Abstract: A decorative post includes an elongated outer polymer shell having at least one longitudinal groove extending a majority of a length of the elongated shell sized and shaped to hold a decorative fence panel. The decorative fence post also includes an elongated reinforcing member disposed in the outer polymer shell, and substantially extending a length of the fence post. A foam filler is disposed inside the outer polymer shell between the shell and the reinforcement member. An aperture is disposed in the outer polymer shell near an end of the reinforcing member, and a void extends from the aperture into the foam filler adjacent to and exposing an end of the reinforcing member. The void defines a slip zone at the end of the reinforcing member into which the reinforcing member extends as the outer shell shrinks longitudinally during post mold cooling.

Abstract: The opposite plastic walls 20a and 20b can be made from a polymeric resin material such as thermoplastic or thermoset resin, and/or can be made from olefins, styrenes, nylons, or mixtures of these polymeric families. In one aspect, the opposite plastic walls can be formed from an olefin, such as polyethylene or polypropylene, or the like. In another aspect, the opposite plastic walls can be formed from a styrene, such as acrylonitrile or butadiene styrene, or the like. In still another aspect, the opposite plastic walls can be formed from a mixture of olefins and styrenes. The polymeric resin material can also be made from recycled olefin, styrene, or nylon products. It will also be appreciated that the material of the walls can include additives, such as glass, fiber, talc, UV resistive or protective materials, etc. In one aspect, plastic granules of different colors can be combined to obtain a wall color that is a composite color to more readily simulate another material.

Abstract: A drop box for a rotational molding system includes a substantially rigid outer shell, a substantially rigid inner shell, configured to contain unmelted polymer material, and thermal insulating material, disposed between the inner and outer shells. Substantially rigid bridge material interconnects the inner and outer shells and forms part of the rigid structure thereof. The bridge material is configured to provide a thermal break between the inner and outer shells, to reduce heat transfer therebetween.

Abstract: A plastic table structure includes a tabletop comprising a thin polymer shell layer surrounding an expanded foam core. The multiple layers of the finished tabletop are molded concurrently in a one-pass biaxial or centrifugal rotational molding process, and cured in an oven. The method includes the steps of introducing polymeric material into a mold, and rotating the mold while heating it to a first temperature so as to form a molten shell of a portion of the polymeric material on the inside of the mold. A foaming agent is introduced within the mold and mixes with a second unmelted portion of the polymeric material and distributes throughout the mold. When the mold reaches a second higher decomposition temperature, the foaming agent causes expansion of the second portion of the polymeric material, forming an expanded foam core inside the shell.