| 摘要 |
<p>A method of manufacturing a contoured sports board comprising the steps of providing a non-expanded film layer (16), providing a polymer foam layer (18, 19), bonding the film layer to the foam layer to form a top laminated sheet (16/17/18/19), providing a bottom sheet (21/22/23, 30), providing a mold having a top portion (44) and a bottom portion (45), the top and bottom portions having inner surfaces (63, 64) and configured to be placed in opposition to each other with their inner surfaces defining a cavity (49) therebetween, the inner surface of the top portion of the mold having contouring defining at least one valley (61, 62), placing the film layer of the top sheet against the inner surface of the top mold portion, mixing an isocyanate and a polyol component to provide a urethane foam forming mixture (50), spraying the mixture on the foam layer of the top sheet, placing the bottom sheet on the top sheet with the mixture between the top sheet and the bottom sheet, placing the inner surface of the bottom portion of the mold on the bottom sheet, mating the bottom portion of the mold with the top portion of the mold, applying pressure to the mold, allowing the mixture time to expand between the top sheet and the bottom sheet, unmating the top and bottom portions of the mold, whereby heat from the expansion of the mixture to form a polyurethane foam core heat laminates the top sheet and the bottom sheet to the polyurethane core to form a board having an outer surface contour generally conforming to the contour of the inner surfaces of the mold.
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