Patent ID: 7575493

Claim:
A method of applying a contoured thermoformed foam skin to a molded foam board, which has a thickness generally exceeding 0.25 inch, wherein the method comprises the steps of: molding a foam core having molded contour surface on at least one primary surface; applying an adhesive resin film layer to a polyolefin foam skin layer forming a film foam laminate; heat laminating the film side of the film foam laminate to the molded contour surface of the molded foam core in a press mold wherein the foam core acts as a face of a die for pressing against the film foam laminate; heating the film foam laminate to a temperature of about 180 F to 220 F; placing the heated film foam laminate on top of a thermoforming bottom die; thermoforming and heat laminating the film foam laminate to the molded foam core by pressing the molded foam core towards the film side of the film foam laminate and mating against the profile of thermoforming bottom die surface, wherein the contour surface of molded foam core operates as an upper thermoforming die when pressed onto the adhesive resin film layer adhered to the polyolefin foam sheet.