Process for the production of a multi-layer composite article having fasteners affixed to a surface thereof and the article produced thereby

Abstract

A process for the production of a rigid multi-layer composite articles (20) prepared from reacting inter alia a sheet of an open cell foam material (22) impregnated with a binder resin, such as isocyanate resin, to fill the cells of the foam material (22) and a polymerization catalyst to cause the reaction of isocyanate and form isocyanurate linkages, urethane linkages, urea linkages, trimer linkages, biuret linkages, and/or allophante linkages to render the composite article (20) rigid, and having a layer of reinforcing fibers, such as glass fibers, completely (24) or partially (25) impregnated by the binder resin affixed to a surface of the foam material (22) by the binder resin. Fasteners (27) formed of a thermoplastic material are provided having an appropriate adhesion surface. The adhesion surface of each of the fasteners (27) is melted by any of the well known techniques such as spin welding, etc., and caused to engulf the fibers of the layer which are not impregnated or are partially impregnated, or to strip the polymerized resin from the layer of reinforcing fibers which may be completely impregnated and to engulf the stripped fibers. Upon resolidification of the molten material of the fasteners (27), the fasteners (27) are firmly affixed to the layer of reinforcing fibers and thereby to the composite article.

Dependencies are inferred from the claim text.