Patent ID: 6899835
Filing Date: 2005-05-31
Classification: B29C,B29K,B29L,B44C,E06B,Y10T

Abstract:
1. A method for manufacturing an article of composite construction with at least part of the article having an appearance imitating natural wood, the method comprising: (a) providing a first skin sheet including a transparent outer gel coat layer having an outer surface molded to imitate a wood grain, a subsurface pigmented gel coat layer and a reinforced synthetic resin structural support layer; (b) providing a second skin sheet; (c) providing a frame structure for said article; (d) fastening said first and second skin sheets to said frame structure, thereby defining a cavity between said first and second skin sheets and surrounded by said frame structure; (e) filling said cavity with a structural resin foam adhering to said frame structure and said first and second skin sheets; (f) curing said structural resin foam, thereby forming a substantially rigid core structure adhered to said frame structure and to said first and second skin sheets; and (g) thereafter applying a protective finish to said outer surface of said first skin.