Patent ID: 8715437
Filing Date: 2014-05-06
Classification: B29C,B32B,Y10T

Abstract:
1. A process for forming a composite foam product comprising: forming a foam core from a foamable material and a blowing agent, said foam core having a plurality of cells therein, said plurality of cells retaining a gas from said blowing agent therein at a pressure above an ambient pressure, and said foam core having an exterior surface; and then placing a first gas impermeable film in a molding cavity; placing said foam core in said molding cavity; placing a second gas impermeable film over said foam core in said molding cavity; adhering the first and second gas impermeable films to said exterior surface of said foam core by heating the first and second gas impermeable films to their softening temperatures, wherein the first and second gas impermeable films are adhered to substantially all of the exterior surface of the foam core such that said gas from said blowing agent is retained in said cells of said foam core at said pressure above said ambient pressure; wherein the process further comprises applying a first adhesive between said foam core and said first gas impermeable film and applying a second adhesive between said foam core and said second gas impermeable film.