Method of making a three-dimensional laminate

Claim 1

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising: (a) continuously feeding a normally solid adhesive layer between a heat-sensitive, unfoamed three-dimensional layer and a near molten thermoplastic substrate sheet to form a three-layer laminate, the temperature of said substrate being sufficiently above the melting temperature of said adhesive layer to effect the fusion bonding of said substrate in said three-dimensional layer; (b) simultaneously inhibiting the loss of heat from the exposed surface of said substrate to balance the heat flow from opposing surfaces of said substrate; and (c) maintaining a balanced heat flow from the opposing surfaces of said substrate as said laminate cools.

Claim 2

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising: (a) continuously feeding a normally solid adhesive layer between a heat-sensitive, unfoamed three-dimensional layer and a near molten thermoplastic substrate sheet to form a three-layer laminate, the temperature of said substrate being sufficiently above the melting temperature of said adhesive layer to effect the fusion bonding of said substrate in said three-dimensional layer; (b) simultaneously inhibiting the loss of heat from the exposed surface of said substrate to balance the heat flow from opposing surfaces of said substrate; and (c) maintaining a balanced heat flow from the opposing surfaces of said substrate as said laminate cools.

Claim 9

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously contacting a first surface of a near molten thermoplastic substrate sheet with a heat-sensitive three-dimensional grass-like thermoplastic layer to form a laminate, the temperature of said substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three-dimensional layer to said substrate; (b) simultaneously inhibiting the loss of heat from the surface of said substrate opposite to said first surface to balance the heat flow from opposing surfaces of said substrate during said contacting; and (c) maintaining a balanced heat flow from opposed surfaces of said substrate as said laminate cools; said three-dimensional layer comprising low density polyethylene and said substrate comprising high density polyethylene.

Claim 10

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously contacting a first surface of a near molten thermoplastic substrate sheet with a heat-sensitive three-dimensional grass-like thermoplastic layer to form a laminate, the temperature of said substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three-dimensional layer to said substrate; (b) simultaneously inhibiting the loss of heat from the surface of said substrate opposite to said first surface to balance the heat flow from opposing surfaces of said substrate during said contacting; and (c) maintaining a balanced heat flow from opposed surfaces of said substrate as said laminate cools; said three-dimensional layer comprising low density polyethylene and said substrate comprising high density polyethylene.

Claim 11

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously extruding a near molten thermoplastic substrate sheet; (b) passing said near molten substrate between a pair of laminating rolls comprising a pressure roll and heated roll; (c) simultaneously passing a heat-sensitive, unfoamed three-dimensional thermoplastic layer through said pair of laminating rolls, said pressure roll urging said three-dimensional layer into contact with said near molten substrate, said heated roll being at a temperature sufficient to balance the heat flow from opposing surfaces of said substrate, and the temperature of said near molten substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three-dimensional layer to said substrate to form a laminate; and (d) subsequently cooling the three-dimensional layer side of said laminate to prevent thermal damage to said three-dimensional layer and to balance the heat flow from opposing surfaces of said substrate.

Claim 12

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously extruding a near molten thermoplastic substrate sheet; (b) passing said near molten substrate between a pair of laminating rolls comprising a pressure roll and heated roll; (c) simultaneously passing a heat-sensitive, unfoamed three-dimensional thermoplastic layer through said pair of laminating rolls, said pressure roll urging said three-dimensional layer into contact with said near molten substrate, said heated roll being at a temperature sufficient to balance the heat flow from opposing surfaces of said substrate, and the temperature of said near molten substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three-dimensional layer to said substrate to form a laminate; and (d) subsequently cooling the three-dimensional layer side of said laminate to prevent thermal damage to said three-dimensional layer and to balance the heat flow from opposing surfaces of said substrate.

Claim 19

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously extruding a near molten thermoplastic substrate sheet; (b) passing said near molten substrate between a pair of sizing rolls; (c) passing said sized near molten substrate between a pair of laminating rolls comprising a pressure roll and a heated roll; (d) simultaneously passing a heat-sensitive, three-dimensional, grass-like thermoplastic layer through said pair of laminating rolls, said pressure roll urging said three-dimensional layer into contact with said near molten substrate, said heated roll being at a temperature sufficient to balance the heat flow from opposing surfaces of said substrate, and the temperature of said near molten substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three-dimensional layer to said substrate to form a laminate; and (e) subsequently cooling the three-dimensional layer side of said laminate to prevent thermal damage to said three-dimensional layer and to balance the heat flow from opposing surfaces of said substrate; said substrate comprising high density polyethylene and said three-dimensional layer comprising low density polyethylene.

