needed between natural fibre material or resin applied.

[0188] Further, the use of a double belt press unit allows for application of a gentler compression due to the design of the double belt system, which ensures that the material is compressed uniformly and without causing damage or degradation.

[0189] In one or more embodiments, the upper belt and / or the lower belt is a polytetrafluoroethylene belt.

[0190] Polytetrafluoroethylene (PTFE) is a synthetic fluoropolymer of tetrafluoroethylene and is a PFAS that has numerous applications. The commonly known brand name of PTFE-based composition is Teflon by Chemours, a spin-off from DuPont, which originally discovered the compound in 1938. Polytetrafluoroethylene is a fluorocarbon solid, as it is a high-molecular-weight polymer consisting wholly of carbon and fluorine. PTFE is hydrophobic: neither water nor water-containing substances wet PTFE, as fluorocarbons exhibit only small London dispersion forces due to the low electric polarizability of fluorine. PTFE has one of the lowest coefficients of friction of any solid.

[0191] In one or more embodiments, the system further comprises one or more massage rollers, wherein the one or more massage rollers are configured for applying a pressure to the first side and / or the second side of the natural fibre material downstream the first and / or second extruder apparatus. In one or more embodiments, the applied pressure from the one or more massage rollers is controlled using an air pressure, such as a pneumatic system. In one or more embodiments, the system is configured such that applying the pressure to the first side and / or the second side of the natural fibre material by means of one or more massage rollers is performed while subjecting the natural fibre material to the fourth predetermined temperature. In one or more embodiments, the system further comprises a drying unit positioned upstream of the first and / or second extruder apparatus. In one or more embodiments, the drying unit is configured for drying the high viscosity thermoplastic biobased resin prior to introducing the high viscosity thermoplastic biobased resin into the first and / or second extruder apparatus.

[0192] In one or more embodiments, the system further comprises an ultra-sonic vibrator. In one or more embodiments, the ultra-sonic vibrator is configured for subjecting the natural fibre material to ultra sonic vibration downstream of the first and / or second extruder apparatus. In one or more embodiments, the ultra-sonic vibrator is configured for subjecting the natural fibre material to ultra sonic vibration downstream of the one or more first and / or second rollers.

[0193] In one or more embodiments, the system further comprises a cutting unit. In one or more embodiments, the cutting unit is configured to cutting the thermoplastic prepreg material into sheets having a predetermined dimension. In one or more embodiments, the predetermined dimension is a dimension having a length of at least 800 mm, such as at least 900 mm, such as at least 1000 mm, such as at least 1100 mm, or such as a length of at least 1200 mm.

[0194] In one or more embodiments, the system further comprises a rolling unit. In one or more embodiments, the rolling unit is configured for rolling the thermoplastic prepreg material onto rolls.

[0195] In one or more embodiments, the feeding unit is configured to work with different amounts of rolls, such as having one roll, two rolls, and / or more than two rolls. The number of rolls being able to be attached to the feed unit may depend on the further process, where for the extrusion impregnation or powder it may preferable be one to two rolls of natural fiber material, but can also be two to ten rolls or more.

[0196] In one or more embodiments, the oven unit is a single single oven unit, wherein the oven unit is located after the feeding unit. This means down-stream the process compared to the feeding unit.

[0197] In one or more embodiments, the heating unit comprises multiple sub heating units, wherein the heating unit is configured to ensure that the overall impregnation process is performed at a suitable temperature. This can e.g. be that the heating unit ensures a correct temperature of the natural fiber material before the material comes into contact with the first layer of the extruded resins. Further or alternatively, the heating unit may ensure that the material of the process has the correct temperature prior to coming into contact with the material of the second extrusion process. It may additionally serve to heat the material to a suitable temperature, during one or more of the other steps that are performed during the process or to. In one or more embodiments, the system further comprises a compression zone, wherein the compression zone comprises one or more rollers and / or pressure plates configured to ensure a predefined thickness of the thermoplastic prepreg material by controlling the pressure applied to said material. In one or more embodiments, the compression zone comprises two to five rolls or plates. In one or more embodiments, the compression zone comprises more than five rolls or plates.

[0198] In one or more embodiments, the system further comprises a cooling zone. In one or more embodiments, the cooling zone is positioned after the compression zone. In one or more embodiments, the cooling zone is between two and four meters long. In one or more embodiments, the cooling zone is longer than four meters.

[0199] In one or more embodiments, the system further comprises one or more coils onto which the thermoplastic prepreg material is wound. The finish thermoplastic prepreg material (preferably when cooled down) may hereby be cut into sheets or winded unto coils.

[0200] When describing the embodiments, the combinations and permutations of all possible embodiments have not been explicitly described. Nevertheless, the mere fact that certain measures are recited in mutually different dependent claims or described in different embodiments does not indicate that a combination of these measures cannot be used to advantage. The present invention envisages all possible combinations and permutations of the described embodiments.

[0201] The invention will hereafter be described by way of the following non-limiting items.

[0202] 1 . A process for producing a thermoplastic prepreg material, the thermoplastic prepreg material being a fibre-reinforced polymer composite material comprising a polymer matrix and a natural fibre material, the thermoplastic prepreg material is produced from a high viscosity thermoplastic biobased resin and a natural fibre material, the process comprising the steps of:

[0203] • providing the natural fibre material;

[0204] • drying the natural fibre material in an oven unit at a first predetermined temperature, hereby obtaining a dried natural fibre material;

[0205] • heating the dried natural fibre material in a heating system to a second predetermined temperature, hereby obtaining a heated natural fibre material;

[0206] • maintaining the heated natural fibre material at the second predetermined temperature while providing a first layer of the high viscosity thermoplastic biobased resin to a first side of the heated natural fibre material, the first layer of high viscosity thermoplastic biobased resin being provided using a first extruder apparatus, hereby obtaining a heated natural fibre material having a first resin layer;

[0207] • maintaining the heated natural fibre material having a first resin layer at the second predetermined temperature while impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated natural fibre material having a first resin layer using one or more first rollers, hereby obtaining a heated intermediate prepreg material;

[0208] • maintaining the heated intermediate prepreg material at the second predetermined temperature while providing a second layer of high viscosity thermoplastic biobased resin to a second side of the heated intermediate prepreg material, the second layer of high viscosity thermoplastic biobased resin being provided using a second extruder apparatus, hereby obtaining a heated intermediate prepreg material having a second resin layer;

[0209] • maintaining the heated intermediate prepreg material having a second resin layer at the second predetermined temperature while impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated intermediate prepreg material having a second resin layer using one or more second rollers, hereby obtaining a heated prepreg material; and

[0210] • cooling the heated prepreg material to a third predetermined temperature during a cooling down process, hereby obtaining the thermoplastic prepreg material. The process for producing a thermoplastic prepreg material according to item 1 , wherein the applied pressure from the one or more first rollers and / or the one or more second rollers is controlled using an air pressure, such as a pneumatic system. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the first predetermined temperature is a temperature between 60 °C and 130 °C, such as between 70 °C and 120 °C, such as between 75 °C and 115 °C, or such as between 80 °C and 110 °C. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the second predetermined temperature is a temperature between 130 °C and 210 °C, such as between 140 °C and 200 °C, such as between 150 °C and 190 °C, or such as between 160 °C and 180 °C. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the process further comprises the step of subjecting the heated prepreg material to a fourth predetermined temperature prior to cooling the heated prepreg material to a third predetermined temperature, wherein the fourth predetermined temperature is a temperature between 90 °C and 130 °C, such as a temperature between 100 °C and 120 °C, such as a temperature around 110 °C. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the process further comprises the step of applying a pressure to the first side and / or the second side of the heated prepreg material by means of one or more massage rollers. The process for producing a thermoplastic prepreg material according to item 6, wherein the applied pressure from the one or more massage rollers is controlled using an air pressure, such as a pneumatic system. The process for producing a thermoplastic prepreg material according to any one of items 6-7, wherein the step of applying a pressure to the first side and / or the second side of the heated prepreg material by means of one or more massage rollers is performed while subjecting the heated prepreg material to the fourth predetermined temperature. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the first extruder apparatus applies 50% or more of the high viscosity thermoplastic biobased resin compared to the amount of high viscosity thermoplastic biobased resin in the thermoplastic prepreg material, and wherein the second extruder apparatus applies 50% or less of the high viscosity thermoplastic biobased resin compared to the amount of high viscosity thermoplastic biobased resin in the thermoplastic prepreg material. The process for producing a thermoplastic prepreg material according to item 9, wherein the first extruder apparatus applies between 50% and 75% of the high viscosity thermoplastic biobased resin compared to the amount of high viscosity thermoplastic biobased resin in the thermoplastic prepreg material. The process for producing a thermoplastic prepreg material according to any one or items 9-10, wherein the second extruder apparatus applies between 25% and 50% of the high viscosity thermoplastic biobased resin compared to the amount of high viscosity thermoplastic biobased resin in the thermoplastic prepreg material. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the first layer of high viscosity thermoplastic biobased resin is being provided using a first extruder apparatus having a first extruder process, the first extruder process having the following steps: • providing a first extruder apparatus;

[0211] • introducing the high viscosity thermoplastic biobased resin into the first extruder apparatus;

[0212] • subjecting the high viscosity thermoplastic biobased resin to controlled pressure and temperature within the first extruder apparatus; and

[0213] • extruding the high viscosity thermoplastic biobased resin through a die of predetermined shape, thereby forming a first layer of the high viscosity thermoplastic biobased resin to the first side of the heated natural fibre material.

[0214] 13. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the second layer of high viscosity thermoplastic biobased resin is being provided using a second extruder apparatus having a second extruder process, the second extruder process having the following steps:

[0215] • providing a second extruder apparatus;

[0216] • introducing the high viscosity thermoplastic biobased resin into the second extruder apparatus;

[0217] • subjecting the high viscosity thermoplastic biobased resin to controlled pressure and temperature within the second extruder apparatus; and

[0218] • extruding the high viscosity thermoplastic biobased resin through a die of predetermined shape, thereby forming a second layer of the high viscosity thermoplastic biobased resin to the second side of the heated intermediate prepreg material.

