Abstract: A method for making a fiber-reinforced resin sheet includes providing an array of a plurality of resin film layers and fiber layers, passing the array through a die in order to consolidate the array. A pair of belts which are interposed respectively between the upper surface of the array and the die and the lower surface of the array and the die and move through the die, preferably without substantial relative movement between the array and the belts is provided in order to facilitate efficient manufacture while preserving desired end product surface characteristics. The process is preferably a pultrusion process with the belts moving under the influence of pulling force applied to the array. Pultrusion apparatus employing such belts in the manufacture of fiber-reinforced resin sheet is also disclosed.

Abstract: A method and apparatus for automated resistance welding of materials is provided. The material may be thermoplastic material. The material has a layer of a second material adjacent thereto. The second material is a dissimilar material which may be applied as a film or a coating on the first material, or the second material may be a separate layer placed adjacent the first material. A heating element is placed in the interface between overlapping portions of the two pieces of material to be welded together. The layers are directly adjacent to the heating element. The layers can be consolidated onto the heating element if desired. The heating element can be composed of carbon fibers in a polymer matrix. The heating element is supplied with current to generate resistive heating. The heating causes melting of the layers adjacent to and contacting the material. Pressure is applied to the area being welded to fuse the materials together.

Abstract: A metal-polymer-metal laminate is made by joining adjacent laminate sections in a staggered relationship. Terminal portions of metal layers in a first laminate section are opposed to ends of fiber-reinforced polymer layers in a second laminate section. End portions of fiber-reinforced polymer layers in the first laminate section are opposed to ends of metal layers in a second laminate section. The two laminate sections are then joined by an adhesive layer.