Patent ID: 6537405
Filing Date: 2003-03-25
Classification: B29C,B29K,B29L

Abstract:
A method for manufacturing foam thermoplastic products comprising the steps of:A. continuously extruding a foam thermoplastic member in an elongated, longitudinally extending, substantially continuous length having a desired cross-sectional shape, using a fixed immovable extruder; B. advancing the elongated, longitudinally extending foam thermoplastic member into association with a puller member constructed for continuously drawing the foam thermoplastic member from the extruder and feeding the foam thermoplastic member to forming means, having a fixed base and at least two separate and independent rotatable mandrels mounted thereto, each of said mandrels comprising a single, longitudinally extending, substantially continuous surface having a substantially uniform cross section throughout its length; C. controllably winding the elongated, longitudinally extending, foam thermoplastic member directly on said rotatable mandrels of said forming means in a manner to cause opposed sides of the foam thermoplastic member to be positioned in a side-to-side, adjacent relationship when wound on said rotatable mandrels; D. continuously bonding/joining the adjacent side edges of the foam thermoplastic member to each other as the foam member is wound on the rotatable mandrels; E. continuously forming a foam thermoplastic member which a. continuously advances longitudinally along the length of the rotatable mandrel; and b. continuously advances beyond a terminating end of the mandrel; and F. repeatedly cutting desired lengths of the foam thermoplastic member from the length thereof extending beyond the terminating end of the rotatable mandrel; thereby providing hollow foam thermoplastic products having any desired size or shape.