Method for making shaped members using a foam froth

A method of making a shaped member, comprising the steps of:

• (a) extruding an expandable foam material from an extruder;
• (b) continuously forming a composite foam by introducing the expandable foam material from the extruder together with a reinforcing veil into a foam die defining a cavity having inner walls, the reinforcing veil having an outer surface lining at least a portion of the inner walls and an inner surface surrounding at least a portion of the expandable foam material, continuously moving the reinforcing veil through the foam die while forcing the expandable foam material through nozzles to form a continuous foam froth surrounded by the moving reinforcing veil, and expanding the foam material to form a foam core that forces the veil against the inner walls of the cavity, with the foam material adhering to the inner surface of the reinforcing veil to yield a composite foam;
• (c) pulling the composite foam from the foam die through a curing die;
• and
• (d) pultruding a continuous shaped member by injecting a liquid resin into the curing die to impregnate the composite foam and curing the liquid resin in the curing die to form a resin skin on the composite foam.