Patent ID: 9272484
Filing Date: 2016-03-01
CPC Classification: B29C,B29L,B32B,Y10T

Claim Text:
1. A method for forming a plastic article, the steps comprising: providing a first heated plastic layer to a first mold section having a first molding surface to form a first molded skin; thermoforming the first heated plastic layer to first molding surface; providing a second heated plastic layer to a second mold section having a second molding surface to form a second molded skin; thermoforming the second heated plastic layer to the second molding surface; moving the first and second mold sections into cooperation with one another, connecting the first and second molded skins to form an internal cavity there between; substantially filling the internal cavity with pre-puff polymer foam beads; injecting a heated medium into the cavity for a limited period of time sufficient to cause the polymer foam beads to expand, melt together and bond to the first and second molded skins, while simultaneously venting cooled heating medium from the internal cavity, expanding the polymer foam beads to form an in-situ core of expanded polymer foam beads, the core being heat-bonded to the first and second molded skins forming the plastic article; and releasing the plastic article from the first and second mold section.