Method of forming a resin laminate containing foam beads

Abstract

A resin laminate of the invention includes a sheet laminate including a skin, which is securely joined with a foamed bead base by heating. The resin laminate is manufactured according to the following steps. The foamed bead base and the sheet laminate consisting of the skin, a foam layer, and a thermoplastic resin film are prepared separately. The thermoplastic resin film is made of a resin material which thermally adheres to both the foam layer and the foamed bead base and has a softening temperature lower than those of the foam layer and the foamed bead base. The thermoplastic resin film is softened by heating the sheet laminate, which is then softened by heating the sheet laminate, which is then pressed against and bonded to the foamed bead base by vacuum molding or press forming. The thermoplastic resin film thermally adheres to both the foam .layer of the sheet laminate and the foamed bead base, thus joining the sheet laminate with the foamed bead base.

Dependencies are inferred from the claim text.