Process of forming a fiber reinforced, stampable thermoplastic laminate

Claim 1

A continuous process of forming a nonsiliceous fiber reinforced, stampable thermoplastic laminate consisting essentially of: (a) extruding a first sheet of thermoplastic resin containing about 5 to 35% by weight nonsiliceous fibers on an extruded basis; (b) embedding a layer of nonsiliceous fibers into one side of said first sheet; (c) extruding a second sheet of thermoplastic resin containing about 5 to 35% by weight of nonsiliceous fibers on an extruded basis; and (d) laminating, in a lamination zone, said second sheet to said first sheet and said layer of nonsiliceous fibers without substantially impairing the integrity of or rearranging said nonsiliceous fibers of said first and second sheets, wherein said lamination zone comprises a set of three heated rolls, said first sheet and said layer of nonsiliceous fibers being in the form of a prelaminate and being passed serially around the first and second of said heated rolls and then between the second and third rolls, advancing said second sheet to the nip formed by the second and third rolls and onto said prelaminate and laminating said prelaminate and said second sheet between said second and third rolls, the lamination being conducted at a temperature ranging from the melting point of the resin to about 650° F.