Patent ID: 8568641

Claim:
A process of making composite material human body supports comprising the steps of: molding a base frame of a composite material having a top surface and a bottom surface, the composite material comprising one or more skins of a fibrous material embedded in a polymer matrix that includes a thermosetting resin; and thereafter, associating a cover element made of at least one layer of a first polymer thermoplastic material to the molded base frame to form an integral human body support; wherein the step of molding the base frame comprises causing at least one film of a second thermoplastic material to become stably attached to the base frame at least at one of the top or bottom surfaces, the second thermoplastic material being selected to be thinner than the at least one layer of the first thermoplastic material, the second thermoplastic material being selected to have one or more of a physical or chemical affinity for the first polymer thermoplastic material to provide a junction therebetween such that the cover element is stably attached to the base frame, and wherein the at least one film of the second thermoplastic material is at least partly embedded in the polymer matrix of the base frame such that a top or bottom face of the at least one film of the second thermoplastic material is fixedly attached to the top or bottom surface of the base frame.