Method of forming a resin laminate containing foam beads

Details Method of forming a resin laminate containing foam beads Method of forming a resin laminate containing foam beads

1993-08-10

1995-12-19

Kuhns, Allan R.

Plastic and nonmetallic article shaping or treating: processes

Pore forming in situ

Composite article making

264 464, 264 465, 264 468, 264 459, 264273, 264321, 264511, 264126, B29C 4406, B29C 4412

Patent

active

054766184

ABSTRACT:
A resin laminate of the invention includes a sheet laminate including a skin, which is securely joined with a foamed bead base by heating. The resin laminate is manufactured according to the following steps. The foamed bead base and the sheet laminate consisting of the skin, a foam layer, and a thermoplastic resin film are prepared separately. The thermoplastic resin film is made of a resin material which thermally adheres to both the foam layer and the foamed bead base and has a softening temperature lower than those of the foam layer and the foamed bead base. The thermoplastic resin film is softened by heating the sheet laminate, which is then softened by heating the sheet laminate, which is then pressed against and bonded to the foamed bead base by vacuum molding or press forming. The thermoplastic resin film thermally adheres to both the foam .layer of the sheet laminate and the foamed bead base, thus joining the sheet laminate with the foamed bead base.

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