Patent ID: 6527992
Filing Date: 2003-03-04
Classification: B29C,B29K,B32B,B44C,D06M,D06Q,G09F,Y10T

Abstract:
A method for making a formed laminate comprising:depositing a quick reacting foamable liquid mixture onto a rigid transfer member for reaction that causes expansion to provide a foam which subsequently cures but which, after substantial completion of the expansion and before curing has taken place, has a transitory state when the liquid mixture is viscous and defines cells enclosing the gas generated during the expansion stage of the reaction; transferring reacted foam and any foamable liquid mixture that has not yet reacted from the transfer member onto a flexible sheet; and providing relative movement of a pair of contoured mold surfaces toward each other with the flexible sheet and foam therebetween and without the transfer member therebetween while the foam is in the transitory state such that the foam is collapsed and formed with the flexible sheet to the contoured shapes of the mold surfaces as the collapsed foam is bonded to the flexible sheet to provide the formed laminate.