Bendable foam covered rod-like article and method and apparatus for making same

A bendable rod-like article having a flexible core and a foam sheath produced by the method comprising the steps of:

• advancing a continuous flexible core along a predetermined path of travel;
• applying an adhesive coating to the flexible core;
• feeding the thus-coated core to an extruder;
• extruding a foam sheath about the core with the extruder to foam a composite structure defining a central axis;
• cutting the composite structure to form predetermined lengths of discrete rod-like elements each having opposed ends defined by the axially coextensive ends of the core and sheath;
• securing each respective rod-like element in a fixed position;
• pressing an orificed plate and one of the ends of the foam sheath of the rod-like element against each other in an axial direction such that the respective end of the foam sheath is compressed and the corresponding end of the core extends through the orifice of the plate;
• cutting and removing the portion of the core end extending through the plate orifice;
• releasing the pressure between the plate and the foam sheath such that the sheath decompresses to extend beyond the core end;
• pressing an orificed plate and the other of the ends of the foam sheath of the rod-like element against each other in an axial direction such that the respective end of the foam sheath is compressed and the corresponding end of the core extends through the orifice of the pate;
• cutting and removing the portion of the core end extending through the plate orifice;
• releasing the pressure between the plate and the foam sheath such that the sheath decompressed to extend beyond the core end;
• smoothing each of the ends of the core such that each end has a diameter which is not substantially greater than a central portion of the flexible core;
• and
• sealing each of the ends of the foam sheath to enclose the core ends within the foam sheath.

A bendable, rod-like article having a flexible core and a foam sheath made by the process comprising the steps of:

• providing a continuous composite structure including a foam a sheath extruded about a flexible core and defining a central axis;
• cutting the composite structure to form predetermined lengths of discrete rod like elements each having opposed ends;
• positioning an orificed plate against one of the ends of said element such that the plate orifice is axially aligned with said core;
• compressing the orificed plate against the end of the foam sheath of the composite structure such that a corresponding end of the core extends through the plate orifice;
• cutting and removing a portion of the core end extending through the plate orifice, to thereby shorten the length of the core;
• releasing the compression of the plate against the foam sheath such that the sheath returns substantially to its original orientation and the core end is recessed within the foam sheath;
• smoothing the end of the core with an orbital riveting head such that the core end has a diameter which is not substantially greater than that of the core;
• and
• sealing the end of the foam sheath such that the core end is enclosed within the foam sheath.