Abstract: A hot water heater includes a storage tank and an outer decorative shell spaced from the tank. A foam insulation fills a cavity between the tank and the shell and a bottom wall in the form of preassembled fiberglass belt. The belt is wrapped and secured about to the tank by an encircling compressing and centrally located band. The outer ends of the belts flare outwardly to a diameter in excess of the inner diameter of the shell. A flat, flexible plastic sheet has a narrow portion draped over the top of the tank and sides extended down and overlap the opposite sides of the belt. The lower ends of the sheet essentially covers the belt. The flexible plastic sheet has a slight angle between the tank top and the belt. The outer shell which has a diameter somewhat less than that of the flared belt is telescoped downwardly over the tank and sheet folds the apron into a circular configuration, compressing the belt tightly between the storage tank and the shell.

Abstract: A fiber matrix burner and method of manufacture in which a shaped burner element is formed by accreting a slurry onto a foraminous support. The slurry is comprised of ceramic fibers, a binding agent, a vaporizable filler, and a powdered, normally non-flammable aluminum alloy having a melting point between 660.degree. C. and 1,000.degree. C. After the drying and firing, a porous matrix of the fibers is formed which flamelessly combusts a fuel-air mixture. During combustion, the aluminum alloy inhibits growth of alumina crystals on the fiber surface to prolong burner life and, in addition, protects the burner both from extreme temperature and flashback.

Abstract: A spool for a fishing reel made of engineering polymer and fitted on a shaft for rotation. The shaft may include a number of peripheral protrusions therearound to present a greater linear surface of contact to assure a bonding of the polymer and shaft to withstand lateral line pressure and to aid in reducing the shrinkage of the polymer during drying in the molding process or other locking means may be employed to prevent movement.

Abstract: An extrusion process is controlled by feeding the material to be extruded from a supply station (5) to an extruder (1) and repeatedly weighing the supply station to calculate the throughput of the extruder. The initial line speed necessary to produce a predetermined weight/meter of extrudate is calculated and the line speed is adjusted accordingly. Subsequently, the throughput and the line speed are increased simultaneously, such that the weight/meter is maintained substantially constant until any one of a plurality of parameters such as line speed, screw speed, motor load current, extrudate temperature, melt pressure, etc reaches a predetermined maximum value. Thereafter either the line speed or extruder throughput is adjusted such as to maintain the weight/meter of the extrudate substantially constant at the desired value.

Abstract: In a process and apparatus for the production of a cushion element with a cover means enclosing same, at least one cover means is clamped with edge portions thereof between first and second clamping frames in such a way that the cover means defines a space therewithin. The clamping frames with the cover means clamped thereby are then held between first and second mold portions, with the cover means disposed in the mold cavity defined by the co-operation of the clamping frames and the mold portions. The cover means is drawn by suction against the mold cavity surface and a reaction mixture is then introduced into the space defined by the cover means within the mold cavity, through at least one feed opening. After reaction of the mixture the mold portions are separated and the cushion element with cover thereon from the mold.

Abstract: A method of making a pole and coil assembly for a dynamo-electric machine (e.g., interpole for locomotive traction motors) comprising providing the coil wires with a polyphenylene sulfide coating, filling the pole-coil interspace with solid, foamable polyphenylene sulfide ground insulation and heating the assembly such as to foam the ground insulation in place and cause it to constrictively engage and bond to the pole as well as fuse to the PPS coating on the coil. The pole surface may be roughened and/or coated with PPS for improved pole retention and/or may be nickel plated for improved corrosion resistance.

Abstract: A process for preparing a multilayer structure. The structure is produced at an elevated temperature. The structure is characterized in that it distorts upon changes in temperature; includes at least two layers of different materials, at least one of which creeps significantly at the elevated temperature at which the structure is prepared and; contains no layers which creep significantly at ambient temperature. The process includes cooling said structure such that at least one of the layer(s) which creeps at said elevated temperature is cooled at a rate which is least 50% less than the material cooling rate thereof.

Abstract: An injection ski comprises a pair of spaced composite elements and an expanded plastic interposed between the composite elements. The upper composite element is provided with convex portions formed thereon to prevent the composite element from sagging due to its own weight during moulding operation of the ski.

