Method and apparatus for forming layered thermoformable materials

Abstract

A method for continuously producing high-strength welded composite panels from thermoformable material facings and expanded thermoformable material cores comprising the steps of: simultaneously feeding facing sheets and core into a welder that has automated feed rollers; heating the lower side of the top face and the upper side of the lower face simultaneously with both faces of the inner core of expanded thermoformable material; continuing to heat them to 100-400° C. until the surfaces reach the initial melt and/or hot tack temperature of the materials; pressing the heated faces together against the heated surface of the core material to consolidate the composite structure; and allowing the materials to cool while under pressure and continuing to move forward in the engaged roller mechanism until the entire panel has been welded and is dimensionally stable.

Dependencies are inferred from the claim text.