Patent ID: 6416614
Filing Date: 2002-07-09
Classification: B29C,B32B,Y02T

Abstract:
A method for manufacturing a composite material comprising a particle foam consisting essentially of at least one of an expanded polypropylene and an expanded polymer, a mixed fiber layer comprising a first fraction of polypropylene fibers welded to said particle foam and a second fraction of first reinforcement fibers, said mixed fiber layer having a wetability, and with a polymer layer introduced onto said mixed fiber layer in a liquid phase, said polymer layer being one of hardened, cured, and cross-linked, the method comprising the steps of:a) densely packing said particle foam; b) introducing said densely packed particle foam and said mixed fiber layer into a mold; c) bringing, following step b), said particle foam and said mixed fiber layer to a temperature sufficient to melt surfaces of particles in said particle foam and of polypropylene fibers in said mixed fiber layer; d) cooling said particle foam and said mixed fiber layer following step c); e) introducing a polymer layer in a liquid phase onto a surface of said mixed fiber layer; and f) effecting, following step e), at least one of a hardening, a curing, and a cross-linking of said polymer layer.