A machine and a process for producing lightweight thermoplastic composite
products in a continuous manner is disclosed. An oven is provided for
heating a dry unconsolidated fabric sheet of commingled fibers of
thermoplastic and re-enforcing fibers or carbon fibers to a temperature
sufficient to ensure melting and flow of the resin in the voids of the
commingled fibers. The unconsolidated composite sheet is conveyed through
the oven and then through a first pair of heated rollers at an outlet of
the oven whereby to maintain the fabric sheet heated to prevent abrupt
cooling at the surfaces while compressing it under pressure. A further
pair of rollers at a further reduced temperature is provided whereby the
heated sheet is gradually lowered in temperature and the pressure is
maintained thereon during consolidation of the commingled fibers to
ensure complete flow of the resin in the voids between the reinforcing
fibers. The continuous composite consolidated sheet can then be processed
to sheet form, or laminated in a sandwich, or profiled whereby to form a
desired product.