Method and apparatus for fabricating resin mats

A method of fabricating resin mats comprising:

• advancing first and second mat layers through a gap formed between a pair of spaced rollers and a pair of dam members positioned between and adjacent opposing ends of said pair of rollers;
• positioning a resin feeding device at a resin feeding position located between the first and second mat layers;
• actuating the resin feeding device and delivering resin from said resin feeding device to opposing sides of said first and second mat layers for a period of time in order to build up at least one resin reservoir between the mat layers and the dam members while the spaced rollers are stationary;
• rotating the pair of spaced rollers to advance the mat layers through the space between the rollers thereby causing the mat layers to become impregnated with resin and be joined together;
• terminating the fabrication of resin mats by de-actuating said resin feeding device while continuing to rotate the pair of spaced rollers until the resin remaining in the at least one resin reservoir is consumed and then stopping the rotation of the pair of spaced rollers;
• and
• rotating said resin feeding device from said resin feeding position located between said first and second mat layers to a non-resin feeding position whereat said means for feeding resin can be cleaned wherein said non-resin feeding position is remote from said first and second mat layers.

An apparatus for fabricating resin mats comprising:

• a frame;
• first and second mat material spools each housing a supply of first and second mat layers respectively;
• a pair of rollers rotatably mounted about respective rotational axes on said frame in a spaced, substantially parallel configuration;
• means for advancing said first and second mat layers in alignment from said first and second mat material spools to between said pair of rollers;
• means for feeding resin between said first and second mat layers prior to said mat layers being advanced through said pair of rollers, said means for feeding resin delivering resin to opposing sides of said first and second mat layers, wherein said first and second mat layers become impregnated with resin and are joined by advancing through said pair of rollers, said means for feeding resin being rotatable relative to said frame so as to be shiftable between a resin feeding position located between said first and second mat layers and a non-resin feeding position whereby said means for feeding resin may be rotated to a position remote from said first and second mat layers whereat said means for feeding resin can be cleaned;
• and
• first and second dam members positioned between said pair of rollers on either longitudinal side of said first and second mat layers such that said first and second mat layers are located between said first and second dam members, said first and second dam members further defining said at least one reservoir, at least one of the dam members being movable in an axial direction parallel to the rotational axes of the rollers.