Patent ID: 8147733

Claim:
A process for producing a foam composite having a skin with an even thickness and a core comprising foamed bodies with homogeneous and fine bubbles and spherical plastic reinforcing members with an even thickness covering each of the foamed bodies, comprising: charging a mold with one of plastic powders and plastic minute particles, and polyolefin pellets that are larger than the one of the plastic powders and the plastic minute particles, wherein the polyolefin pellets are covered in the whole surface with plastic and are cross-linkable and foamable; and heating the mold from the outside of the mold; rotating the mold at within a range from 1 to 20 rpm, so that a plastic skin is formed and the pellets adhere to the skin; and further heating the mold, thereby permitting the polyolefin cross-links and the pellets to expand by the decomposition of a foaming agent, wherein the thickness of the skin is within a range from 1 to 10 mm; a number of the foamed bodies, which are bonded each other to constitute the core, are formed from the polyolefin pellets; a number of the foamed bodies are connected in three dimensions; the density of the foamed bodies is from 0.1 to 0.01 g/cm 3 ; the thickness of the core is from 10 to 100 mm; and the thickness of the foam composite is 25 mm or more, and wherein the polyolefin pellets are formed by covering a rod of polyolefin with plastic; compressing the rod of polyolefin in a molten state to a thickness of plastic in a bonded region of 0.3 mm or more; cutting the rod of polyolefin; bonding edge sections of the rod of polyolefin, thereby obtaining pellets with a covering of the plastic in the whole polyolefin surface to form the polyolefin pellets; and foaming the polyolefin pellets, thereby permitting the foam composite to have a skin with an even thickness and a core, in which nearly even size granular foamed bodies with a covering of a reinforcing member with practically even thickness are integrated, bonded mutually, filling in the core, and further, bonded to the skin.