METHOD OF FORMING A LAMINATE COMPRISING A FOAMED MATERIAL COMPRISING SYNTHETIC RESIN AND A LAYER OF VISCOUS OR PASTY SETTABLE MATERIAL WHICH HAS PARTIALLY PENETRATED THE FOAM MATERIAL AND THEN SET; BUILDING PANELS

摘要

Foam laminates wherein the bond between the foam layer and the adjacent layer is enhanced by mechanical keying, which exhibit excellent surface finishes and are suitable in a wide variety of uses are obtained very simply in a single step and without the need for complicated molding equipment or expensive mold materials by a method comprising: (i) providing a solid body of foamed material comprising foamed synthetic resin with or without a filler, said body containing substantially an open-cell structure and having a face containing pores open to the surface; (ii) applying to or forming on said face a layer of viscous or pasty settable material; (iii) applying pressure to the layer to force some of the material to enter into at least some of said pores while in the unset state and simultaneously to mold the external surface of the layer; and thereafter (iv) causing or allowing said settable material to set whereby to form a foam laminate including a layer of set material which is mechanically keyed to said solid body of foamed material. d