Process for manufacturing a composite sheet
AssigneeOwens Corning Fiberglas Technology, Inc.
InventorsJames G. Bledsoe, Donald C. Ray, Mark E. Farver
Life of this patent
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Abstract
A method of manufacturing a composite sheet includes perforating a reinforcement panel. A mold surface onto which the composite sheet may be formed is provided. At least one outer coat of material is applied onto the mold surface. At least one coat of resin and reinforcement material is applied over the outer coat to form a reinforcement layer. The perforated reinforcement panel is applied to the reinforcement layer, and the resin is forced into the perforations formed in the reinforcement panel, thereby bonding the reinforcement layer to the reinforcement panel.
Claims44
A method of manufacturing a composite sheet comprising the steps of:
- perforating a reinforcement panel;
- providing a mold surface onto which a composite sheet may be formed;
- applying at least one outer coat of material onto the mold surface;
- applying at least one coat of resin and reinforcement material over the outer coat to form a reinforcement layer;
- applying the perforated reinforcement panel to the reinforcement layer;
- and
- forcing the resin into the perforations formed in the reinforcement panel, thereby bonding the reinforcement layer to the reinforcement panel.
An apparatus for manufacturing a composite sheet comprising:
- a perforating mechanism to perforate reinforcement panels;
- a mold surface onto which a composite sheet may be formed;
- at least one dispensing mechanism to dispense at least one outer coat of material onto the mold surface;
- at least one dispensing mechanism to dispense at least one coat of resin over the outer coat;
- at least one applicator to apply reinforcement material over the outer coat, wherein the resin and the reinforcement material form a reinforcement layer;
- and
- at least one mechanism to force the resin into the perforations of the perforated reinforcement panel after the reinforcement panel has been applied to the reinforcement layer.
A composite sheet comprising:
- a layer of resin and reinforcement material, the layer of resin and reinforcement material forming a reinforcement layer;
- and
- a perforated reinforcement panel applied to the reinforcement layer, a portion of the reinforcement layer being forced into the perforations of the perforated reinforcement panel, thereby bonding the reinforcement layer to the reinforcement panel.
A method of manufacturing a composite sheet comprising the steps of:
- forming perforations in a reinforcement panel;
- providing a mold surface onto which a composite sheet may be formed;
- applying at least one coat of resin and reinforcement material over the mold to form a reinforcement layer;
- applying the perforated reinforcement panel to the reinforcement layer;
- and
- evacuating substantially all air trapped between the resin and the resin and the reinforcement panel through the perforations.
Dependencies are inferred from the claim text.