Thermoplastic fiber composites having high volume fiber loading and methods and apparatus for making same

Abstract

A method and apparatus are provided which enable formation of a thermoplastic article having a high volume loading of a long fiber reinforcement. The method includes providing a first thermoplastic composite material having at least about 40 volume percent of at least one reinforcing fiber; providing at least one mold, the mold(s) each comprising at least one first mold section having an inlet and an outlet and defining a first mold cavity and at least one second mold section having an inlet and an outlet and defining a second mold cavity, wherein the outlet of the first mold section is in communication with the inlet of the second mold section; introducing the first thermoplastic composite material into the first mold cavity; applying heat and pressure to the first thermoplastic composite material in the first mold cavity until the first mold section reaches at least a first process temperature; releasing the pressure on the mold; and reapplying pressure to the mold while cooling, wherein at least a portion of the first thermoplastic composite material flows out of the least one outlet of the first mold section and into the second mold cavity, wherein said cooling solidifies the first thermoplastic composite to form a molded article having the shape of the second mold cavity. Articles formed from such methods and apparatus are also disclosed.