Abstract: The plastic structural article includes an elongated tubular shell having opposed end sections, a middle section there between and an interior cavity. The interior cavity has a foam core situated therein. The foam core comprises steam expandable polymer beads which when expanded substantially fill the interior cavity. The bead and shell are of a similar plastic composition enabling the articles to be reground and recycled. An apparatus for forming the articles and an associated method of manufacture are also disclosed.

Abstract: In at least one embodiment, a plastic article comprises a first plastic layer having a periphery and defining a cavity. An expanded polymer particle core is formed in-situ and heat-bonded to the cavity. The expanded polymer particle core has an apparent bulk density ranging from 1 lb/ft3 to 20 lb/ft3. The article supports a dynamic load or static load exceeding 1.3 lbf/in2.

Abstract: A floor support structure for a bathtub or a shower tray floor, taking the form of a separate element to be used in conjunction with a traditional bathtub or shower tray floor, or as a unitary shower tray floor formed with the support structure integrated therein. The supports include a hollow plastic shell having a lower surface for lying on a planar subfloor, an upper surface contoured to the desired shape and a peripheral sidewall extending there between. Preferably, a drain hole is formed in the plastic shell which also interconnects the upper and lower surfaces thereby defining a hollow interior cavity. The cavity is filled with expandable thermoplastic foam beads which are expanded in place with steam in order to substantially fill the interior cavity thermally bonding the beads together and to the shell interior wall. The expanded foam bead is capable of being compressed without substantial permanent set.

Abstract: An energy management system for use with a vehicle having an interior includes an elongated plastic member having a wall defining a cavity. Disposed within the cavity is an elongated first in-situ foam core member, which has a first thermal bond to the wall. The wall having a first portion facing towards the vehicle interior and a second portion opposed to the first portion. A second in-situ foam core member is connected to at least a portion of the elongated plastic member forming the energy management system. The energy management system is capable of passing a 5-mph crash test passing Federal Motor Vehicle Safety Standard 215 (FMVSS 215) Phase II.

Abstract: A floor support structure for a bathtub or a shower tray floor, taking the form of a separate element to be used in conjunction with a traditional bathtub or shower tray floor, or as a unitary shower tray floor formed with the support structure integrated therein. The supports include a hollow plastic shell having a lower surface for lying on a planar subfloor, an upper surface contoured to the desired shape and a peripheral sidewall extending there between. Preferably, a drain hole is formed in the plastic shell which also interconnects the upper and lower surfaces thereby defining a hollow interior cavity. The cavity is filled with expandable thermoplastic foam beads which are expanded in place with steam in order to substantially fill the interior cavity thermally bonding the beads together and to the shell interior wall. The expanded foam bead is capable of being compressed without substantial permanent set.

Abstract: An energy management system for use with a vehicle having an interior includes an elongated plastic member having a wall defining a cavity. Disposed within the cavity is an elongated first in-situ foam core member, which has a first thermal bond to the wall. The wall having a first portion facing towards the vehicle interior and a second portion opposed to the first portion. A second in-situ foam core member is connected to at least a portion of the elongated plastic member forming the energy management system. The energy management system is capable of passing a 5-mph crash test passing Federal Motor Vehicle Safety Standard 215 (FMVSS 215) Phase II.

Abstract: The plastic structural article includes an elongated tubular shell having opposed end sections, a middle section there between and an interior cavity. The interior cavity has a foam core situated therein. The foam core comprises steam expandable polymer beads which when expanded substantially fill the interior cavity. The bead and shell are of a similar plastic composition enabling the articles to be reground and recycled. An apparatus for forming the articles and an associated method of manufacture are also disclosed.

Abstract: A packaging component for use with an article includes a panel having a first shell with a first surface facing the exterior of the package and a first opposing, spaced apart inward-facing surface. The first shell defines a first cavity. The panel further includes a first core situated in the first cavity wherein the first core includes a plurality of in-situ expanded polymer particles.

Abstract: In at least one embodiment, a plastic article comprises a first plastic layer having a periphery and defining a cavity. An expanded polymer particle core is formed in-situ and heat-bonded to the cavity. The expanded polymer particle core has an apparent bulk density ranging from 1 lb/ft3 to 20 lb/ft3. The article supports a dynamic load or static load exceeding 1.3 lbf/in2.

Abstract: The plastic structural article includes an elongated tubular shell having opposed end sections, a middle section therebetween and an interior cavity. The interior cavity has a foam core situated therein. The foam core comprises steam expandable polymer beads which when expanded substantially fill the interior cavity.

Abstract: A packaging component for use with an article includes a panel having a first shell with a first surface facing the exterior of the package and a first opposing, spaced apart inward-facing surface. The first shell defines a first cavity. The panel further includes a first core situated in the first cavity wherein the first core includes a plurality of in-situ expanded polymer particles.

Abstract: The plastic structural article includes an elongated tubular shell having opposed end sections, a middle section therebetween and an interior cavity. The interior cavity has a foam core situated therein. The foam core comprises steam expandable polymer beads which when expanded substantially fill the interior cavity.