# US 5,344,687 A · Structurally reinforced thermoplastic-fabric composite construction materials that are moldable > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 5,344,687 A - Document ID: US5344687A - Status: Granted - Kind: A - Application number: 07/766,516 - Filed: 1991-09-27 - Granted: 1994-09-06 - Earliest claimed: 1991-09-27 - Assignees: Brunswick Technologies, Inc. - Inventors: Martin S. Grimnes - Web page: https://patentgrep.com/patent/US5344687A ## CPC - B32B 27/12: next to a fibrous or filamentary layer - B29C 70/08: comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers - B29C 70/086: {and with one or more layers of pure plastics material, e.g. foam layers (applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86)} - B29C 70/543: {Fixing the position or configuration of fibrous reinforcements before or during moulding (for non-woven fabrics D04H3/08)} - B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} - B29K 2101/12: Thermoplastic materials - B29K 2105/0845: {Woven fabrics} - B29K 2105/128: {in the form of a mat} - B32B 2419/00: Buildings or parts thereof - Y10S 428/902: High modulus filament or fiber - Y10T 428/24033: including stitching and discrete fastener[s], coating or bond - Y10T 442/3496: Coated, impregnated, or autogenously bonded - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - Y10S: TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract Binded and structurally reinforced thermoplastic-fabric composite construction materials, that are moldable, are described, comprising a structurally reinforced multilayer binded together in a binding process. A barrier fabric layer, and/or a decorative layer, may also be included in order to produce or vary decorative, and/or other effects. The structurally reinforced multilayer is made from a thermoplastic resin system and at least one fabric layer containing reinforcing fibers. Reinforcing fibers are introduced into components of the structurally reinforced multilayer, within the fabric layers, and may also be comingled with or layered into the thermoplastic resin system before addition to the fabric. ## Claims ### Claim 1 A unitary thermoplastic-fabric flexible web, adapted to be molded under heat and pressure to form an internally reinforced molded article; said web comprising at least on thermo-plastic resin layer (16), at least one woven fabric layer (22) containing reinforcing fibers, and stitching (26) extending completely through all of said layers, whereby said layers are bound together to form a flexible web that can be handled as a unit. ### Claim 2 (depends on 1) A unitary thermoplastic-fabric flexible web, as described in claim 1, wherein said web has a length dimension and a width dimension; said stitching comprising multiple rows of stitches, extending parallel to said length dimension of said web. ### Claim 3 (depends on 1) A unitary thermoplastic-fabric flexible web, as described in claim 1, wherein said web has a length dimension substantially greater than a transverse width dimension, whereby said web can be wound on a transverse axis into a roll configuration; said wound web being adapted to be unwound for cutting into pattern shapes, suitable for individual placement in a mold cavity. ### Claim 4 (depends on 1) A unitary thermoplastic-fabric flexible web, as described in claim 1, wherein there are at least two fabric layers (22); said layers being arranged so that each resin layer is sandwiched between two fabric layers. ### Claim 5 (depends on 1) A unitary thermoplastic-fabric flexible web, as described in claim 1, and further comprising a decorative layer (20), laminated with said fabric and resin layers, so that said decorative layer forms one face of the flexible web; said stitching extending completely through all of said layers, including said decorative layer. ### Claim 6 (depends on 5) A unitary thermoplastic-fabric flexible web, as described in claim 5, and further comprising a relatively non-porous barrier layer (18), located between said decorative layer and one of the fabric layers, to prevent migration of the resin beyond said one fabric layer. ### Claim 7 (depends on 1) A unitary thermoplastic-fabric flexible web, as described in claim 1, wherein said stitching comprises a stitching material that has approximately the same melting point as said resin layer, whereby the stitching layer melts during the molding operation. ### Claim 8 (depends on 7) A unitary thermoplastic-fabric flexible web, as described in claim 7, wherein said stitching material is the same material as said resin layer. ### Claim 9 (depends on 1) A unitary thermoplastic-fabric flexible web, as described in claim 1, wherein there are two fabric layers (22), and one resin layer (16); said layers being arranged so that the single resin layer is sandwiched between said two fabric layers. ### Claim 10 (depends on 1) A unitary thermoplastic-fabric flexible web, as described in claim 1, wherein each resin layer comprises a film of discrete resin particles deposited onto one of said fabric layers. ### Claim 11 (depends on 1) A unitary thermoplastic-fabric flexible web, as described in claim 1, wherein said resin layer comprises a continuous thermoplastic film, having a continuity prior to incorporation into the web. ### Claim 12 (depends on 11) A unitary thermoplastic-fabric flexible web, as described in claim 11, wherein said resin layer has included therein strands of reinforcing fibers.