Patent ID: 7732044

Claim:
A surface-reinforced article, comprising: a core assembly which includes a core of unreinforced foam material and a first surface region which includes at least one inner layer of inner fibrous material impregnated with the same foam material as said core, said foam material which impregnates said inner layer of fibrous material being integral with the foam material in said core; an outer reinforcing covering which includes at least one outer layer of outer fibrous material lying around said core assembly and resin which impregnates said outer reinforcing covering by surrounding said outer layer of fibrous material and forming a continuous layer, said resin being bound to said core assembly by molding said resin to said core assembly; said outer reinforcing covering having a greater stiffness per unit volume than said first surface region of said core assembly, and said first surface region of said core assembly having a greater stiffness per unit volume than said core of unreinforced foam of said core assembly; said inner layer of fibrous material includes multiple coupling fibers with inner portions surrounded by said foam material and with outer portions that project outside said foam material; said outer portions of said coupling fibers are embedded in said resin, to thereby securely hold said covering to said core assembly.