[0219] 14. The process for producing a thermoplastic prepreg material according to any one of items 12-13, further comprising the step of drying the high viscosity thermoplastic biobased resin prior to introducing the high viscosity thermoplastic biobased resin into the first and / or second extruder apparatus.

[0220] 15. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the ratio between the polymer matrix and the natural fibre material in the fibre-reinforced composite polymer is between 30:70 and 70:30 wt. / wt.%, such as between 40:60 and 60:40 wt. / wt.%, or such as between 45:55 and 55:45 wt. / wt.%.

[0221] 16. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the first and / or second extruder apparatus is a twin-screw extruder apparatus. 17. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the process is configured such that the thermoplastic prepreg material has a thickness of at least 0.2 mm, such as at least 0.3 mm, or such that the thermoplastic prepreg material has a thickness of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm.

[0222] 18. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the one or more first and / or second rollers are at least two rollers positioned one on top of the other hereby crating a gap between them, wherein the natural fibre material with the resin layer is fed into the gap and pulled through the at least two rollers.

[0223] 19. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the one or more first and / or second rollers are at least four rollers positioned in pairs parallel to each other, wherein the rollers in each pair are positioned one on top of the other hereby crating a gap between them, wherein the natural fibre material with the resin layer is fed into the gap and pulled through by rotation of the at least four rolls.

[0224] 20. The process for producing a thermoplastic prepreg material according to any one of items 18-19, wherein the gap has a size of at least 0.2 mm, such as at least 0.3 mm, or such as a size of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm.

[0225] 21 . The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the third predetermined temperature is a temperature below 60 °C, such as below 55 °C, such as below 50 °C, such as below 40 °C, or such as below 30 °C.

[0226] 22. The process for producing a thermoplastic prepreg material according to any one of the preceding items, further comprising a step of subjecting one or more of the intermediate products to ultra-sonic vibration.

[0227] 23. The process for producing a thermoplastic prepreg material according to item 21 , wherein the heated natural fibre material having a first resin layer is subjected to ultra-sonic vibration.

[0228] 24. The process for producing a thermoplastic prepreg material according to any one of items item 22-23, wherein the heated intermediate prepreg material is subjected to ultra-sonic vibration. 25. The process for producing a thermoplastic prepreg material according to any one of items item 22-24, wherein the heated intermediate prepreg material having a second resin layer is subjected to ultra-sonic vibration.

[0229] 26. The process for producing a thermoplastic prepreg material according to any one of items item 22-25, wherein the heated prepreg material is subjected to ultra-sonic vibration.

[0230] 27. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the second side of the heated intermediate prepreg material is the side corresponding to the side opposite of the first side of the heated natural fibre material to which the first layer of the high viscosity thermoplastic biobased resin is applied.

[0231] 28. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the first side of the heated natural fibre material is the bottom side of the heated natural fibre material.

[0232] 29. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the second side of the heated intermediate prepreg material is the top side of the heated intermediate prepreg material.

[0233] 30. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the process further comprises the step of cutting the thermoplastic prepreg material into sheets having a predetermined dimension.

[0234] 31 . The process for producing a thermoplastic prepreg material according to item 30, wherein the predetermined dimension is a dimension having a length of at least 800 mm, such as at least 900 mm, such as at least 1000 mm, such as at least 1100 mm, or such as a length of at least 1200 mm.

[0235] 32. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the process further comprises the step of rolling the thermoplastic prepreg material onto rolls.

[0236] 33. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the natural fibre material is provided having a width of at least 500 mm, such as at least 600 mm, such as at least 700 mm, such as at least 800 mm, such as at least 900 mm, or such as at least 1000 mm. 34. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the cooling down process is a temperature drop zone.

[0237] 35. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the natural fibre material is provided on a continues roll of natural fibre material.

[0238] 36. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the high viscosity thermoplastic biobased resin is selected from one or more bio-based and biodegradable resins, such that the thermoplastic prepreg material is a bio-based and biodegradable material.

[0239] 37. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the high viscosity thermoplastic biobased resin is based on plant triglycerides, such as a poly lactic acid resin.

[0240] 38. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the natural fibre material comprises a plurality of fibres, which are woven and / or bonded together.

[0241] 39. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the natural fibre material is selected from sisal, hemp, coconut, flax, jute, kenaf, bamboo, sphagnum, hay or combinations thereof.

[0242] 40. The process for producing a thermoplastic prepreg material according to item 39, wherein the natural fibre material at least comprises a flax material.

[0243] 41 . The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the natural fibre material has a fabric weight of at least 250 grams for every square meter of material, such as at least 300 grams for every square meter of material.

[0244] 42. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the natural fibre material has a fabric weight of less than or equal to 600 grams for every square meter of material, such as less than or equal to 500 grams for every square meter of material. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the diagonal lines in the natural fibre material cross at least two warp threads and two weft threads consecutively before moving on to a next set of two, such as the diagonal lines in the natural fibre material cross at least four warp threads and four weft threads consecutively before moving on to the next set of four. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the high viscosity thermoplastic biobased resin is a 100% biobased resin. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the high viscosity thermoplastic biobased resin is a resin having a viscosity of at least 400 Pacal-seconds (Pa*S), such as at least at least 425 Pacal- seconds, such as at least 450 Pacal-seconds, or such as at least 475 Pacal-seconds. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the high viscosity thermoplastic biobased resin is a resin having a viscosity of at least 400.000 centipoise, such as at least at least 425.000 centipoise, such as at least 450.000 centipoise, or such as at least 475.000 centipoise. A system for producing a thermoplastic prepreg material from a natural fibre material and a high viscosity thermoplastic biobased resin, the system comprising: a feeding unit; an oven unit; a heating unit; a first extruder apparatus; one or more first rollers; a second extruder apparatus; and one or more second rollers. The system for producing a thermoplastic prepreg material according to item 47, wherein the feeding unit is configured for providing the natural fibre material to the oven unit. The system for producing a thermoplastic prepreg material according to any one of items 47-48, wherein the oven unit is positioned downstream of the feeding unit. The system for producing a thermoplastic prepreg material according to any one of items 47-49, wherein the oven unit is configured for drying the natural fibre material at a first predetermined temperature. 51 . The system for producing a thermoplastic prepreg material according to item 50, wherein the first predetermined temperature is a temperature between 60 °C and 130 °C, such as between 70 °C and 120 °C, such as between 75 °C and 115 °C, or such as between 80 °C and 110 °C.

[0245] 52. The system for producing a thermoplastic prepreg material according to any one of items 47-51 , wherein the heating unit is positioned downstream of the oven unit.

[0246] 53. The system for producing a thermoplastic prepreg material according to any one of items 47-52, wherein the heating unit is configured for heating the natural fibre material to a second predetermined temperature.

[0247] 54. The system for producing a thermoplastic prepreg material according to item 53, wherein the second predetermined temperature is a temperature between 130 °C and 210 °C, such as between 140 °C and 200 °C, such as between 150 °C and 190 °C, or such as between 160 °C and 180 °C.

[0248] 55. The system for producing a thermoplastic prepreg material according to any one of items 53-54, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the first extruder apparatus.

[0249] 56. The system for producing a thermoplastic prepreg material according to any one of items 53-55, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the one or more first rollers.

[0250] 57. The system for producing a thermoplastic prepreg material according to any one of items 53-56, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the second extruder apparatus.

[0251] 58. The system for producing a thermoplastic prepreg material according to any one of items 53-57, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the one or more second rollers.

[0252] 59. The system for producing a thermoplastic prepreg material according to any one of items 47-58, wherein the first extruder apparatus is configured for providing a first layer of a high viscosity thermoplastic biobased resin to a first side of the natural fibre material. The system for producing a thermoplastic prepreg material according to any one of items 47-59, wherein the first extruder apparatus is positioned downstream of the oven unit. The system for producing a thermoplastic prepreg material according to any one of items 47-60, wherein the one or more first rollers are positioned downstream of the first extruder apparatus. The system for producing a thermoplastic prepreg material according to any one of items 47-61 , wherein the one or more first rollers are configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the natural fibre material comprising the first layer of a high viscosity thermoplastic biobased resin. The system for producing a thermoplastic prepreg material according to item 62, wherein the applied pressure from the one or more first rollers is controlled using an air pressure, such as a pneumatic system. The system for producing a thermoplastic prepreg material according to any one of items 47-63, wherein the second extruder apparatus is positioned downstream of the one or more first rollers. The system for producing a thermoplastic prepreg material according to any one of items 47-64, wherein the second extruder apparatus is configured for providing a second layer of a high viscosity thermoplastic biobased resin to a second side of the natural fibre material. The system for producing a thermoplastic prepreg material according to any one of items 47-65, wherein the one or more second rollers are positioned downstream of the second extruder apparatus. The system for producing a thermoplastic prepreg material according to any one of items 47-66, wherein the one or more second rollers are configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the natural fibre material comprising the second layer of a high viscosity thermoplastic biobased resin. The system for producing a thermoplastic prepreg material according to item 67, wherein the applied pressure from the one or more second rollers is controlled using an air pressure, such as a pneumatic system. 69. The system for producing a thermoplastic prepreg material according to any one of items 47-68, wherein the system further comprises a first cooling unit, wherein the first cooling unit is configured for cooling the natural fibre material to a third predetermined temperature.

[0253] 70. The system for producing a thermoplastic prepreg material according to item 69, wherein the third predetermined temperature is a temperature below 60 °C, such as below 55 °C, such as below 50 °C, such as below 40 °C, or such as below 30 °C.

[0254] 71. The system for producing a thermoplastic prepreg material according to any one of items 69-70, wherein the first cooling unit is positioned downstream of the one or more second rollers.

[0255] 72. The system for producing a thermoplastic prepreg material according to any one of items 47-71 , wherein the system further comprises a second cooling unit, wherein the second cooling unit is configured for cooling the natural fibre material to a fourth predetermined temperature.

[0256] 73. The system for producing a thermoplastic prepreg material according to item 72, wherein the second cooling unit is positioned downstream of the one or more second rollers and upstream of the first cooling unit.

