Abstract: A multi-layer fiber reinforced thermoplastic panel is fabricated using a first fiber reinforced thermoplastic sheet having thermoplastic with a first melting point, a second fiber reinforced thermoplastic sheet having thermoplastic with a second melting point, and a connecting layer therebetween. The connecting layer is made of a thermoplastic-compatible material having a third melting point which is less than the first melting point and second melting point. The connecting layer is bonded to the thermoplastic in the first sheet and the second sheet. The subject invention is also directed to a method of fabricating such a panel.

Abstract: A composite sheet has a layer of reinforcing fiber impregnated with a thermoplastic resin. Non-woven fiber is partially impregnated with the thermoplastic resin to provide a bondable surface that can be subsequently bonded to other materials, such as plastics, foam and metal. Such an apparatus may be formed by heating and compressing the thermal plastic resin against the reinforcing fibers of the base layer and against the non-woven fibers, such that the base layer may be fully impregnated while the non-woven fibers may be partially impregnated. A thermal plastic resin must have a melting point less than either the reinforcing fibers of the base layer or the non-woven fibers.

Abstract: A composite sheet has a layer of reinforcing fiber impregnated with a thermoplastic resin. Non-woven fiber is partially impregnated with the thermoplastic resin to provide a bondable surface that can be subsequently bonded to other materials, such as plastics, foam and metal. Such an apparatus may be formed by heating and compressing the thermal plastic resin against the reinforcing fibers of the base layer and against the non-woven fibers, such that the base layer may be fully impregnated while the non-woven fibers may be partially impregnated. A thermal plastic resin must have a melting point less than either the reinforcing fibers of the base layer, or the non-woven fibers.