Patent ID: 7201625

Claim:
A method for producing a foam product comprising the steps of: providing a mold defining a cavity having dimensions identical to those of the foam product; placing a plastic skin in the cavity, wherein the plastic skin is produced by the following steps: providing a polyethylene foam skin, which has a density in a range of 1.5 to 12 PCF and a thickness in a range of 1 to 6 mm; forming a plastic plate on a first surface of the polyethylene foam skin, wherein the plastic plate is made of wear-resistant plastic; and forming a bonding film on a second surface of the polyethylene foam skin, so as to allow the second surface of the polyethylene foam skin heat-bonding with polystyrene foam beads; filling the cavity of the mold with polystyrene foam beads; and injecting steam into the cavity, whereby the polystyrene foam beads are heat-bonded with one another and the plastic skin is accordingly heat-bonded with the polystyrene foam beads entirely under the steam.