Patent ID: 7820087

Claim:
A method for manufacturing a composite board, comprising: providing a matrix material; shaping the matrix material into a predetermined shape to obtain a matrix having a surrounding outside surface; bringing a fiber material into contact with a thermosetting resin to allow the fiber material to absorb the thermosetting resin; determining a number of layer(s) of the fiber material that is required for different portions of the composite board based on a strength required by each portion such that an entire outside surface of the shaped matrix is covered by at least one layer of the fiber material and a number of layers of the fiber material that cover an inside surface of a concave formed in the shaped matrix is greater than a number of the layer(s) of the fiber material that covers a portion of the outside surface of the shaped matrix which is in a vicinity of the concave; covering the shaped matrix with one or more continuous layers of the fiber material that have absorbed the thermosetting resin according to the determined number of layer(s) for each portion; and drying or raising a surrounding temperature such that the shaped matrix, the one or more layers of the fiber material and the thermosetting resin melt into an integral unit by a thermosetting process, whereby at least one layer of the fiber material remains distinct from the integral unit.