Patent ID: 8663515

Claim:
A process for moulding a plastic article using a machine comprising a pair of moulds each defining a mould cavity, the moulds movable between an open position in which the mould cavities are open and a closed position in which the moulds co-operate to define a completely closed mould cavity, and means to heat and cool the moulds; the method comprising the steps of placing the moulds in the open position, heating the moulds in the open position by conduction to a temperature above the melting point of a given plastic material, placing the plastic material in particulate form into the moulds in the open position, whereupon the plastic forms a skin lining each mould in the open position, placing expandable filler material in the plastic skin formed in one mould, closing the moulds to create a completely closed mould cavity, whereupon the plastic skins in the moulds bond to each other to form a continuous plastic shell which completely encases the filler material, cooling the moulds and opening the moulds to remove the moulded article.