Importance

Loading Importance Indicators...

Abstract

A method of forming a molded, multi-layer structure begins with a pre-laminated, multi-layer structure having a thermoplastic substrate layer and a cover layer. One or more optional layers laminated may be provided between the cover layer and substrate layer. Thermoplastic materials are selected having various physical characteristics (e.g. degrees of cross-linking) to produce a molded structure having a desired shape, rigidity, hardness/softness, and other physical properties. All of the multiple layers can be made of thermoplastic materials having the same polymers to allow the molded structure to be recycled into a reusable thermoplastic material. The pre-laminated, multi-layer structure is uniformly heated, by a method which provides heat penetration and absorption substantially throughout the multi-layer structure. During thermoforming, such as with male/female molds or vacuum molds, the thickness and rigidity of the multi-layer structure can be varied. A textured or decorative surface can be pre-formed in the cover layer(s) or formed during the thermoforming process.

Loading the Abstract Image...

First Claim