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US 7,201,625 B2Granted
Foam product having outer skin and method for producing the same
OwnerTzong In Yehinventor
Life of this patent
Estimating the term…
Abstract
A method for producing a foam product having an outer skin is provided. The outer skin is firstly placed in a mold and then a plurality of polystyrene foam beads are introduced into the mold in order to fill a cavity of the mold with the foam beads, which are heat-bonded with one another under steam pressure subsequently. Accordingly, a surface of the outer skin, which contacts with the foam beads, is entirely heat-bonded with the foam beads. Thus, the foam product with the outer skin is produced and the foam product comprises the outer skin and a polystyrene foam core composed of the foam beads, which are heat-bonded with one another without any spaces.
Claims21
A method for producing a foam product comprising the steps of:
- providing a mold defining a cavity having dimensions identical to those of the foam product;
- placing a plastic skin in the cavity, wherein the plastic skin is produced by the following steps:
- providing a polyethylene foam skin, which has a density in a range of 1.5 to 12 PCF and a thickness in a range of 1 to 6 mm;
- forming a plastic plate on a first surface of the polyethylene foam skin,
- wherein the plastic plate is made of wear-resistant plastic;
- and
- forming a bonding film on a second surface of the polyethylene foam skin, so as to allow the second surface of the polyethylene foam skin heat-bonding with polystyrene foam beads;
- filling the cavity of the mold with polystyrene foam beads;
- and
- injecting steam into the cavity, whereby the polystyrene foam beads are heat-bonded with one another and the plastic skin is accordingly heat-bonded with the polystyrene foam beads entirely under the steam.
7 more elements
A method for producing a foam product comprising the steps of:
- providing a mold defining a cavity having dimensions identical to those of the foam product;
- placing a plastic skin in the cavity, wherein the plastic skin is produced by the following steps:
- providing a polyethylene foam skin, which has a density in a range of 1.5 to 12 PCF and a thickness in a range of 1 to 6 mm;
- providing a plastic film, which has visible patterns therein;
- causing a first surface of the plastic film to heat-bond with a first surface of the polyethylene foam skin;
- forming a plastic plate on a second surface of the plastic film, wherein the plastic plate is made of wear-resistant plastic and has a thickness greater than the plastic film;
- and
- forming a bonding film on a second surface of the polyethylene foam skin, so as to allow the second surface of the polyethylene foam skin heat-bonding with the polystyrene foam beads;
- filling the cavity of the mold with polystyrene foam beads;
- and
- injecting steam into the cavity, whereby the polystyrene foam beads are heat-bonded with one another and the plastic skin is accordingly heat-bonded with the polystyrene foam beads entirely under the steam.
8 more elements
A method for producing a foam product comprising the steps of:
- providing a mold defining a cavity having dimensions identical to those of the foam product;
- placing a plastic skin in the cavity, wherein the plastic skin is produced by the following steps:
- providing a plastic film, which has visible patterns therein, wherein the plastic film is produced by the following steps:
- providing a first film;
- printing the patterns on a surface of the first film;
- and
- forming a second film on the surface of the first film via extrusion coating processes, so as to cover the patterns;
- and
- forming a bonding film on the plastic film to allow the heat-bonding of the plastic film with polystyrene foam beads;
- filling the cavity of the mold with polystyrene foam beads;
- and
- injecting steam into the cavity, whereby the polystyrene foam beads are heat-bonded with one another and the plastic skin is accordingly heat-bonded with the polystyrene foam beads entirely under the steam.
9 more elements
A method for producing a foam product comprising the steps of:
- providing a mold defining a cavity having dimensions identical to those of the foam product;
- placing a plastic skin in the cavity, wherein the plastic skin is produced by the following steps:
- providing a polyethylene foam skin, which has a density in a range of 1.5 to 12 PCF and a thickness in a range of 1 to 6 mm;
- providing a plastic film, which has visible patterns therein, wherein the plastic film is produced by the following steps:
- providing a first film;
- printing the patterns on a surface of the first film;
- and
- forming a second film on the surface of the first film via extrusion coating processes, so as to cover the patterns;
- causing the plastic film to heat-bond with a first surface of the polyethylene foam skin;
- and
- forming a bonding film on a second surface of the polyethylene foam skin, so as to allow the second surface of the polyethylene foam skin heat-bonding with the polystyrene foam beads;
- filling the cavity of the mold with polystyrene foam beads;
- and
- injecting steam into the cavity, whereby the polystyrene foam beads are heat-bonded with one another and the plastic skin is accordingly heat-bonded with the polystyrene foam beads entirely under the steam.
11 more elements
A foam product comprising:
- a first foam product comprising a first core and a first plastic outer skin formed on a top and edges of the first core, wherein the first core is composed of foam beads, which are heat-bonded with one another;
- and
- a second foam product comprising a second core and a second plastic outer skin formed on a top and edges of the second core, wherein the second core is composed of foam beads, which are heat-bonded with one another, and a bottom of the second core is connected to a bottom of the first core accordingly, so as to integrate the first foam product and the second foam product into the foam product.
Dependencies are inferred from the claim text.