Patent ID: 9144955
Filing Date: 2015-09-29
Classification: B32B,Y10T

Abstract:
1. A method of making a composite material, the method comprising: applying a resin to a nonwoven fibrous web, wherein the nonwoven fibrous web comprises a combination of glass fibers and polymer fibers; drying the web at a first stage temperature at or below a curing temperature of the resin for a time sufficient to substantially dry but not substantially cure the resin; laminating the web and a first material at a second stage temperature sufficient to fully cure the resin to produce the composite material, wherein the second stage temperature is above the melting point of the polymer fibers, and wherein the resin causes the composite material to retain a substantially rigid shape upon completion of the laminating operation; coupling a layer of a second material to a surface of the composite material; and saturating the layer of a second material with a gel coat to produce a Class A finish to the composite material.