Patent ID: 8021589

Claim:
Manufacturing a composite article comprising a metal reinforcing element and molded plastic coating firmly attached thereto, wherein the reinforcing element is formed to define an open channel having a longitudinal axis and an open side parallel to the axis, and the plastic coating includes a portion formed as a wall mechanically closing the open side of the channel, where the form of the metal reinforcing element allows insertion, via the open side of the channel, of a mold core which is configured to provide mechanical stability to the reinforcing element, the manufacturing comprising: providing the metal reinforcing element; providing the mold core; providing a mold comprising at least two parts formed to define a mold cavity therebetween when the mold is assembled, the mold being adapted to accommodate the metal reinforcing element fixedly in the mold cavity, allowing space for the plastic coating; inserting the mold core in the metal reinforcing element via the open side, so that the mold core provides mechanical support to the element; assembling the mold parts and the metal reinforcing element with the inserted core therein so as to fix the reinforcing element in the mold cavity; injecting flowable and settable plastic coating into the space to form the composite article; releasing the obtained article including the reinforcing element, the set plastic coating and the mold core, by disassembling the mold; and removing the entire mold core from the article in a direction along the channel axis.