[0257] 74. The system for producing a thermoplastic prepreg material according to any one of items 72-73, wherein the fourth predetermined temperature is a temperature between 90 °C and 130 °C, such as a temperature between 100 °C and 120 °C, such as a temperature around 110 °C.

[0258] 75. The system for producing a thermoplastic prepreg material according to any one of items 47-74, wherein the system further comprises a double belt compression unit comprising an upper belt and a lower belt.

[0259] 76. The system for producing a thermoplastic prepreg material according to item 75, wherein the upper belt and / or the lower belt is a polytetrafluoroethylene (PTFE) belt.

[0260] 77. The system for producing a thermoplastic prepreg material according to any one of items 47-76, wherein the system further comprises one or more massage rollers, wherein the one or more massage rollers are configured for applying a pressure to the first side and / or the second side of the natural fibre material downstream the first and / or second extruder apparatus. The system for producing a thermoplastic prepreg material according to item 77, wherein the applied pressure from the one or more massage rollers is controlled using an air pressure, such as a pneumatic system. The system for producing a thermoplastic prepreg material according to any one of items 77-78, wherein the system is configured such that applying the pressure to the first side and / or the second side of the natural fibre material by means of one or more massage rollers is performed while subjecting the natural fibre material to the fourth predetermined temperature. The system for producing a thermoplastic prepreg material according to any one of items 47-79, wherein the system further comprises a drying unit positioned upstream of the first and / or second extruder apparatus. The system for producing a thermoplastic prepreg material according to item 80, wherein the drying unit is configured for drying the high viscosity thermoplastic biobased resin prior to introducing the high viscosity thermoplastic biobased resin into the first and / or second extruder apparatus. The system for producing a thermoplastic prepreg material according to any one of items 47-81 , wherein the first and / or second extruder apparatus is a twin-screw extruder apparatus. The system for producing a thermoplastic prepreg material according to any one of items 47-82, wherein the one or more first and / or second rollers are at least two rollers positioned one on top of the other hereby crating a gap between them. The system for producing a thermoplastic prepreg material according to item 83, wherein the gap between the one or more first and / or second rollers are at a gap size of at least 0.2 mm, such as at least 0.3 mm, or such as a size of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm. The system for producing a thermoplastic prepreg material according to any one of items 47-84, wherein the one or more first and / or second rollers are at least four rollers positioned in pairs parallel to each other, wherein the rollers in each pair are positioned one on top of the other hereby crating a gap between them. 86. The system for producing a thermoplastic prepreg material according to item 85, wherein the gap has a size of at least 0.2 mm, such as at least 0.3 mm, or such as a size of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm.

[0261] 87. The system for producing a thermoplastic prepreg material according to any one of items 47-86, wherein the system further comprises an ultra-sonic vibrator.

[0262] 88. The system for producing a thermoplastic prepreg material according to item 87, wherein the ultra-sonic vibrator is configured for subjecting the natural fibre material to ultra sonic vibration downstream of the first and / or second extruder apparatus.

[0263] 89. The system for producing a thermoplastic prepreg material according to any one or items 87-88, wherein the ultra-sonic vibrator is configured for subjecting the natural fibre material to ultra sonic vibration downstream of the one or more first and / or second rollers.

[0264] 90. The system for producing a thermoplastic prepreg material according to any one of items 47-89, wherein the system further comprises a cutting unit.

[0265] 91 . The system for producing a thermoplastic prepreg material according to item 90, wherein the cutting unit is configured to cutting the thermoplastic prepreg material into sheets having a predetermined dimension.

[0266] 92. The system for producing a thermoplastic prepreg material according to item 91 , wherein the predetermined dimension is a dimension having a length of at least 800 mm, such as at least 900 mm, such as at least 1000 mm, such as at least 1100 mm, or such as a length of at least 1200 mm.

[0267] 93. The system for producing a thermoplastic prepreg material according to any one of items 47-92, wherein the system further comprises a rolling unit.

[0268] 94. The system for producing a thermoplastic prepreg material according to item 93, wherein the rolling unit is configured for rolling the thermoplastic prepreg material onto rolls.

[0269] 95. The system for producing a thermoplastic prepreg material according to any one of items 47-94, wherein the natural fibre material is provided having a width of at least 500 mm, such as at least 600 mm, such as at least 700 mm, such as at least 800 mm, such as at least 900 mm, or such as at least 1000 mm. The system for producing a thermoplastic prepreg material according to any one of items 47-95, wherein the high viscosity thermoplastic biobased resin is selected from one or more bio-based and biodegradable resins, such that the thermoplastic prepreg material is a bio-based and biodegradable material. The system for producing a thermoplastic prepreg material according to any one of items 47-96, wherein the high viscosity thermoplastic biobased resin is based on plant triglycerides, such as a poly lactic acid resin. The system for producing a thermoplastic prepreg material according to any one of items 47-97, wherein the natural fibre material comprises a plurality of fibres, which are woven and / or bonded together. The system for producing a thermoplastic prepreg material according to any one of items 47-98, wherein the natural fibre material is selected from sisal, hemp, coconut, flax, jute, kenaf, bamboo, sphagnum, hay or combinations thereof. . The system for producing a thermoplastic prepreg material according to item 99, wherein the natural fibre material at least comprises a flax material. . The system for producing a thermoplastic prepreg material according to any one of items 47-100, wherein the natural fibre material has a fabric weight of at least 250 grams for every square meter of material, such as at least 300 grams for every square meter of material. . The system for producing a thermoplastic prepreg material according to any one of items 47-101 , wherein the natural fibre material has a fabric weight of less than or equal to 600 grams for every square meter of material, such as less than or equal to 500 grams for every square meter of material. . The system for producing a thermoplastic prepreg material according to any one of items 47-102, wherein the diagonal lines in the natural fibre material cross at least two warp threads and two weft threads consecutively before moving on to a next set of two, such as the diagonal lines in the natural fibre material cross at least four warp threads and four weft threads consecutively before moving on to the next set of four. . The system for producing a thermoplastic prepreg material according to any one of items 47-103, wherein the high viscosity thermoplastic biobased resin is a 100% biobased resin. . The system for producing a thermoplastic prepreg material according to any one of items 47-104, wherein the high viscosity thermoplastic biobased resin is a resin having a viscosity of at least 400 Pacal-seconds (Pa*S), such as at least at least 425 Pacal- seconds, such as at least 450 Pacal-seconds, or such as at least 475 Pacal-seconds. . The system for producing a thermoplastic prepreg material according to any one of items 47-105, wherein the high viscosity thermoplastic biobased resin is a resin having a viscosity of at least 400.000 centipoise, such as at least at least 425.000 centipoise, such as at least 450.000 centipoise, or such as at least 475.000 centipoise. . A system for producing a thermoplastic prepreg material, the system comprising:

[0270] • a feeding unit configured for providing a natural fibre material;

[0271] • an oven unit configured for drying the provided natural fibre material at a first predetermined temperature, hereby obtaining a dried natural fibre material;

[0272] • a heating unit configured for heating the dried natural fibre material to a second predetermined temperature, hereby obtaining a heated natural fibre material;

[0273] • a first extruder apparatus configured for providing a first layer of a high viscosity thermoplastic biobased resin to a first side of the heated natural fibre material, hereby obtaining a heated natural fibre material having a first resin layer;

[0274] • one or more first rollers configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated natural fibre material having a first resin layer, hereby obtaining a heated intermediate prepreg material;

[0275] • a second extruder apparatus configured for providing a second layer of the high viscosity thermoplastic biobased resin to a second side of the heated intermediate prepreg material, hereby obtaining a heated intermediate prepreg material having a second resin layer;

[0276] • one or more second rollers configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated intermediate prepreg material having a second resin layer using, hereby obtaining a heated prepreg material; and

[0277] • a first cooling unit configured for cooling the heated prepreg material to a third predetermined temperature, hereby obtaining the thermoplastic prepreg material. . The system for producing a thermoplastic prepreg material according to item 107, wherein the feeding unit is configured for providing the natural fibre material to the oven unit. 109. The system for producing a thermoplastic prepreg material according to any one of items 107-108, wherein the oven unit is positioned downstream of the feeding unit.

[0278] 110. The system for producing a thermoplastic prepreg material according to any one of items 107-109, wherein the first predetermined temperature is a temperature between 60 °C and 130 °C, such as between 70 °C and 120 °C, such as between 75 °C and 115 °C, or such as between 80 °C and 110 °C.

[0279] 111. The system for producing a thermoplastic prepreg material according to any one of items 107-110, wherein the heating unit is positioned downstream of the oven unit.

[0280] 112. The system for producing a thermoplastic prepreg material according to any one of items 107-111 , wherein the second predetermined temperature is a temperature between 130 °C and 210 °C, such as between 140 °C and 200 °C, such as between 150 °C and 190 °C, or such as between 160 °C and 180 °C.

[0281] 113. The system for producing a thermoplastic prepreg material according to any one of items 107-112, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the first extruder apparatus.

[0282] 114. The system for producing a thermoplastic prepreg material according to any one of items 107-113, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the one or more first rollers.

[0283] 115. The system for producing a thermoplastic prepreg material according to any one of items 107-114, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the second extruder apparatus

[0284] 116. The system for producing a thermoplastic prepreg material according to any one of items 107-115, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the one or more second rollers.

[0285] 117. The system for producing a thermoplastic prepreg material according to any one of items 107-116, wherein the first extruder apparatus is positioned downstream of the oven unit.

