In-situ foam core structural articles and methods of manufacture of profiles
OwnerRichard W. Robertsinventor
Life of this patent
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Abstract
A method of manufacturing an elongated article is recited to include extruding a first and a second layer each having peripheries. The second layer is spaced apart from and opposed to the first layer. Together, they define a cavity between them. Into that cavity particles are dispensed. The particles are expanded with an expansion fluid to form an in-situ foam core and to thermally bond the in-situ foam core to the first and second layers. The first and second layers having the thermal bond to the in-situ foam core are shaped to form the article. An elongated article from this process is also recited.
Claims14
A method of manufacturing an elongated article, the method comprising the steps of:
- extruding a first layer plastic resin having a periphery which forms at least a portion of a wall of an elongate member having a hollow internal cavity;
- dispensing a plurality of heat expandable particles into a fill region of the hollow internal cavity while the elongate member is still connected to an extruder and moving along an extrusion axis;
- expanding the particles with a heated expansion fluid which is introduced into an expansion region of the cavity while the elongate member moves downstream of the fill region to form an in-situ foam core which is thermally bonded to the wall of the elongate member;
- and
- supporting the moving elongate member while the in-situ foam core cools to form the elongate article.
Dependencies are inferred from the claim text.