Process for making foam laminates
First Claim
Patent Images
1. A process of forming a laminated article for use in furniture construction comprising:
- providing a thermoplastic sheet;
warming the thermoplastic sheet to a softening temperature;
forming the sheet into a tray-shaped article having an exterior surface and an interior surface;
placing the tray-shaped article within a mold;
suspending at least one insert above the interior surface of the tray-shaped article;
forming in situ a structural foam, the structural foam bonding to at least a portion of the interior surface of the tray-shaped article opposite the insert and further bonding to at least a portion of the insert;
removing the tray-shaped article from the mold.
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Accused Products
Abstract
A method and apparatus for fabrication of foam laminates suitable for use in the construction of furniture and case goods are provided. The panel has an upper surface formed from a thermoplastic sheet of material such as PVC. A cavity formed by the interior surfaces of the sheet have suspended therein attachment or mounting hardware which is subsequently encapsulated by an in situ structural foaming step. The resulting laminated panel is useful as a table top, shelving, and as a structural component in a variety of case goods and furniture.
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Citations
12 Claims
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1. A process of forming a laminated article for use in furniture construction comprising:
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providing a thermoplastic sheet;
warming the thermoplastic sheet to a softening temperature;
forming the sheet into a tray-shaped article having an exterior surface and an interior surface;
placing the tray-shaped article within a mold;
suspending at least one insert above the interior surface of the tray-shaped article;
forming in situ a structural foam, the structural foam bonding to at least a portion of the interior surface of the tray-shaped article opposite the insert and further bonding to at least a portion of the insert;
removing the tray-shaped article from the mold. - View Dependent Claims (2, 3, 4)
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5. A process of forming a laminated article for use in furniture construction comprising:
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providing a thermoplastic rigid sheet, said sheet having a thickness of at least 2 mm;
warming the thermoplastic sheet to a softening temperature;
forming the thermoplastic sheet into a tray-shaped article having an exterior surface and an interior surface;
placing the tray-shaped article within a mold;
suspending at least one insert above the interior surface of the thermoplastic sheet;
forming in situ a rigid foam, the rigid foam bonding to at least a portion of the interior surface of the thermoplastic sheet and to at least a portion of the insert, a portion of said form positioned between said insert and said interior surface opposite said insert; and
,removing the article from the mold.
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6. A process of forming a laminated article comprising:
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providing a substantially rigid sheet comprising a thermoplastic material;
heating the thermoplastic material to a softening temperature;
forming the thermoplastic material into a tray-shaped configuration having an exterior surface, an interior surface, and an edge, an interior of the edge and the interior surface of said tray-shaped configuration defining a cavity;
placing said tray-shaped sheet within a mold;
suspending at least one insert within said cavity and above the interior surface, a portion of said insert extending outside of said cavity;
forming in situ a rigid foam within said cavity, said rigid foam bonding to at least a portion of the interior surface of the thermoplastic sheet and opposite the insert and further bonding to at least a portion of said insert;
removing the article form the mold. - View Dependent Claims (7, 8, 9, 10, 11, 12)
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Specification