Process for manufacturing a composite sheet

1. A method of manufacturing a composite sheet comprising the steps of:

perforating a reinforcement panel;

providing a mold surface onto which a composite sheet may be formed;

applying at least one outer coat of material onto the mold surface;

applying at least one coat of resin and reinforcement material over the outer coat to form a reinforcement layer;

applying the perforated reinforcement panel to the reinforcement layer; and

forcing the resin into the perforations formed in the reinforcement panel, thereby bonding the reinforcement layer to the reinforcement panel, wherein the perforating step is accomplished by moving the reinforcement panel through three sets of opposed pinch-rollers, one roller of a middle set of the three sets being a perforating mandrel having a plurality of tapered perforating pins.

2. The method of manufacturing a composite sheet according to claim 1 wherein the forcing step is accomplished by applying a vacuum to the perforated reinforcement panel.

3. The method of manufacturing a composite sheet according to claim 1 wherein a polymer sheet is applied to the perforated reinforcement panel prior to the forcing step.

4. A method of manufacturing a composite sheet comprising the steps of:

perforating a reinforcement panel;

providing a mold surface onto which a composite sheet may be formed;

applying at least one outer coat of material onto the mold surface;

applying at least one coat of resin and reinforcement material over the outer coat to form a reinforcement layer;

applying the perforated reinforcement panel to the reinforcement layer; and

forcing the resin into the perforations formed in the reinforcement panel, thereby bonding the reinforcement layer to the reinforcement panel,

wherein the perforating step includes creating a plurality of tapered holes in the reinforcement panel, the tapered holes having an opening diameter within the range of from about 1/32 inch to about 1/16 inch in a first side of the reinforcement panel and having an opening diameter within the range of from about 5/32 inch to about 3/16 inch in a second side of the reinforcement panel, and

wherein the perforating step is accomplished by moving the reinforcement panel through three sets of opposed pinch-rollers, one roller of a middle set of the three sets being a perforating mandrel having a plurality of perforating pins.

5. The method of manufacturing a composite sheet according to claim 4 wherein the forcing step is accomplished by applying a vacuum to the perforated reinforcement panel.

6. The method of manufacturing a composite sheet according to claim 4 wherein a polymer sheet is applied to the perforated reinforcement panel prior to the forcing step.

7. A method of manufacturing a composite sheet comprising the steps of:

forming perforations in a reinforcement panel;

providing a mold surface onto which a composite sheet may be formed;

applying at least one coat of resin and reinforcement material over the mold to forte a reinforcement layer,

applying the perforated reinforcement panel to the reinforcement layer; and

evacuating substantially all air trapped between the resin and the resin and the reinforcement panel through the perforations, wherein the perforating step is accomplished by moving the reinforcement panel Through three sets of opposed pinch-rollers, one roller of a middle set of the three sets being a perforating mandrel having a plurality of perforating pins.

8. The method of manufacturing a composite sheet according to claim 7 wherein the forcing step is accomplished by applying a vacuum to the perforated reinforcement panel.

9. The method of manufacturing a composite sheet according to claim 7 wherein a polymer sheet is applied to the perforated reinforcement panel prior to the forcing step.