Patent ID: 8496860
Filing Date: 2013-07-30
Classification: B29C,B29K,B29L,G09B,Y10T

Abstract:
1. A method for making a hollow molded article that is resistant to heat and impact distortion, said method comprising: a. introducing a first polymer mix containing uncured thermosetting polymer components for a rigid, hollow polymer shell into a mold in an amount sufficient to form a shell coating of said first polymer mix on the inside surface of the mold; b. rocking and rotating the mold in multiple directions in a cold rotational molding process to form said shell coating until at least the inner surface of said coating has become tacky; c. introducing said second polymer mix into the mold in an amount sufficient to form a foam coating on said shell coating; d. rocking and rotating the mold at room temperature to about 115° F. in multiple directions to form said foam coating bonded to said shell coating and allow said shell coating to cure sufficiently that a molded hollow article made by the foregoing method can be removed from the mold; and e. removing the molded article consisting essentially of an outer shell layer bonded to an inner foam backing layer from the mold.