Patent ID: 8623252

Claim:
A process of manufacturing a fibrous article comprising the steps of: submerging a fiber substrate in a bath of first thermoplastic resin to impregnate the fiber substrate with the first thermoplastic resin; heating the impregnated fiber substrate at a first temperature until the fiber substrate becomes a thick continuous fiber substrate; cutting the thick continuous fiber substrate into a plurality of units of predetermined size; stacking a predetermined number of the fiber substrate units; pressing and heating the stacked fibrous structure units at a second temperature until a stacked fibrous structure is formed; heating a mold to a third temperature; conveying the stacked fibrous structure to the mold to melt into a molten fibrous structure; cooling the mold to harden the molten fibrous structure into a half-finished article of a predetermined shape; removing the half-finished article out of the mold; eliminating burrs and sharp edges of the half-finished article; after the step of eliminating, conveying the half-finished article to the mold; and uniformly applying a molten second thermoplastic resin on an inner surface of the half-finished article by injection molding in the mold to produce the finished fibrous article having a second thermoplastic resin layer on an inner surface.