Patent ID: 8246882
Filing Date: 2012-08-21
Classification: B29B,B29C,B29K,B32B,C08J,D04H,Y10T

Abstract:
1. A method for continuously forming a composite material, the method comprising: providing a plurality of reinforcing layers formed of fibers of a reinforcing material; providing a plurality of interlayers, each interlayer being formed of a nonwoven fabric of continuous thermoplastic fibers different than the fibers of the reinforcing layers, wherein providing the plurality of interlayers comprises forming the nonwoven fabric by at least one of the group consisting of spunbonding and spunlacing; continuously feeding the reinforcing layers and the interlayers in an alternating configuration to a nip; and stitching, at a knitting unit downstream of the nip, the continuously fed reinforcing layers and the interlayers with a thread, wherein providing the interlayers comprises providing the interlayers of a substantially tackless material such that the reinforcing layers and the interlayers are substantially unbonded prior to said stitching step.