Abstract: A composite panel includes a mold surface, a layer of gel coat applied to the mold surface, a wet laminate containing a resin applied to the layer of gel coat, a substrate of lauan or another moisture-carrying or moisture-absorbing material placed on the wet laminate, and a layer of a bonding promoter provided at the interface of the substrate with the wet laminate, additional to any amount of promoter(s) present in the resin of the wet laminate. Without previously curing or drying the layer consisting essentially of the bonding promoter in the solvent, each of the wet laminate, the bonding promoter, and the gel coat are simultaneously cured.

Abstract: A method of manufacturing a composite panel with lauan or another moisture-carrying or moisture-absorbing material, and the panel so made, are provided. A layer of gel coat is formed on a mold surface, a wet laminate containing a resin is applied to the layer of gel coat on the mold surface, a substrate of lauan or another moisture-carrying or moisture-absorbing material is placed on the wet laminate, and the combination is cured. Prior to curing, there is provided a layer of a bonding promoter at the interface of the substrate with the wet laminate, additional to any amount of promoter(s) present in the resin of the wet laminate.

Abstract: Embodiments of the present disclosure include a composite panel and a method of manufacturing the composite panel. The composite panel includes first and second fiber reinforced plastic (FRP) layers. The composite panel also includes a core layer disposed between the first and second FRP layers. The core layer includes one of: a honeycomb material and a foam material. The composite panel further includes an exterior layer disposed on a surface of the first FRP layer opposite the core layer and an interior layer disposed on a surface of the second FRP layer opposite the core layer. The layers are cured together in one processing step.

Abstract: A panel for use in a foundation or above-grade may be made with studs for strength, and for attachment to an interior wall. The composite panel has two outer facing sheets, and a core. Studs are provided on one of the outer facing sheets. The manufacturing process involves forming the panel on a mold by laying down a gel coat (optional), a lower facing sheet (used instead of, or with, the gel coat), the core piece(s), and the top facing layer. This can be done by a lamination process, or preferably is done by laying down fibrous material for the facing sheet(s) and vacuum-infusing it with resin, and curing the panel. The core pieces may either be pre-made, or (if infusion is used) may themselves be made in this process, by infusing them with the resin as well. The studs are preferably of galvanized steel and are secured by means of an adhesive.

Abstract: A durable composite sheet is provided, with a method of manufacturing the composite sheet. The method includes using a crack-resistant reinforcement panel between a gel coat and a reinforcement panel, which may be of lauan or of other materials. At least one outer coat of material is applied onto a mold surface. A barrier layer may be formed on the outer coat, preferably by spraying. At least one coat of a resin material, containing a curable resin and optionally a filler, and a fibrous reinforcement material are applied over the outer coat (over the barrier layer if present) to form a reinforcement layer. The reinforcement panel is applied to the crack-resistant reinforcement layer, and is bonded thereto.

Abstract: Embodiments of the present disclosure include a composite panel and a method of manufacturing the composite panel. The composite panel includes first and second fiber reinforced plastic (FRP) layers. The composite panel also includes a core layer disposed between the first and second FRP layers. The core layer includes one of: a honeycomb material and a foam material. The composite panel further includes an exterior layer disposed on a surface of the first FRP layer opposite the core layer and an interior layer disposed on a surface of the second FRP layer opposite the core layer. The layers are cured together in one processing step.

Abstract: A reinforced composite material includes a decorative layer, and a strengthening panel, preferably directly fused to each other. The decorative layer is preferably made of one to three layers of (preferably printed) paper impregnated with a resin such as polyester or melamine resin. The strengthening panel may have a foil facing on one surface for fusion to the decorative layer, or may be roughed and directly fused to the decorative layer without such foil facing. Also provided is a method for the production of such a material.