Forming a continuous reinforced composite material

Stock material or miscellaneous articles – Sheets or webs edge spliced or joined

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428362, 428 54, 428 98, 428105, 428111, 428130, 428157, 428172, B32B 300

Patent

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058915419

ABSTRACT:
A continuous reinforced composite material, including a first sheet with at least two polymer layers and a first fabric layer operatively coupled therebetween. The first sheet having at least one border where at least some of the fibers of the first fabric layer are continuous thereby having no free ends at the border. The composite material further includes a second sheet with at least two polymer layers with a second fabric layer operatively coupled therebetween. The second sheet having at least one border where at least some of the fibers of the second fabric layer are continuous thereby having no free ends at the border. The composite material further includes a seam wherein the borders of the first sheet and second sheet overlap and are operatively coupled to one another. A method of making a continuous reinforced composite material, including providing a first sheet having two polymer layers and a reinforcing fabric layer disposed between the polymer layers, the fabric layer having at least some continuous fibers without free ends on at least one border of the first sheet. The method further includes providing a second sheet having two polymer layers and a reinforcing fabric layer disposed between the polymer layers, the fabric layer having at least some continuous fibers without free ends on at least one border of the second sheet. The method further includes overlapping the respective borders having continuous fibers of the first and second sheet and seaming the first sheet and the second sheet at the overlapping borders.

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