Blow-molded composite compositions and methods

A method of blow-molding a fibrous composite, comprising the steps of:

• providing upper and lower fiber layers each comprising randomly oriented fibers and a binder dispersed throughout the thickness of each of the layers, and each having first and second surfaces;
• providing upper and lower film layers, each having first and second surfaces;
• placing the second surface of the upper film layer adjacent the second surface of the upper fiber layer;
• placing the second surface of the lower film layer adjacent the first surface of the lower fiber layer;
• locating the lower fiber and film layers on a lower blow-mold plate having a surface, and comprising at least one protrusion extending from that surface and at least one fluid passage disposed in the plate;
• applying a vacuum through the passage between the surface of the lower blow-mold plate and the lower fiber layer;
• drawing the lower fiber and lower film layers against at least a portion of the surface of the lower blow-mold plate;
• piercing the lower fiber and lower film layers with a pin having an opening disposed therein;
• extending the opening beyond the first surface of the lower film layer;
• placing the first surface of the upper film layer against the first surface of the lower film layer forming a cavity around at least a portion of the pin between the first surfaces of the upper and lower film layers;
• applying pressure against the upper fiber and film layers against the lower film and fiber layers;
• and
• blowing fluid from the opening into the cavity to cause at least the lower film and fiber layers to take the shape of the lower blow-mold plate and bond the first and second films together.