Method of laminate formation

摘要

A method is provided that includes a starting material of a first sheet having first and second major sides, with the first side of the first sheet being adapted for adherence to a substrate sheet, and providing a second porous sheet having first and second major sides. The first side of the second porous sheet is aligned against the second side of the first sheet. A molten thermoplastic material is introduced onto the second side of the second porous sheet. The method includes the step of simultaneously urging the molten thermoplastic material against the second porous sheet to force portions of the thermoplastic material to flow through the second porous sheet and into adhering contact with the second side of the first sheet, and molding a desired surface pattern on an exposed surface of the molten thermoplastic material. The molten thermoplastic material is cooled to bind the material to the first and second sheets and define a laminated assembly.