Claim 20

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously extruding a near molten thermoplastic substrate sheet; (b) passing said near molten substrate between a pair of sizing rolls; (c) passing said sized near molten substrate between a pair of laminating rolls comprising a pressure roll and a heated roll; (d) simultaneously passing a heat-sensitive, three-dimensional, grass-like thermoplastic layer through said pair of laminating rolls, said pressure roll urging said three-dimensional layer into contact with said near molten substrate, said heated roll being at a temperature sufficient to balance the heat flow from opposing surfaces of said substrate, and the temperature of said near molten substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three-dimensional layer to said substrate to form a laminate; and (e) subsequently cooling the three-dimensional layer side of said laminate to prevent thermal damage to said three-dimensional layer and to balance the heat flow from opposing surfaces of said substrate; said substrate comprising high density polyethylene and said three-dimensional layer comprising low density polyethylene.

Claim 21

A method for producing a laminate comprising a grass-like layer of low density polyethylene and a substrate sheet of high density polyethylene, said laminate being substantially free of distortion in said grass-like layer and substantially free of warpage in said substrate, said method comprising the steps of: (a) continuously extruding molten high density polyethylene to form a substrate sheet; (b) passing said substrate between a pair of sizing rolls after it has cooled to near molten condition; (c) passing the resulting sized, near molten substrate between a pair of laminating rolls comprising a heated roll and a pressure roll; (d) simultaneously passing said grass-like layer between said pair of laminating rolls, said pressure roll urging said grass-like layer into intimate contact with one surface of said substrate, said heated roll being at a temperature sufficient to balance the heat flow from the opposing surfaces of said substrate, and said second pair of rolls being located at a position downstream of said extruder where said near molten substrate has a temperature sufficient to melt the contacting surface of said grass-like layer to effect fusion bonding of said grass-like layer to said substrate; (e) passing the three-dimensional layer side of the resulting laminate around a cooling roll to protect said three-dimensional layer from thermal distortion; and (f) passing said laminate through a cooling zone in which a controlled flow of a cooling fluid is passed over said three-dimensional layer side of said laminate.

Claim 22

A method for producing a laminate comprising a grass-like layer of low density polyethylene and a substrate sheet of high density polyethylene, said laminate being substantially free of distortion in said grass-like layer and substantially free of warpage in said substrate, said method comprising the steps of: (a) continuously extruding molten high density polyethylene to form a substrate sheet; (b) passing said substrate between a pair of sizing rolls after it has cooled to near molten condition; (c) passing the resulting sized, near molten substrate between a pair of laminating rolls comprising a heated roll and a pressure roll; (d) simultaneously passing said grass-like layer between said pair of laminating rolls, said pressure roll urging said grass-like layer into intimate contact with one surface of said substrate, said heated roll being at a temperature sufficient to balance the heat flow from the opposing surfaces of said substrate, and said second pair of rolls being located at a position downstream of said extruder where said near molten substrate has a temperature sufficient to melt the contacting surface of said grass-like layer to effect fusion bonding of said grass-like layer to said substrate; (e) passing the three-dimensional layer side of the resulting laminate around a cooling roll to protect said three-dimensional layer from thermal distortion; and (f) passing said laminate through a cooling zone in which a controlled flow of a cooling fluid is passed over said three-dimensional layer side of said laminate.

Claim 28

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising: (a) continuously feeding a normally solid adhesive layer between a heat sensitive, three-dimensional grass-like layer and a near molten thermoplastic substrate sheet to form a three layer laminate, the temperature of said substrate being sufficiently above the melting temperature of said adhesive layer to effect fusion bonding of said layers; (b) simultaneously inhibiting the loss of heat from the exposed surface of said substrate to balance the heat flow from opposing surfaces of said substrate; and (c) maintaining a balanced heat flow from the opposing surfaces of said substrate as said laminate cools; said three-dimensional layer comprising low density polyethylene and said substrate comprising high density polyethylene.

Claim 29

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising: (a) continuously feeding a normally solid adhesive layer between a heat sensitive, three-dimensional grass-like layer and a near molten thermoplastic substrate sheet to form a three layer laminate, the temperature of said substrate being sufficiently above the melting temperature of said adhesive layer to effect fusion bonding of said layers; (b) simultaneously inhibiting the loss of heat from the exposed surface of said substrate to balance the heat flow from opposing surfaces of said substrate; and (c) maintaining a balanced heat flow from the opposing surfaces of said substrate as said laminate cools; said three-dimensional layer comprising low density polyethylene and said substrate comprising high density polyethylene.

