Patent ID: 7255822
Filing Date: 2007-08-14
Classification: B29C,Y10T

Abstract:
1. A method of manufacturing a composite sheet comprising the steps of: perforating a reinforcement panel; providing a mold surface onto which a composite sheet may be formed; applying at least one outer coat of material onto the mold surface; applying at least one coat of resin and reinforcement material over the outer coat to form a reinforcement layer; applying the perforated reinforcement panel to the reinforcement layer; and forcing the resin into the perforations formed in the reinforcement panel, thereby bonding the reinforcement layer to the reinforcement panel, wherein the perforating step is accomplished by moving the reinforcement panel through three sets of opposed pinch-rollers, one roller of a middle set of the three sets being a perforating mandrel having a plurality of tapered perforating pins.