[0286] 118. The system for producing a thermoplastic prepreg material according to any one of items 107-117, wherein the one or more first rollers are positioned downstream of the first extruder apparatus. . The system for producing a thermoplastic prepreg material according to any one of items 107-118, wherein the applied pressure from the one or more first rollers is controlled using an air pressure, such as a pneumatic system. . The system for producing a thermoplastic prepreg material according to any one of items 107-119, wherein the second extruder apparatus is positioned downstream of the one or more first rollers. . The system for producing a thermoplastic prepreg material according to any one of items 107-120, wherein the one or more second rollers are positioned downstream of the second extruder apparatus. . The system for producing a thermoplastic prepreg material according to any one of items 107-121 , wherein the applied pressure from the one or more second rollers is controlled using an air pressure, such as a pneumatic system. . The system for producing a thermoplastic prepreg material according to any one of items 107-122, wherein the third predetermined temperature is a temperature below 60 °C, such as below 55 °C, such as below 50 °C, such as below 40 °C, or such as below 30 °C. . The system for producing a thermoplastic prepreg material according to any one of items 107-123, wherein the first cooling unit is positioned downstream of the one or more second rollers. . The system for producing a thermoplastic prepreg material according to any one of items 107-124, wherein the system further comprises a second cooling unit, wherein the second cooling unit is configured for cooling the natural fibre material to a fourth predetermined temperature. . The system for producing a thermoplastic prepreg material according to item 125, wherein the second cooling unit is positioned downstream of the one or more second rollers and upstream of the first cooling unit. . The system for producing a thermoplastic prepreg material according to any one of items 125-126, wherein the fourth predetermined temperature is a temperature between 90 °C and 130 °C, such as a temperature between 100 °C and 120 °C, such as a temperature around 110 °C. 128. The system for producing a thermoplastic prepreg material according to any one of items 107-127, wherein the system further comprises a double belt compression unit comprising an upper belt and a lower belt.

[0287] 129. The system for producing a thermoplastic prepreg material according to item 128, wherein the upper belt and / or the lower belt is a polytetrafluoroethylene (PTFE) belt.

[0288] 130. The system for producing a thermoplastic prepreg material according to any one of items 107-129, wherein the system further comprises one or more massage rollers, wherein the one or more massage rollers are configured for applying a pressure to the first side and / or the second side of the natural fibre material downstream the first and / or second extruder apparatus.

[0289] 131 . The system for producing a thermoplastic prepreg material according to item 130, wherein the applied pressure from the one or more massage rollers is controlled using an air pressure, such as a pneumatic system.

[0290] 132. The system for producing a thermoplastic prepreg material according to any one of items 130-131 , wherein the system is configured such that applying the pressure to the first side and / or the second side of the natural fibre material by means of one or more massage rollers is performed while subjecting the natural fibre material to the fourth predetermined temperature.

[0291] 133. The system for producing a thermoplastic prepreg material according to any one of items 107-132, wherein the system further comprises a drying unit positioned upstream of the first and / or second extruder apparatus.

[0292] 134. The system for producing a thermoplastic prepreg material according to item 133, wherein the drying unit is configured for drying the high viscosity thermoplastic biobased resin prior to introducing the high viscosity thermoplastic biobased resin into the first and / or second extruder apparatus.

[0293] 135. The system for producing a thermoplastic prepreg material according to any one of items 107-134, wherein the first and / or second extruder apparatus is a twin-screw extruder apparatus. 136. The system for producing a thermoplastic prepreg material according to any one of items 107-135, wherein the one or more first and / or second rollers are at least two rollers positioned one on top of the other hereby crating a gap between them.

[0294] 137. The system for producing a thermoplastic prepreg material according to item 136, wherein the gap between the one or more first and / or second rollers are at a gap size of at least 0.2 mm, such as at least 0.3 mm, or such as a size of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm.

[0295] 138. The system for producing a thermoplastic prepreg material according to any one of items 107-137, wherein the one or more first and / or second rollers are at least four rollers positioned in pairs parallel to each other, wherein the rollers in each pair are positioned one on top of the other hereby crating a gap between them.

[0296] 139. The system for producing a thermoplastic prepreg material according to item 138, wherein the gap has a size of at least 0.2 mm, such as at least 0.3 mm, or such as a size of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm.

[0297] 140. The system for producing a thermoplastic prepreg material according to any one of items 107-139, wherein the system further comprises an ultra-sonic vibrator.

[0298] 141 . The system for producing a thermoplastic prepreg material according to item 140, wherein the ultra-sonic vibrator is configured for subjecting the natural fibre material to ultra sonic vibration downstream of the first and / or second extruder apparatus.

[0299] 142. The system for producing a thermoplastic prepreg material according to any one or items 140-141 , wherein the ultra-sonic vibrator is configured for subjecting the natural fibre material to ultra sonic vibration downstream of the one or more first and / or second rollers.

[0300] 143. The system for producing a thermoplastic prepreg material according to any one of items 107-142, wherein the system further comprises a cutting unit.

[0301] 144. The system for producing a thermoplastic prepreg material according to item 143, wherein the cutting unit is configured to cutting the thermoplastic prepreg material into sheets having a predetermined dimension.

[0302] 145. The system for producing a thermoplastic prepreg material according to item 144, wherein the predetermined dimension is a dimension having a length of at least 800 mm, such as at least 900 mm, such as at least 1000 mm, such as at least 1100 mm, or such as a length of at least 1200 mm.

[0303] 146. The system for producing a thermoplastic prepreg material according to any one of items 107-145, wherein the system further comprises a rolling unit.

[0304] 147. The system for producing a thermoplastic prepreg material according to item 146, wherein the rolling unit is configured for rolling the thermoplastic prepreg material onto rolls.

[0305] 148. The system for producing a thermoplastic prepreg material according to any one of items 107-147, wherein the natural fibre material is provided having a width of at least 500 mm, such as at least 600 mm, such as at least 700 mm, such as at least 800 mm, such as at least 900 mm, or such as at least 1000 mm.

[0306] 149. The system for producing a thermoplastic prepreg material according to any one of items 107-148, wherein the high viscosity thermoplastic biobased resin is selected from one or more bio-based and biodegradable resins, such that the thermoplastic prepreg material is a bio-based and biodegradable material.

[0307] 150. The system for producing a thermoplastic prepreg material according to any one of items 107-149, wherein the high viscosity thermoplastic biobased resin is based on plant triglycerides, such as a poly lactic acid resin.

[0308] 151 . The system for producing a thermoplastic prepreg material according to any one of items 107-150, wherein the natural fibre material comprises a plurality of fibres, which are woven and / or bonded together.

[0309] 152. The system for producing a thermoplastic prepreg material according to any one of items 107-151 , wherein the natural fibre material is selected from sisal, hemp, coconut, flax, jute, kenaf, bamboo, sphagnum, hay or combinations thereof.

[0310] 153. The system for producing a thermoplastic prepreg material according to item 152, wherein the natural fibre material at least comprises a flax material.

[0311] 154. The system for producing a thermoplastic prepreg material according to any one of items 107-153, wherein the natural fibre material has a fabric weight of at least 250 grams for every square meter of material, such as at least 300 grams for every square meter of material. 155. The system for producing a thermoplastic prepreg material according to any one of items 107-154, wherein the natural fibre material has a fabric weight of less than or equal to 600 grams for every square meter of material, such as less than or equal to 500 grams for every square meter of material.

[0312] 156. The system for producing a thermoplastic prepreg material according to any one of items 107-155, wherein the diagonal lines in the natural fibre material cross at least two warp threads and two weft threads consecutively before moving on to a next set of two, such as the diagonal lines in the natural fibre material cross at least four warp threads and four weft threads consecutively before moving on to the next set of four.

[0313] 157. The system for producing a thermoplastic prepreg material according to any one of items 107-156, wherein the high viscosity thermoplastic biobased resin is a 100% biobased resin.

[0314] 158. The system for producing a thermoplastic prepreg material according to any one of items 107-157, wherein the high viscosity thermoplastic biobased resin is a resin having a viscosity of at least 400 Pacal-seconds (Pa*S), such as at least at least 425 Pacal- seconds, such as at least 450 Pacal-seconds, or such as at least 475 Pacal-seconds.

[0315] 159. The system for producing a thermoplastic prepreg material according to any one of items 107-158, wherein the high viscosity thermoplastic biobased resin is a resin having a viscosity of at least 400.000 centipoise, such as at least at least 425.000 centipoise, such as at least 450.000 centipoise, or such as at least 475.000 centipoise.

[0316] The following is an itemized list of further, preferred embodiments according to the invention:

[0317] Item 2.1 . A process for producing a thermoplastic prepreg material, the thermoplastic prepreg material being a fibre-reinforced polymer composite material comprising a polymer matrix and a natural fibre material, the thermoplastic prepreg material is produced from a high viscosity thermoplastic biobased resin and a natural fibre material, the process comprising the steps of:

[0318] • providing the natural fibre material;

[0319] • drying the natural fibre material in an oven unit at a first predetermined temperature, hereby obtaining a dried natural fibre material;

[0320] • heating the dried natural fibre material in a heating system to a second predetermined temperature, hereby obtaining a heated natural fibre material;

[0321] • maintaining the heated natural fibre material at the second predetermined temperature while providing a first layer of the high viscosity thermoplastic biobased resin to a first side of the heated natural fibre material, the first layer of high viscosity thermoplastic biobased resin being provided using a first extruder apparatus, hereby obtaining a heated natural fibre material having a first resin layer;

[0322] • maintaining the heated natural fibre material having a first resin layer at the second predetermined temperature while impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated natural fibre material having a first resin layer using one or more first rollers, hereby obtaining a heated intermediate prepreg material;

[0323] • maintaining the heated intermediate prepreg material at the second predetermined temperature while providing a second layer of high viscosity thermoplastic biobased resin to a second side of the heated intermediate prepreg material, the second layer of high viscosity thermoplastic biobased resin being provided using a second extruder apparatus, hereby obtaining a heated intermediate prepreg material having a second resin layer;

[0324] • maintaining the heated intermediate prepreg material having a second resin layer at the second predetermined temperature while impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated intermediate prepreg material having a second resin layer using one or more second rollers, hereby obtaining a heated prepreg material; and

[0325] • cooling the heated prepreg material to a third predetermined temperature during a cooling down process, hereby obtaining the thermoplastic prepreg material.

[0326] Item 2.2. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the process further comprises the step of applying a pressure to the first side and / or the second side of the heated prepreg material by means of one or more massage rollers.

