Method of forming molded and laminated curved surface composites

A process for simultaneously molding a product and laminating a pattern layer having a selected thickness to a top surface of the molded product comprising the steps in sequence of:

• supplying a molding press comprising a bottom mold plate, a top mold plate, a mold ring element containing an inner edge surrounding the mold plates and moveable independently of the top and bottom mold plates, an upper surface on said mold ring for engaging a peripheral edge of the top mold plate, and a flat groove in said mold ring upper surface adjacent said inner edge of said mold ring and surrounding the interior periphery of said mold ring which is slightly deeper than the thickness of said pattern layer to be laminated to the top surface of the molded product;
• supporting said pattern layer at the edges of said pattern layer in said flat groove while maintaining a space slightly thicker than the thickness of the pattern layer so that said pattern layer is free to slide laterally across the upper surface of said mold ring towards an interior of the mold during the molding process;
• lowering said bottom mold plate relative to said top mold plate and said mold ring and filling the volume provided by the lowered bottom mold plate and interior walls of the mold ring to a level of said inner edge of said mold ring with a heat curing molding powder;
• and
• raising the lowered bottom plate to simultaneously compression mold the molding powder within the molding press to form the molded product and laminate the pattern layer to the top surface of the molded product.