Patent ID: 8066836

Claim:
A process of forming a composite material comprising: providing a prepreg material comprising fibers infiltrated with an infiltrating material comprising a partially cured resin, wherein the infiltrating material does not include a pultrusion lubricating additive, the fibers having a tensile strength, the prepreg material having a thickness dimension; preheating the prepreg material; introducing the preheated prepreg material into a heated pultrusion die with a barrier layer between surfaces of the prepreg material and facing inner surfaces of the die, the barrier layer comprising a material that reduces friction and bonding between the prepreg material and the inner surfaces of the die, the barrier layer comprising a plurality of layers provided on each surface of the prepreg material; and continuously pulling the prepreg material and the barrier layers through the pultrusion die, the prepreg material consolidating and curing under heat and compression in the die.