[0327] Item 2.3. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the ratio between the polymer matrix and the natural fibre material in the fibre-reinforced composite polymer is between 30:70 and 70:30 wt. / wt.%, such as between 40:60 and 60:40 wt. / wt.%, or such as between 45:55 and 55:45 wt. / wt.%.

[0328] Item 2.4. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the one or more first and / or second rollers are at least four rollers positioned in pairs parallel to each other, wherein the rollers in each pair are positioned one on top of the other hereby crating a gap between them, wherein the natural fibre material with the resin layer is fed into the gap and pulled through by rotation of the at least four rolls.

[0329] Item 2.5. The process for producing a thermoplastic prepreg material according to any one of items 18-19, wherein the gap has a size of at least 0.2 mm, such as at least 0.3 mm, or such as a size of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm.

[0330] Item 2.6. The process for producing a thermoplastic prepreg material according to any one of the preceding items, further comprising a step of subjecting one or more of the intermediate products to ultra-sonic vibration.

[0331] Item 2.7. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the process further comprises the step of cutting the thermoplastic prepreg material into sheets having a predetermined dimension.

[0332] Item 2.8. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the process further comprises the step of rolling the thermoplastic prepreg material onto rolls.

[0333] Item 2.9. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the high viscosity thermoplastic biobased resin is selected from one or more bio-based and biodegradable resins, such that the thermoplastic prepreg material is a bio-based and biodegradable material.

[0334] Item 2.10. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the natural fibre material is selected from sisal, hemp, coconut, flax, jute, kenaf, bamboo, sphagnum, hay or combinations thereof.

[0335] Item 2.11 . The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the high viscosity thermoplastic biobased resin is a 100% biobased resin.

[0336] Item 2.12. The process for producing a thermoplastic prepreg material according to any one of the preceding items, wherein the high viscosity thermoplastic biobased resin is a resin having a viscosity of at least 400 Pacal-seconds (Pa*S), such as at least at least 425 Pacal-seconds, such as at least 450 Pacal-seconds, or such as at least 475 Pacal- seconds. Item 2.13. A system for producing a thermoplastic prepreg material from a natural fibre material and a high viscosity thermoplastic biobased resin, the system comprising: a feeding unit; an oven unit; a heating unit; a first extruder apparatus; one or more first rollers; a second extruder apparatus; and one or more second rollers.

[0337] Item 2.14. The system for producing a thermoplastic prepreg material according to item

[0338] 2.13, wherein:

[0339] • the feeding unit is configured for providing a natural fibre material;

[0340] • the oven unit is configured for drying the provided natural fibre material at a first predetermined temperature, hereby obtaining a dried natural fibre material;

[0341] • the heating unit is configured for heating the dried natural fibre material to a second predetermined temperature, hereby obtaining a heated natural fibre material;

[0342] • the first extruder apparatus is configured for providing a first layer of a high viscosity thermoplastic biobased resin to a first side of the heated natural fibre material, hereby obtaining a heated natural fibre material having a first resin layer;

[0343] • the one or more first rollers are configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated natural fibre material having a first resin layer, hereby obtaining a heated intermediate prepreg material;

[0344] • the second extruder apparatus is configured for providing a second layer of the high viscosity thermoplastic biobased resin to a second side of the heated intermediate prepreg material, hereby obtaining a heated intermediate prepreg material having a second resin layer; and

[0345] • the one or more second rollers are configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated intermediate prepreg material having a second resin layer using, hereby obtaining a heated prepreg material.

[0346] Item 2.15. The system for producing a thermoplastic prepreg material according to any one of items 2.13-2.14, wherein the system further comprises a double belt compression unit comprising an upper belt and a lower belt. The present disclosure will now be described with reference to the accompanying drawings, in which preferred example embodiments of the disclosure are shown. The disclosure may, however, be embodied in other forms and should not be construed as limited to the herein disclosed embodiments. The disclosed embodiments are provided to fully convey the scope of the disclosure to the skilled person.

[0347] Detailed description of the drawings

[0348] Various examples are described hereinafter with reference to the figures. It should also be noted that the figures are only intended to facilitate the description of the examples. They are not intended as an exhaustive description of the claimed invention or as a limitation on the scope of the claimed invention. In addition, an illustrated example needs not have all the aspects or advantages shown. An aspect or an advantage described in conjunction with a particular example is not necessarily limited to that example and can be practiced in any other examples even if not so illustrated, or if not so explicitly described.

[0349] Figure 1 shows one embodiment of the disclosure herein. In this embodiment, a natural fibre material is provided on a roll 1 . The natural fibre material is feed from the roll 1 into an oven unit 2, hereby being dried at a specific temperature set by the system in accordance with the fibre material and potentially the amount of water in said material. A dried natural fibre material is then exiting the oven unit 2. In this embodiment, the dried natural fibre material is then being pulled by a spindle 3, however this may be omitted or additional spindles 3 may be added, depending on the position of the oven unit 2 on the process line.

[0350] The dried fibre material is then entering the heating system 4, comprised in this embodiment of multiple sub units. The dried fibre material is in this embodiment then pulled down by another spindle 3 down onto a PTFE belt 5. On or at the PTFE belt 5 an extruder 6 is providing a first layer of the high viscosity thermoplastic biobased resin to a first side of the heated natural fibre material. This means that the resin will be impregnated in to the fibre material by being extrude into the fibre material. Then the material goes through a heating zone to ensure good impregnation ability. In the heating zone, i.e. after the extruder 6 has applied a layer of the biobased resin, the fibre material including the resin on the PTFE belt 5 is in this embodiment being subjected to multiple rollers 7 (or pressure plates) that are applying a pressure to the resin and fibre material.

[0351] Further, in the embodiment of figure 1 , in the heating zone, ultra sonic vibration 8 is also applied to the material after it has entered through the multiple rollers. The ultra sonic vibration 8 may also be applied at other positions, or omitted entirely. After passing through another sub unit of the heating unit 4 another extruder 6 is applying a second layer of high viscosity thermoplastic biobased resin to a second side of the heated intermediate prepreg material. The fibre material, now having two layers of resin applied, is entering a double belted press, made of the PTFE belt 5 the material is already on, on another PTFE belt 5 on top of the material.

[0352] In this embodiment, the material then is subjected to another round of multiple rollers 7 (or pressure plates) that are applying a pressure to the resin and fibre material. Afterwards multiple massage rollers 9 are applying a pressure onto the fibre material while the fibre material is being pressured in the double belted press by the two PTFE belts 5.

[0353] After being subjected to the massage rollers 9, the material is being (optional) pulled through by one or more spindles prior to being cooled down in a cooling down process, here shown as a cooling unit 10. After cooling the thermoplastic prepreg material is obtained, which can then be rolled onto rolls or cut into sheets of thermoplastic prepreg material 11 , using a cutting unit 12.

[0354] The shown embodiment further comprises one or more means for controlling tension 13 of the PTFE belts 5, here shown as a spring type device.

[0355] References

[0356] 1 - Roll with natural fibre material

[0357] 2 - Oven unit

[0358] 3 - Spindle

[0359] 4 - Heating system

[0360] 5 - PTFE belt

[0361] 6 - Extruder

[0362] 7 - Rollers

[0363] 8 - Ultra sonic vibration

[0364] 9 - Massage roller

[0365] 10 - Cooling unit

[0366] 11 - Sheet of thermoplastic prepreg material

[0367] 12 - Cutting unit

[0368] 13 - Means for controlling tension

Claims

Claims1 . A process for producing a thermoplastic prepreg material, the thermoplastic prepreg material being a fibre-reinforced polymer composite material comprising a polymer matrix and a natural fibre material, the thermoplastic prepreg material is produced from a high viscosity thermoplastic biobased resin and a natural fibre material, the process comprising the steps of:• providing the natural fibre material;• drying the natural fibre material in an oven unit at a first predetermined temperature, hereby obtaining a dried natural fibre material;• heating the dried natural fibre material in a heating system to a second predetermined temperature, hereby obtaining a heated natural fibre material;• maintaining the heated natural fibre material at the second predetermined temperature while providing a first layer of the high viscosity thermoplastic biobased resin to a first side of the heated natural fibre material, the first layer of high viscosity thermoplastic biobased resin being provided using a first extruder apparatus, hereby obtaining a heated natural fibre material having a first resin layer;• maintaining the heated natural fibre material having a first resin layer at the second predetermined temperature while impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated natural fibre material having a first resin layer using one or more first rollers, hereby obtaining a heated intermediate prepreg material;• maintaining the heated intermediate prepreg material at the second predetermined temperature while providing a second layer of high viscosity thermoplastic biobased resin to a second side of the heated intermediate prepreg material, the second layer of high viscosity thermoplastic biobased resin being provided using a second extruder apparatus, hereby obtaining a heated intermediate prepreg material having a second resin layer;• maintaining the heated intermediate prepreg material having a second resin layer at the second predetermined temperature while impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated intermediate prepreg material having a second resin layer using one or more second rollers, hereby obtaining a heated prepreg material; and• cooling the heated prepreg material to a third predetermined temperature during a cooling down process, hereby obtaining the thermoplastic prepreg material.

2. The process for producing a thermoplastic prepreg material according to claim 1 , wherein the applied pressure from the one or more first rollers and / or the one or more second rollers is controlled using an air pressure, such as a pneumatic system.

3. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the first predetermined temperature is a temperature between 60 °C and 130 °C, such as between 70 °C and 120 °C, such as between 75 °C and 115 °C, or such as between 80 °C and 110 °C.

4. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the second predetermined temperature is a temperature between 130 °C and 210 °C, such as between 140 °C and 200 °C, such as between 150 °C and 190 °C, or such as between 160 °C and 180 °C.

5. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the process further comprises the step of subjecting the heated prepreg material to a fourth predetermined temperature prior to cooling the heated prepreg material to a third predetermined temperature, wherein the fourth predetermined temperature is a temperature between 90 °C and 130 °C, such as a temperature between 100 °C and 120 °C, such as a temperature around 110 °C.

6. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the process further comprises the step of applying a pressure to the first side and / or the second side of the heated prepreg material by means of one or more massage rollers.

