Importance

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Abstract

A thermoplastic thermoformable resin material defines a core of a thermoformable thermoplastic composite material. First and second layers of fabric material are disposed against opposite sides of the core. An additional layer of a fabric material is positioned on the first fabric layer to impart a particular color to the composite material. A resin envelopes and impregnates the different fabric layers and bonds these layers to the core. The fabric layers have a total thickness sufficient to impart strength and rigidity to the fabric material. The core is sufficiently thick to provide for a shaping of the composite material at an elevated temperature to any desired configuration without any rippling or buckling of the composite material. Additional layers of a thermoplastic thermoformable resin material may be disposed on the outer layers of the fabric material. They impregnate the fabric layers, provide a continuity with the core and provide a smooth external surface to the composite material. The core and the additional resin layers may be an acrylic. The two fabric layers may be made from carbon and may be woven or formed from discrete particles. The additional fabric layer may be woven from a warp and a woof. The warp may be made from a high strength fiber and the woof may be formed from a colored fiber. Another embodiment of the composite material may be formed from the core, one additional layer of the fabric material and the colored fabric. The invention also relates to methods of forming the composite material.

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First Claim