Patent ID: 6562177
Filing Date: 2003-05-13
Classification: B29B,B29C,B29K,E02B,Y02W,Y10T

Abstract:
A method of forming a continuous composite structure including the steps of preselecting a first liquid reactive resin forming material, a particulate solid additive material and a porous blanket, mixing said additive particles with said first liquid resin forming material substantially continuously to form a substantially uniform mixture thereof, encapsulating substantially all of said additive particles with said first liquid resin forming material, advancing said porous blanket through said liquid resin/additive mixture, migrating part of said mixture through said blanket substantially uniformly to form a continuous resin matrix within said blanket with adhesive outer surfaces, preselecting a second resin forming material which substantially cures immediately upon application and is compatible and reactive with said adhesive first resin forming material, applying a thin coating of said second resin forming material over substantially one major adhesive upper surface of said matrix/blanket while allowing an area of said adhesive surface to remain exposed along one edge of said upper surface thereof, positioning a first preselected length of said coated matrix/blanket into a preselected final configuration while it is flexible and has an adhesive lower surface in contact with a firm base surface and an exposed adhesive area along one edge of said upper surface thereof, positioning a second preselected length of said coated matrix/blanket in an overlapping orientation with said exposed adhesive area of said first positioned length of said coated matrix/blanket, tightly affixing said adhesive lower surface of said second length to said exposed adhesive area of said first length and the remaining portion of said adhesive lower surface to said firm base surface, and successively positioning and tightly affixing together a plurality of additional lengths of said coated matrix/blanket in overlapping orientation to form a substantially continuous composite structure with high strength and exceptional durability tightly affixed to said firm base surface.