7. The process for producing a thermoplastic prepreg material according to claim 6, wherein the applied pressure from the one or more massage rollers is controlled using an air pressure, such as a pneumatic system.

8. The process for producing a thermoplastic prepreg material according to any one of claims 6-7, wherein the step of applying a pressure to the first side and / or the second side of the heated prepreg material by means of one or more massage rollers is performed while subjecting the heated prepreg material to the fourth predetermined temperature.

9. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the first extruder apparatus applies 50% or more of the high viscosity thermoplastic biobased resin compared to the amount of high viscositythermoplastic biobased resin in the thermoplastic prepreg material, and wherein the second extruder apparatus applies 50% or less of the high viscosity thermoplastic biobased resin compared to the amount of high viscosity thermoplastic biobased resin in the thermoplastic prepreg material.

10. The process for producing a thermoplastic prepreg material according to claim 9, wherein the first extruder apparatus applies between 50% and 75% of the high viscosity thermoplastic biobased resin compared to the amount of high viscosity thermoplastic biobased resin in the thermoplastic prepreg material.11 . The process for producing a thermoplastic prepreg material according to any one or claims 9-10, wherein the second extruder apparatus applies between 25% and 50% of the high viscosity thermoplastic biobased resin compared to the amount of high viscosity thermoplastic biobased resin in the thermoplastic prepreg material.

12. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the first layer of high viscosity thermoplastic biobased resin is being provided using a first extruder apparatus having a first extruder process, the first extruder process having the following steps:• providing a first extruder apparatus;• introducing the high viscosity thermoplastic biobased resin into the first extruder apparatus;• subjecting the high viscosity thermoplastic biobased resin to controlled pressure and temperature within the first extruder apparatus; and• extruding the high viscosity thermoplastic biobased resin through a die of predetermined shape, thereby forming a first layer of the high viscosity thermoplastic biobased resin to the first side of the heated natural fibre material.

13. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the second layer of high viscosity thermoplastic biobased resin is being provided using a second extruder apparatus having a second extruder process, the second extruder process having the following steps:• providing a second extruder apparatus;• introducing the high viscosity thermoplastic biobased resin into the second extruder apparatus;• subjecting the high viscosity thermoplastic biobased resin to controlled pressure and temperature within the second extruder apparatus; and• extruding the high viscosity thermoplastic biobased resin through a die of predetermined shape, thereby forming a second layer of the high viscositythermoplastic biobased resin to the second side of the heated intermediate prepreg material.

14. The process for producing a thermoplastic prepreg material according to any one of claims 12-13, further comprising the step of drying the high viscosity thermoplastic biobased resin prior to introducing the high viscosity thermoplastic biobased resin into the first and / or second extruder apparatus.

15. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the ratio between the polymer matrix and the natural fibre material in the fibre-reinforced composite polymer is between 30:70 and 70:30 wt. / wt.%, such as between 40:60 and 60:40 wt. / wt.%, or such as between 45:55 and 55:45 wt. / wt.%.

16. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the first and / or second extruder apparatus is a twin-screw extruder apparatus.

17. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the process is configured such that the thermoplastic prepreg material has a thickness of at least 0.2 mm, such as at least 0.3 mm, or such that the thermoplastic prepreg material has a thickness of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm.

18. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the one or more first and / or second rollers are at least two rollers positioned one on top of the other hereby crating a gap between them, wherein the natural fibre material with the resin layer is fed into the gap and pulled through the at least two rollers.

19. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the one or more first and / or second rollers are at least four rollers positioned in pairs parallel to each other, wherein the rollers in each pair are positioned one on top of the other hereby crating a gap between them, wherein the natural fibre material with the resin layer is fed into the gap and pulled through by rotation of the at least four rolls.

20. The process for producing a thermoplastic prepreg material according to any one of claims 18-19, wherein the gap has a size of at least 0.2 mm, such as at least 0.3 mm, or such as a size of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm.21 . The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the third predetermined temperature is a temperature below 60 °C, such as below 55 °C, such as below 50 °C, such as below 40 °C, or such as below 30 °C.

22. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, further comprising a step of subjecting one or more of the intermediate products to ultra-sonic vibration.

23. The process for producing a thermoplastic prepreg material according to claim 21 , wherein the heated natural fibre material having a first resin layer is subjected to ultrasonic vibration.

24. The process for producing a thermoplastic prepreg material according to any one of claims claim 22-23, wherein the heated intermediate prepreg material is subjected to ultra-sonic vibration.

25. The process for producing a thermoplastic prepreg material according to any one of claims claim 22-24, wherein the heated intermediate prepreg material having a second resin layer is subjected to ultra-sonic vibration.

26. The process for producing a thermoplastic prepreg material according to any one of claims claim 22-25, wherein the heated prepreg material is subjected to ultra-sonic vibration.

27. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the second side of the heated intermediate prepreg material is the side corresponding to the side opposite of the first side of the heated natural fibre material to which the first layer of the high viscosity thermoplastic biobased resin is applied.

28. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the first side of the heated natural fibre material is the bottom side of the heated natural fibre material.

29. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the second side of the heated intermediate prepreg material is the top side of the heated intermediate prepreg material.

30. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the process further comprises the step of cutting the thermoplastic prepreg material into sheets having a predetermined dimension.31 . The process for producing a thermoplastic prepreg material according to claim 30, wherein the predetermined dimension is a dimension having a length of at least 800 mm, such as at least 900 mm, such as at least 1000 mm, such as at least 1100 mm, or such as a length of at least 1200 mm.

32. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the process further comprises the step of rolling the thermoplastic prepreg material onto rolls.

33. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the natural fibre material is provided having a width of at least 500 mm, such as at least 600 mm, such as at least 700 mm, such as at least 800 mm, such as at least 900 mm, or such as at least 1000 mm.

34. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the cooling down process is a temperature drop zone.

35. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the natural fibre material is provided on a continues roll of natural fibre material.

36. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the high viscosity thermoplastic biobased resin is selected from one or more bio-based and biodegradable resins, such that the thermoplastic prepreg material is a bio-based and biodegradable material.

37. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the high viscosity thermoplastic biobased resin is based on plant triglycerides, such as a poly lactic acid resin.

38. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the natural fibre material comprises a plurality of fibres, which are woven and / or bonded together.

39. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the natural fibre material is selected from sisal, hemp, coconut, flax, jute, kenaf, bamboo, sphagnum, hay or combinations thereof.

40. The process for producing a thermoplastic prepreg material according to claim 39, wherein the natural fibre material at least comprises a flax material.41 . The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the natural fibre material has a fabric weight of at least 250 grams for every square meter of material, such as at least 300 grams for every square meter of material.

42. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the natural fibre material has a fabric weight of less than or equal to 600 grams for every square meter of material, such as less than or equal to 500 grams for every square meter of material.

43. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the diagonal lines in the natural fibre material cross at least two warp threads and two weft threads consecutively before moving on to a next set of two, such as the diagonal lines in the natural fibre material cross at least four warp threads and four weft threads consecutively before moving on to the next set of four.

44. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the high viscosity thermoplastic biobased resin is a 100% biobased resin.

45. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the high viscosity thermoplastic biobased resin is a resin having a viscosity of at least 400 Pacal-seconds (Pa*S), such as at least at least 425 Pacal-seconds, such as at least 450 Pacal-seconds, or such as at least 475 Pacal- seconds.

46. The process for producing a thermoplastic prepreg material according to any one of the preceding claims, wherein the high viscosity thermoplastic biobased resin is a resinhaving a viscosity of at least 400.000 centipoise, such as at least at least 425.000 centipoise, such as at least 450.000 centipoise, or such as at least 475.000 centipoise.

47. A system for producing a thermoplastic prepreg material from a natural fibre material and a high viscosity thermoplastic biobased resin, the system comprising: a feeding unit; an oven unit; a heating unit; a first extruder apparatus; one or more first rollers; a second extruder apparatus; and one or more second rollers.

48. The system for producing a thermoplastic prepreg material according to claim 47, wherein the feeding unit is configured for providing the natural fibre material to the oven unit.

49. The system for producing a thermoplastic prepreg material according to any one of claims 47-48, wherein the oven unit is positioned downstream of the feeding unit.

50. The system for producing a thermoplastic prepreg material according to any one of claims 47-49, wherein the oven unit is configured for drying the natural fibre material at a first predetermined temperature.51 . The system for producing a thermoplastic prepreg material according to claim 50, wherein the first predetermined temperature is a temperature between 60 °C and 130 °C, such as between 70 °C and 120 °C, such as between 75 °C and 115 °C, or such as between 80 °C and 110 °C.

52. The system for producing a thermoplastic prepreg material according to any one of claims 47-51 , wherein the heating unit is positioned downstream of the oven unit.

53. The system for producing a thermoplastic prepreg material according to any one of claims 47-52, wherein the heating unit is configured for heating the natural fibre material to a second predetermined temperature.

54. The system for producing a thermoplastic prepreg material according to claim 53, wherein the second predetermined temperature is a temperature between 130 °C and210 °C, such as between 140 °C and 200 °C, such as between 150 °C and 190 °C, or such as between 160 °C and 180 °C.

55. The system for producing a thermoplastic prepreg material according to any one of claims 53-54, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the first extruder apparatus.

56. The system for producing a thermoplastic prepreg material according to any one of claims 53-55, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the one or more first rollers.

57. The system for producing a thermoplastic prepreg material according to any one of claims 53-56, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the second extruder apparatus.

58. The system for producing a thermoplastic prepreg material according to any one of claims 53-57, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the one or more second rollers.

59. The system for producing a thermoplastic prepreg material according to any one of claims 47-58, wherein the first extruder apparatus is configured for providing a first layer of a high viscosity thermoplastic biobased resin to a first side of the natural fibre material.

60. The system for producing a thermoplastic prepreg material according to any one of claims 47-59, wherein the first extruder apparatus is positioned downstream of the oven unit.61 . The system for producing a thermoplastic prepreg material according to any one of claims 47-60, wherein the one or more first rollers are positioned downstream of the first extruder apparatus.

