초록 ▼

A process for fabricating an article having a rigid foam core and a resilient outer plastic shell by extruding a heated thermoplastic material to form the shell, partially hardening the extruded plastic shell, injecting a liquid foam material into the interior of the partially hardened plastic shell

A process for fabricating an article having a rigid foam core and a resilient outer plastic shell by extruding a heated thermoplastic material to form the shell, partially hardening the extruded plastic shell, injecting a liquid foam material into the interior of the partially hardened plastic shell, and cooling the shell and the liquid foam material to fully harden the plastic shell and the foam under conditions which cause the article to have a predetermined shape and size.

대표청구항 ▼

[ What we claim is:] [1.] A continuous extrusion process for use with an extrusion line for fabricating an article having a rigid foam core and a resilient outer plastic shell, the process comprising the steps of:(a) continuously extruding a heated thermoplastic material from a die to form a continu

[ What we claim is:] [1.] A continuous extrusion process for use with an extrusion line for fabricating an article having a rigid foam core and a resilient outer plastic shell, the process comprising the steps of:(a) continuously extruding a heated thermoplastic material from a die to form a continuous extruded plastic shell, with the continuous extruded plastic shell moving in a substantially linear direction along a substantially linear path;(b) partially hardening the extruded plastic shell in a first cooling element located at a first position along the linear path as the continuous extruded plastic shell moves in the linear direction;(c) injecting a liquid foam material into the interior of the partially hardened plastic shell at a location between an exit of the first cooling element and an entrance of a second cooling element linearly-disposed from the first cooling element at a second position along the linear path; and(d) subsequently cooling the plastic shell and the liquid foam material in the second cooling element to more fully harden the plastic shell and the foam.