Patent ID: 7341638

Claim:
A process for fabricating a fiber reinforced polymeric foam composite comprising the steps: a) conveying a length of bottom facing sheet; b) conveying above the bottom facing sheet a first expandable fiber mat; c) conveying above the expandable fiber mat a composite web from a roll; the composite web comprising a low binder fiber mat and a support mat and oriented such that the support mat is below the low binder fiber mat; d) conveying a length of top facing sheet above the composite web; e) dispensing a foamable mixture between at least one of: (i) the bottom facing sheet and first expandable mat, if dispensing occurs prior to step (b); (ii) the first expandable fiber mat and support mat of the composite web, if dispensing occurs after step (b); and prior to step (c); and (iii) the composite web's low binder fiber mat and top sheet, if dispensing occurs after step (c); f) constricting the bottom and top facing sheet through a metering gap, achieving penetration of the foamable mixture into the expandable fiber mat and low binder fiber mat; and g) expanding the foamable mixture into a polymeric foam.