62. The system for producing a thermoplastic prepreg material according to any one of claims 47-61 , wherein the one or more first rollers are configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the natural fibre material comprising the first layer of a high viscosity thermoplastic biobased resin.

63. The system for producing a thermoplastic prepreg material according to claim 62, wherein the applied pressure from the one or more first rollers is controlled using an air pressure, such as a pneumatic system.

64. The system for producing a thermoplastic prepreg material according to any one of claims 47-63, wherein the second extruder apparatus is positioned downstream of the one or more first rollers.

65. The system for producing a thermoplastic prepreg material according to any one of claims 47-64, wherein the second extruder apparatus is configured for providing a second layer of a high viscosity thermoplastic biobased resin to a second side of the natural fibre material.

66. The system for producing a thermoplastic prepreg material according to any one of claims 47-65, wherein the one or more second rollers are positioned downstream of the second extruder apparatus.

67. The system for producing a thermoplastic prepreg material according to any one of claims 47-66, wherein the one or more second rollers are configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the natural fibre material comprising the second layer of a high viscosity thermoplastic biobased resin.

68. The system for producing a thermoplastic prepreg material according to claim 67, wherein the applied pressure from the one or more second rollers is controlled using an air pressure, such as a pneumatic system.

69. The system for producing a thermoplastic prepreg material according to any one of claims 47-68, wherein the system further comprises a first cooling unit, wherein the first cooling unit is configured for cooling the natural fibre material to a third predetermined temperature.

70. The system for producing a thermoplastic prepreg material according to claim 69, wherein the third predetermined temperature is a temperature below 60 °C, such as below 55 °C, such as below 50 °C, such as below 40 °C, or such as below 30 °C.71 . The system for producing a thermoplastic prepreg material according to any one of claims 69-70, wherein the first cooling unit is positioned downstream of the one or more second rollers.

72. The system for producing a thermoplastic prepreg material according to any one of claims 47-71 , wherein the system further comprises a second cooling unit, wherein the second cooling unit is configured for cooling the natural fibre material to a fourth predetermined temperature.

73. The system for producing a thermoplastic prepreg material according to claim 72, wherein the second cooling unit is positioned downstream of the one or more second rollers and upstream of the first cooling unit.

74. The system for producing a thermoplastic prepreg material according to any one of claims 72-73, wherein the fourth predetermined temperature is a temperature between 90 °C and 130 °C, such as a temperature between 100 °C and 120 °C, such as a temperature around 110 °C.

75. The system for producing a thermoplastic prepreg material according to any one of claims 47-74, wherein the system further comprises a double belt compression unit comprising an upper belt and a lower belt.

76. The system for producing a thermoplastic prepreg material according to claim 75, wherein the upper belt and / or the lower belt is a polytetrafluoroethylene (PTFE) belt.

77. The system for producing a thermoplastic prepreg material according to any one of claims 47-76, wherein the system further comprises one or more massage rollers, wherein the one or more massage rollers are configured for applying a pressure to the first side and / or the second side of the natural fibre material downstream the first and / or second extruder apparatus.

78. The system for producing a thermoplastic prepreg material according to claim 77, wherein the applied pressure from the one or more massage rollers is controlled using an air pressure, such as a pneumatic system.

79. The system for producing a thermoplastic prepreg material according to any one of claims 77-78, wherein the system is configured such that applying the pressure to the first side and / or the second side of the natural fibre material by means of one or more massage rollers is performed while subjecting the natural fibre material to the fourth predetermined temperature.

80. The system for producing a thermoplastic prepreg material according to any one of claims 47-79, wherein the system further comprises a drying unit positioned upstream of the first and / or second extruder apparatus.81 . The system for producing a thermoplastic prepreg material according to claim 80, wherein the drying unit is configured for drying the high viscosity thermoplastic biobased resin prior to introducing the high viscosity thermoplastic biobased resin into the first and / or second extruder apparatus.

82. The system for producing a thermoplastic prepreg material according to any one of claims 47-81 , wherein the first and / or second extruder apparatus is a twin-screw extruder apparatus.

83. The system for producing a thermoplastic prepreg material according to any one of claims 47-82, wherein the one or more first and / or second rollers are at least two rollers positioned one on top of the other hereby crating a gap between them.

84. The system for producing a thermoplastic prepreg material according to claim 83, wherein the gap between the one or more first and / or second rollers are at a gap size of at least 0.2 mm, such as at least 0.3 mm, or such as a size of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm.

85. The system for producing a thermoplastic prepreg material according to any one of claims 47-84, wherein the one or more first and / or second rollers are at least four rollers positioned in pairs parallel to each other, wherein the rollers in each pair are positioned one on top of the other hereby crating a gap between them.

86. The system for producing a thermoplastic prepreg material according to claim 85, wherein the gap has a size of at least 0.2 mm, such as at least 0.3 mm, or such as a size of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm.

87. The system for producing a thermoplastic prepreg material according to any one of claims 47-86, wherein the system further comprises an ultra-sonic vibrator.

88. The system for producing a thermoplastic prepreg material according to claim 87, wherein the ultra-sonic vibrator is configured for subjecting the natural fibre material to ultra sonic vibration downstream of the first and / or second extruder apparatus.

89. The system for producing a thermoplastic prepreg material according to any one or claims 87-88, wherein the ultra-sonic vibrator is configured for subjecting the natural fibre material to ultra sonic vibration downstream of the one or more first and / or second rollers.

90. The system for producing a thermoplastic prepreg material according to any one of claims 47-89, wherein the system further comprises a cutting unit.91 . The system for producing a thermoplastic prepreg material according to claim 90, wherein the cutting unit is configured to cutting the thermoplastic prepreg material into sheets having a predetermined dimension.

92. The system for producing a thermoplastic prepreg material according to claim 91 , wherein the predetermined dimension is a dimension having a length of at least 800 mm, such as at least 900 mm, such as at least 1000 mm, such as at least 1100 mm, or such as a length of at least 1200 mm.

93. The system for producing a thermoplastic prepreg material according to any one of claims 47-92, wherein the system further comprises a rolling unit.

94. The system for producing a thermoplastic prepreg material according to claim 93, wherein the rolling unit is configured for rolling the thermoplastic prepreg material onto rolls.

95. The system for producing a thermoplastic prepreg material according to any one of claims 47-94, wherein the natural fibre material is provided having a width of at least 500 mm, such as at least 600 mm, such as at least 700 mm, such as at least 800 mm, such as at least 900 mm, or such as at least 1000 mm.

96. The system for producing a thermoplastic prepreg material according to any one of claims 47-95, wherein the high viscosity thermoplastic biobased resin is selected from one or more bio-based and biodegradable resins, such that the thermoplastic prepreg material is a bio-based and biodegradable material.

97. The system for producing a thermoplastic prepreg material according to any one of claims 47-96, wherein the high viscosity thermoplastic biobased resin is based on plant triglycerides, such as a poly lactic acid resin.

98. The system for producing a thermoplastic prepreg material according to any one of claims 47-97, wherein the natural fibre material comprises a plurality of fibres, which are woven and / or bonded together.

99. The system for producing a thermoplastic prepreg material according to any one of claims 47-98, wherein the natural fibre material is selected from sisal, hemp, coconut, flax, jute, kenaf, bamboo, sphagnum, hay or combinations thereof.

100. The system for producing a thermoplastic prepreg material according to claim 99, wherein the natural fibre material at least comprises a flax material.101 . The system for producing a thermoplastic prepreg material according to any one of claims 47-100, wherein the natural fibre material has a fabric weight of at least 250 grams for every square meter of material, such as at least 300 grams for every square meter of material.

102. The system for producing a thermoplastic prepreg material according to any one of claims 47-101 , wherein the natural fibre material has a fabric weight of less than or equal to 600 grams for every square meter of material, such as less than or equal to 500 grams for every square meter of material.

103. The system for producing a thermoplastic prepreg material according to any one of claims 47-102, wherein the diagonal lines in the natural fibre material cross at least two warp threads and two weft threads consecutively before moving on to a next set of two, such as the diagonal lines in the natural fibre material cross at least four warp threads and four weft threads consecutively before moving on to the next set of four.

104. The system for producing a thermoplastic prepreg material according to any one of claims 47-103, wherein the high viscosity thermoplastic biobased resin is a 100% biobased resin.

105. The system for producing a thermoplastic prepreg material according to any one of claims 47-104, wherein the high viscosity thermoplastic biobased resin is a resin having a viscosity of at least 400 Pacal-seconds (Pa*S), such as at least at least 425 Pacal- seconds, such as at least 450 Pacal-seconds, or such as at least 475 Pacal-seconds.

106. The system for producing a thermoplastic prepreg material according to any one of claims 47-105, wherein the high viscosity thermoplastic biobased resin is a resin having aviscosity of at least 400.000 centipoise, such as at least at least 425.000 centipoise, such as at least 450.000 centipoise, or such as at least 475.000 centipoise.

107. A system for producing a thermoplastic prepreg material, the system comprising:• a feeding unit configured for providing a natural fibre material;• an oven unit configured for drying the provided natural fibre material at a first predetermined temperature, hereby obtaining a dried natural fibre material;• a heating unit configured for heating the dried natural fibre material to a second predetermined temperature, hereby obtaining a heated natural fibre material;• a first extruder apparatus configured for providing a first layer of a high viscosity thermoplastic biobased resin to a first side of the heated natural fibre material, hereby obtaining a heated natural fibre material having a first resin layer;• one or more first rollers configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated natural fibre material having a first resin layer, hereby obtaining a heated intermediate prepreg material;• a second extruder apparatus configured for providing a second layer of the high viscosity thermoplastic biobased resin to a second side of the heated intermediate prepreg material, hereby obtaining a heated intermediate prepreg material having a second resin layer;• one or more second rollers configured for impregnating the high viscosity thermoplastic biobased resin into the natural fibre material by applying a pressure to the heated intermediate prepreg material having a second resin layer using, hereby obtaining a heated prepreg material; and• a first cooling unit configured for cooling the heated prepreg material to a third predetermined temperature, hereby obtaining the thermoplastic prepreg material.