Claim 30

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously contacting a first surface of a near molten thermoplastic substrate sheet with a heat-sensitive unfoamed three-dimensional thermoplastic layer to form a laminate, the temperature of said substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three-dimensional layer to said substrate, said contacting being accomplished by simultaneously feeding said substrate and said three-dimensional layer together between a pair of rolls; (b) simultaneously inhibiting the loss of heat from the surface of said substrate opposite to said first surface to balance the heat flow from opposing surfaces of said substrate during said contacting, said inhibiting of heat loss being effected by heating the one of said rolls which contacts said opposite surface; and (c) maintaining a balanced heat flow from opposed surfaces of said substrate as said laminate cools.

Claim 31

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously contacting a first surface of a near molten thermoplastic substrate sheet with a heat-sensitive unfoamed three-dimensional thermoplastic layer to form a laminate, the temperature of said substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three-dimensional layer to said substrate, said contacting being accomplished by simultaneously feeding said substrate and said three-dimensional layer together between a pair of rolls; (b) simultaneously inhibiting the loss of heat from the surface of said substrate opposite to said first surface to balance the heat flow from opposing surfaces of said substrate during said contacting, said inhibiting of heat loss being effected by heating the one of said rolls which contacts said opposite surface; and (c) maintaining a balanced heat flow from opposed surfaces of said substrate as said laminate cools.

Claim 32

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously contacting a first surface of a near molten thermoplastic substrate sheet with a heat-sensitive unfoamed three-dimensional thermoplastic layer to form a laminate, the temperature of said substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three-dimensional layer to said substrate; (b) simultaneously inhibiting the loss of heat from the surface of said substrate opposite to said first surface to balance the heat flow from opposing surfaces of said substrate during said contacting; and (c) maintaining a balanced heat flow from opposed surfaces of said substrate as said laminate cools by cooling the three-dimensional layer side of said laminate.

Claim 33

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously contacting a first surface of a near molten thermoplastic substrate sheet with a heat-sensitive unfoamed three-dimensional thermoplastic layer to form a laminate, the temperature of said substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three-dimensional layer to said substrate; (b) simultaneously inhibiting the loss of heat from the surface of said substrate opposite to said first surface to balance the heat flow from opposing surfaces of said substrate during said contacting; and (c) maintaining a balanced heat flow from opposed surfaces of said substrate as said laminate cools by cooling the three-dimensional layer side of said laminate.

Claim 34

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously contacting a first surface of a near molten thermoplastic substrate sheet with a heat-sensitive unfoamed three-dimensional thermoplastic layer to form a laminate, the temperature of said substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three dimensional layer to said substrate; (b) simultaneously inhibiting the loss of heat from the surface of said substrate opposite to said first surface to balance the heat flow from opposing surfaces of said substrate during said contacting; and (c) maintaining a balanced heat flow from opposed surfaces of said substrate as said laminate cools by insulating the substrate side of said laminate.

Claim 35

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously contacting a first surface of a near molten thermoplastic substrate sheet with a heat-sensitive unfoamed three-dimensional thermoplastic layer to form a laminate, the temperature of said substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three dimensional layer to said substrate; (b) simultaneously inhibiting the loss of heat from the surface of said substrate opposite to said first surface to balance the heat flow from opposing surfaces of said substrate during said contacting; and (c) maintaining a balanced heat flow from opposed surfaces of said substrate as said laminate cools by insulating the substrate side of said laminate.

Claim 36

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously contacting a first surface of a near molten thermoplastic substrate sheet with a heat-sensitive three-dimensional grass-like thermoplastic layer to form a laminate, the temperature of said substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three-dimensional layer to said substrate; (b) simultaneously inhibiting the loss of heat from the surface of said substrate opposite to said first surface to balance the heat flow from opposing surfaces of said substrate during said contacting; and (c) maintaining a balanced heat flow from opposed surfaces of said substrate as said laminate cools.

Claim 37

A method for producing a three-dimensional laminate substantially free of thermal distortion, said method comprising the steps of: (a) continuously contacting a first surface of a near molten thermoplastic substrate sheet with a heat-sensitive three-dimensional grass-like thermoplastic layer to form a laminate, the temperature of said substrate being sufficiently above the melting temperature of said three-dimensional layer to effect fusion bonding of said three-dimensional layer to said substrate; (b) simultaneously inhibiting the loss of heat from the surface of said substrate opposite to said first surface to balance the heat flow from opposing surfaces of said substrate during said contacting; and (c) maintaining a balanced heat flow from opposed surfaces of said substrate as said laminate cools.