Abstract: A process is provided for preparing recyclable reinforced composite structures having enhanced surface appearance by heating a self-supporting porous batt comprised of an intimate homogenous blend of high modulus reinforcing fibers and thermoplastic resin fibers to a temperature sufficient to melt the resin component and convert the batt into moldable form, placing the moldable batt into a heated mold to flow, solidify and substantially crystallize the component, introducing a thermosetting resin-containing coating material into the mold adjacent at least one surface of the crystallized structure to provide a coating on the one surface and dwelling the coated structure in the mold for a time sufficient to set the coating material.

Abstract: A method of shaping elongated composite structures of a resin matrix reinforced with randomly broken fibers oriented in transverse and non-transverse directions with respect to the longitudinal axis of the structure is implemented by a computer aided apparatus for forming the structure. The apparatus is provided with a heated fixed forming tool, a means for stretching the structure from each end and means associated with the forming tool for separately holding each formed component length of the structure in place against the forming tool. The formed structure is characterized by the particular orientation of the fibers in the transverse and non-transverse direction after the structure is formed.

Abstract: Reinforced poly(ethylene terephthalate) sheets are thermoformed to articles having one or more surfaces in contact with the mold of such a degree of smoothness that they virtually completely replicate the mold face. When the mold face is completely smooth, the concave imperfections caused by air entrapment in the plastic material account for less than 6% of the surface area. Composite articles consisting of a face member and a backing member are made by thermoforming in a single mold a face member having one or more surfaces in contact with the mold face of such a degree of smoothness that it completely replicates the mold face, and its proportion of concave imperfections is less than about 6% of the surface area. The backing member is bonded in the mold with an adhesive to the face member, and the composite structure is allowed to remain in the mold for a sufficient time to permit subsequent removal without distortion.

Abstract: Fiber-reinforced poly(ethylene terephthalate) sheet is laminated to a sheet of amorphous, adhesive copolyester at a temperature at which poly(ethylene terephthalate) is in a molten state. The resulting composite sheet is useful in making thermoformed articles in which one member is bonded to another member, for example, a face member and a backing member. The different members are arranged so that their copolyester layers face each other. Hollow thermoformed articles bonded with amorphous copolyester adhesive exhibit very good bond strength and minimum distortion.

Abstract: Reinforced poly(ethylene terephthalate) sheets are thermoformed to articles having one or more surfaces in contact with the mold of such a degree of smoothness that they virtually completely replicate the mold face. When the mold face is completely smooth, the concave imperfections caused by air entrapment in the plastic material account for less than 6% of the surface area. Composite articles consisting of a face member and a backing member are made by thermoforming in a single mold a face member having one or more surfaces in contact with the mold face of such a degree of smoothness that it completely replicates the mold face, and its proportion of concave imperfections is less than about 6% of the surface area. The backing member is bonded in the mold with an adhesive to the face member, and the composite structure is allowed to remain in the mold for a sufficient time to permit subsequent removal without distortion.