Process for manufacturing resin-based composite material

Abstract

An apparatus for manufacturing fiberglass-reinforced sheet is shown as including a feed mechanism feeding a sheet, whereby the sheet forms the upper mold surface for the fiberglass-reinforced sheets. The fed sheet moves longitudinally through a gel coating sprayer, and through applicators to apply resin in fiberglass. An automatic roller mechanism rolls the fiberglass strands into the resin and an automatic pressure mechanism applies pressure to wooden sheets placed on top of the fiberglass strands to form continuously fed completed sheet.

1 - 25 . (canceled)  
     
     
         33 . A method for manufacturing fiberglass-reinforced sheet, comprising the steps of: 
 providing a continuous mold surface comprising a continuous loop of individual links being arranged in a longitudinal manner;    spraying a first outer coat of material onto said mold surface;    dispensing resin over said first outer coat;    applying fiber strands over said first outer coat; and    rolling said fiber strands and said resin.    
     
     
         34 . The method of  claim 33 , further comprising the steps of: 
 positioning a reinforcement sheet over said fiber strands, and forcing said resin into said reinforcement sheet to form a composite material.    
     
     
         35 . A method for manufacturing fiber-reinforced sheet, comprising: 
 providing a longitudinally movable continuous mold surface onto which a fiber-reinforced sheet may be formed,    continuously feeding sheet material onto said upper movable surface;    spraying a first outer coat of material onto said sheet material;    dispensing resin over said first outer coat;    applying fiber strands over said first outer coat; and    rolling said fiber strands and said resin.    
     
     
         36 . The method of  claim 35 , wherein the step of providing the mold surface comprises providing a continuous loop of individual links being arranged in a longitudinal manner;  
     
     
         37 . The method of  claim 35 , further comprising the steps of 
 positioning a reinforcement sheet over said fiber strands, and    forcing said resin into said reinforcement sheet to form a composite material.    
     
     
         38 . The method of  claim 35 , wherein the step of rolling comprises: 
 providing a roller mechanism with an automatic roller mechanism; and    forming transverse rolling patterns across said mold surface using at least one roller which is driven in a continuous loop in a direction transverse to said longitudinally moving mold surface.    
     
     
         39 . The method of  claim 38 , wherein said roller mechanism is profiled to move said at least one roller in a direction, such that the roller has a transverse velocity component and a longitudinal velocity component, the method further comprising the step of controlling the longitudinal velocity component to be equal to a longitudinal velocity of the moving mold surface.  
     
     
         40 . The method of  claim 39 , further comprising the steps of attaching said roller to a chain loop, and driving said roller on said chain loop guided around a chain guide.  
     
     
         41 . The method of  claim 35 , further comprising the steps of providing a movable support surface beneath said movable mold surface and moving said movable support surface and said movable mold surface at substantially the same speeds.