108. The system for producing a thermoplastic prepreg material according to claim 107, wherein the feeding unit is configured for providing the natural fibre material to the oven unit.

109. The system for producing a thermoplastic prepreg material according to any one of claims 107-108, wherein the oven unit is positioned downstream of the feeding unit.

110. The system for producing a thermoplastic prepreg material according to any one of claims 107-109, wherein the first predetermined temperature is a temperature between 60 °C and 130 °C, such as between 70 °C and 120 °C, such as between 75 °C and 115 °C, or such as between 80 °C and 110 °C.

111. The system for producing a thermoplastic prepreg material according to any one of claims 107-110, wherein the heating unit is positioned downstream of the oven unit.

112. The system for producing a thermoplastic prepreg material according to any one of claims 107-111 , wherein the second predetermined temperature is a temperature between 130 °C and 210 °C, such as between 140 °C and 200 °C, such as between 150 °C and 190 °C, or such as between 160 °C and 180 °C.

113. The system for producing a thermoplastic prepreg material according to any one of claims 107-112, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the first extruder apparatus.

114. The system for producing a thermoplastic prepreg material according to any one of claims 107-113, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the one or more first rollers.

115. The system for producing a thermoplastic prepreg material according to any one of claims 107-114, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the second extruder apparatus116. The system for producing a thermoplastic prepreg material according to any one of claims 107-115, wherein the heating unit is configured to maintain the second predetermined temperature of the natural fibre material at the one or more second rollers.

117. The system for producing a thermoplastic prepreg material according to any one of claims 107-116, wherein the first extruder apparatus is positioned downstream of the oven unit.

118. The system for producing a thermoplastic prepreg material according to any one of claims 107-117, wherein the one or more first rollers are positioned downstream of the first extruder apparatus.

119. The system for producing a thermoplastic prepreg material according to any one of claims 107-118, wherein the applied pressure from the one or more first rollers is controlled using an air pressure, such as a pneumatic system.

120. The system for producing a thermoplastic prepreg material according to any one of claims 107-119, wherein the second extruder apparatus is positioned downstream of the one or more first rollers.121 . The system for producing a thermoplastic prepreg material according to any one of claims 107-120, wherein the one or more second rollers are positioned downstream of the second extruder apparatus.

122. The system for producing a thermoplastic prepreg material according to any one of claims 107-121 , wherein the applied pressure from the one or more second rollers is controlled using an air pressure, such as a pneumatic system.

123. The system for producing a thermoplastic prepreg material according to any one of claims 107-122, wherein the third predetermined temperature is a temperature below 60 °C, such as below 55 °C, such as below 50 °C, such as below 40 °C, or such as below 30 °C.

124. The system for producing a thermoplastic prepreg material according to any one of claims 107-123, wherein the first cooling unit is positioned downstream of the one or more second rollers.

125. The system for producing a thermoplastic prepreg material according to any one of claims 107-124, wherein the system further comprises a second cooling unit, wherein the second cooling unit is configured for cooling the natural fibre material to a fourth predetermined temperature.

126. The system for producing a thermoplastic prepreg material according to claim 125, wherein the second cooling unit is positioned downstream of the one or more second rollers and upstream of the first cooling unit.

127. The system for producing a thermoplastic prepreg material according to any one of claims 125-126, wherein the fourth predetermined temperature is a temperature between 90 °C and 130 °C, such as a temperature between 100 °C and 120 °C, such as a temperature around 110 °C.

128. The system for producing a thermoplastic prepreg material according to any one of claims 107-127, wherein the system further comprises a double belt compression unit comprising an upper belt and a lower belt.

129. The system for producing a thermoplastic prepreg material according to claim 128, wherein the upper belt and / or the lower belt is a polytetrafluoroethylene (PTFE) belt.

130. The system for producing a thermoplastic prepreg material according to any one of claims 107-129, wherein the system further comprises one or more massage rollers, wherein the one or more massage rollers are configured for applying a pressure to the first side and / or the second side of the natural fibre material downstream the first and / or second extruder apparatus.131 . The system for producing a thermoplastic prepreg material according to claim 130, wherein the applied pressure from the one or more massage rollers is controlled using an air pressure, such as a pneumatic system.

132. The system for producing a thermoplastic prepreg material according to any one of claims 130-131 , wherein the system is configured such that applying the pressure to the first side and / or the second side of the natural fibre material by means of one or more massage rollers is performed while subjecting the natural fibre material to the fourth predetermined temperature.

133. The system for producing a thermoplastic prepreg material according to any one of claims 107-132, wherein the system further comprises a drying unit positioned upstream of the first and / or second extruder apparatus.

134. The system for producing a thermoplastic prepreg material according to claim 133, wherein the drying unit is configured for drying the high viscosity thermoplastic biobased resin prior to introducing the high viscosity thermoplastic biobased resin into the first and / or second extruder apparatus.

135. The system for producing a thermoplastic prepreg material according to any one of claims 107-134, wherein the first and / or second extruder apparatus is a twin-screw extruder apparatus.

136. The system for producing a thermoplastic prepreg material according to any one of claims 107-135, wherein the one or more first and / or second rollers are at least two rollers positioned one on top of the other hereby crating a gap between them.

137. The system for producing a thermoplastic prepreg material according to claim 136, wherein the gap between the one or more first and / or second rollers are at a gap size of at least 0.2 mm, such as at least 0.3 mm, or such as a size of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm.

138. The system for producing a thermoplastic prepreg material according to any one of claims 107-137, wherein the one or more first and / or second rollers are at least four rollers positioned in pairs parallel to each other, wherein the rollers in each pair are positioned one on top of the other hereby crating a gap between them.

139. The system for producing a thermoplastic prepreg material according to claim 138, wherein the gap has a size of at least 0.2 mm, such as at least 0.3 mm, or such as a size of between 0.2 mm and 1 .5 mm, such as between 0.3 mm and 1 .2 mm.

140. The system for producing a thermoplastic prepreg material according to any one of claims 107-139, wherein the system further comprises an ultra-sonic vibrator.141 . The system for producing a thermoplastic prepreg material according to claim 140, wherein the ultra-sonic vibrator is configured for subjecting the natural fibre material to ultra sonic vibration downstream of the first and / or second extruder apparatus.

142. The system for producing a thermoplastic prepreg material according to any one or claims 140-141 , wherein the ultra-sonic vibrator is configured for subjecting the natural fibre material to ultra sonic vibration downstream of the one or more first and / or second rollers.

143. The system for producing a thermoplastic prepreg material according to any one of claims 107-142, wherein the system further comprises a cutting unit.

144. The system for producing a thermoplastic prepreg material according to claim 143, wherein the cutting unit is configured to cutting the thermoplastic prepreg material into sheets having a predetermined dimension.

145. The system for producing a thermoplastic prepreg material according to claim 144, wherein the predetermined dimension is a dimension having a length of at least 800 mm, such as at least 900 mm, such as at least 1000 mm, such as at least 1100 mm, or such as a length of at least 1200 mm.

146. The system for producing a thermoplastic prepreg material according to any one of claims 107-145, wherein the system further comprises a rolling unit.

147. The system for producing a thermoplastic prepreg material according to claim 146, wherein the rolling unit is configured for rolling the thermoplastic prepreg material onto rolls.

148. The system for producing a thermoplastic prepreg material according to any one of claims 107-147, wherein the natural fibre material is provided having a width of at least 500 mm, such as at least 600 mm, such as at least 700 mm, such as at least 800 mm, such as at least 900 mm, or such as at least 1000 mm.

149. The system for producing a thermoplastic prepreg material according to any one of claims 107-148, wherein the high viscosity thermoplastic biobased resin is selected from one or more bio-based and biodegradable resins, such that the thermoplastic prepreg material is a bio-based and biodegradable material.

150. The system for producing a thermoplastic prepreg material according to any one of claims 107-149, wherein the high viscosity thermoplastic biobased resin is based on plant triglycerides, such as a poly lactic acid resin.151 . The system for producing a thermoplastic prepreg material according to any one of claims 107-150, wherein the natural fibre material comprises a plurality of fibres, which are woven and / or bonded together.

152. The system for producing a thermoplastic prepreg material according to any one of claims 107-151 , wherein the natural fibre material is selected from sisal, hemp, coconut, flax, jute, kenaf, bamboo, sphagnum, hay or combinations thereof.

153. The system for producing a thermoplastic prepreg material according to claim 152, wherein the natural fibre material at least comprises a flax material.

154. The system for producing a thermoplastic prepreg material according to any one of claims 107-153, wherein the natural fibre material has a fabric weight of at least 250 grams for every square meter of material, such as at least 300 grams for every square meter of material.

155. The system for producing a thermoplastic prepreg material according to any one of claims 107-154, wherein the natural fibre material has a fabric weight of less than or equal to 600 grams for every square meter of material, such as less than or equal to 500 grams for every square meter of material.

156. The system for producing a thermoplastic prepreg material according to any one of claims 107-155, wherein the diagonal lines in the natural fibre material cross at least two warp threads and two weft threads consecutively before moving on to a next set of two,such as the diagonal lines in the natural fibre material cross at least four warp threads and four weft threads consecutively before moving on to the next set of four.

157. The system for producing a thermoplastic prepreg material according to any one of claims 107-156, wherein the high viscosity thermoplastic biobased resin is a 100% biobased resin.

158. The system for producing a thermoplastic prepreg material according to any one of claims 107-157, wherein the high viscosity thermoplastic biobased resin is a resin having a viscosity of at least 400 Pacal-seconds (Pa*S), such as at least at least 425 Pacal- seconds, such as at least 450 Pacal-seconds, or such as at least 475 Pacal-seconds.

159. The system for producing a thermoplastic prepreg material according to any one of claims 107-158, wherein the high viscosity thermoplastic biobased resin is a resin having a viscosity of at least 400.000 centipoise, such as at least at least 425.000 centipoise, such as at least 450.000 centipoise, or such as at least 475.000 centipoise.

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