Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Patent
1997-01-10
1999-11-02
Yao, Sam Chuan
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
1562722, 1562755, 156285, 1563071, B32B 3104, B32B 3120, B32B 702
Patent
active
059762888
ABSTRACT:
A method of forming a molded, multi-layer structure begins with a pre-laminated, multi-layer structure having a thermoplastic substrate layer and a cover layer. One or more optional layers laminated may be provided between the cover layer and substrate layer. Thermoplastic materials are selected having various physical characteristics (e.g. degrees of cross-linking) to produce a molded structure having a desired shape, rigidity, hardness/softness, and other physical properties. All of the multiple layers can be made of thermoplastic materials having the same polymers to allow the molded structure to be recycled into a reusable thermoplastic material. The pre-laminated, multi-layer structure is uniformly heated, by a method which provides heat penetration and absorption substantially throughout the multi-layer structure. During thermoforming, such as with male/female molds or vacuum molds, the thickness and rigidity of the multi-layer structure can be varied. A textured or decorative surface can be pre-formed in the cover layer(s) or formed during the thermoforming process.
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