Patent ID: 8163125

Claim:
A method of constructing a multi-layer laminate structure, comprising the steps of: a. providing a lamination frame, wherein the frame includes a first frame surface, a second frame surface and an external side frame surface interconnecting the first and second surfaces defining a frame thickness, further wherein the frame includes an internal side frame surface that projects towards the second frame surface from the first frame surface at least through a portion of the frame thickness defining a first frame pocket and a first frame pocket side wall profile, further wherein the lamination frame provides at least one of holding, locating, and dimensional control during the manufacturing of the multi-layer laminate structure; b. providing a first layer including a first layer top surface portion, first layer bottom surface portion, and a first layer side surface portion interconnected between the top and bottom portions, wherein the first layer has a first layer length and first layer width adapted to fit within the first frame pocket; c. providing a second layer including a second layer top surface portion, second layer bottom surface portion, and a second layer side surface portion interconnected between the top and bottom portions, wherein the second layer includes an energy activated flowable polymer and further wherein the second layer has a second layer length, a second layer width, and a second layer thickness such that it can at least partially flow into and fill at least a portion of a first gap between the internal side frame surface and the first layer side surface portion; d. introducing the first layer to the first pocket; e. placing the second layer bottom surface portion at least partially in communication with the first layer top surface portion creating a multi-layer stack; f. applying an energy source to the lamination frame, the multi-layer stack, or both, causing the energy activated flowable polymer to bond to the first layer and at least partially flow into the first gap between the first layer side surface portion and the internal side frame surface creating a bead with a bead width and a bead depth, the bead depth defined by a depth of the internal side frame surface; g. allowing the energy activated flowable polymer to at least partially solidify, forming the multi-layer laminate structure, wherein the lamination frame is constructed such that it is capable of being removed after the energy activated flowable polymer has at least partially solidified; and h. separating the multi-layer laminate structure from the lamination frame.