Natural fiber layer with injection molded surface

Abstract

A composite article has an interior layer comprising a natural fiber and an exterior layer injection molded onto the interior layer. The exterior layer forms an outer surface over the interior layer. A method of forming the composite article includes providing a base layer comprising a natural fiber and providing a first tool and a second tool. The first and second tools are configured to cooperate to form a cavity therebetween. The first tool has an injection molding channel formed therein. The base layer is inserted into the cavity between the first and second tools and pressed into a desired shape. A liquid polymeric material is inserted through the injection molding channel of the first tool and onto a surface of the base layer to form an injection molded layer of the polymeric material on the base layer.

Dependencies are inferred from the claim text.