Patent ID: 6190584
Filing Date: 2001-02-20
Classification: B29C

Abstract:
A method of molding, from porous material, a low-density product having an outer decorative surface integrally molded with an impermeable layer encompassing said product, the method comprising the steps of:A. preparing a mold having a cavity the outline of which defines the outline of said product;B. lining the mold with a covering material;C. forming from said porous material a blank having substantially the outline of said product;D. inserting said blank into said cavityE. heating said mold with said blank therein to form said blank permanently into said product; andF. removing said product from said mold and subjecting the product to freezing temperatures;wherein the duration and temperature of said heating and freezing steps are chosen such that a durable impermeable layer is formed around a low density core and said outer decorative surface is integrally molded with the impermeable layer.