Abstract: An elongate fastener assembly comprising a flexible polymeric backing strip from which project a multiplicity of headed stems adapted to engage loops on materials pressed against the heads, and an open porous permanent attachment layer attached to the surface of the backing strip opposite the stems which has sufficient open area to receive foam to permanently attach the fastener assembly to a foamed article. The fastener assembly has a temporary attachment layer comprising granular ferromagnetic material in a polymeric binder sandwiched between the backing strip and the permanent attachment layer which is adapted to be attracted by magnets to temporarily hold the fastener assembly in position during a foaming process, and has a heat shrinkable film cover means overlaying the heads attached to the edges of the backing strip that will shrink transversely to expose the heads upon the application of heat below 125.degree. C.

Abstract: A method for encapsulating electronic components in high acceleration and high thermal cycling environments. A liquid uncured thermal setting polyurethane formulation is mixed with a finely ground particulate foam which serves as a nucleating agent. The mixture is in accordance with the polyurethane formulation. The resultant foam contains open air pockets which allow it to be compressed and then re-expand.

Abstract: A fastening tape (4) is attached to a molded item (2) such as a seat cushion with a face of gripping hooks (5) turned outwardly to hold a seat cover (3) having complementary fastening member thereon. The tape (4) is molded into the seat cushion (2) during the molding process. Since a liquid molding substance is used, the hooks (5) on the tape (4) are covered with a thin plastic film (17) which prevents the molding liquid from contaminating and clogging the hooks (5). In one embodiment, the film (17) has a relatively low disintegration temperature whereby the heat applied to the mold to cure the cushion (2) disintegrates the film (17) after the cushion has cured, leaving the exposed hooks (5) unclogged and ready for use. In another embodiment, film (17) has a relatively high disintegration temperature and is removed in a separate step subsequent to the molding process by additional heat, such as an open flame.

Abstract: A method for integrally forming in place on an exterior side of a foam seat or backrest cushion a hook or loop strip fastener.

Abstract: The present invention teaches a cloth covered pinch welt comprising a flexible, thermoplastic polymeric substrate extruded about a reinforcing member having a layer of partially embedded open cell foam material bonded to the polymeric substrate and wherein a cloth covering is bonded to the foam material. In addition a method for manufacturing the cloth covered pinch welt disclosed herein is also taught.

Abstract: An improved molding structure for producing a building panel or the like of expanded cellular core material having reinforcing strips flush with surfaces thereof and including one or more indentations or depressions having reinforcing elements extending therein and anchored within the core.

Abstract: In a filament winding technique, filaments are wound around a mandrel, and the mandrel remains in the structure and becomes part, normally a structural part, of the article. The mandrel may be any suitable rigid, light-weight material, but a foamed material such as a structural foam is thought to be most suitable. Metal inserts for attaching other components to the filament wound article can be moulded into the mandrel surface, and locked in place by the filament windings. According to a preferred aspect of the invention a motor vehicle suspension wishbone is made according to such filament winding method and the mandrel on which the filaments are wound remains in the structure.

Abstract: An article comprising a generally axially extending outer, tubular member, a plurality of generally axially extending cylindrical members, and a heat expandable foam sealing member. The outer tubular member has at least one opening and occupies a predetermined volume. Each of the cylindrical members is received by outer tubular member in an axially extending, parallel fashion such that the cylindrical members occupy a volume that is less than the volume of the outer tubular member. The sealing member, capable of sealing the opening of outer tubular member, occupies a volume that is generally equal to the difference between the volume of the outer tubular member and the volume of the cylindrical members.

Abstract: A steering wheel having the hand wheel part thereof formed of an injection molded foam of thermoplastic synthetic resin, which injection molded foam has a substantially solid outer surface and is covered with a coating. This steering wheel is produced in attractive appearance without requiring use of any specially formulated resin material or exercise of rigid control of molding conditions.

Abstract: Method for making magnetic rolls having a plurality of magnets integrally set fast with a retaining member at stated portions of the periphery of a roll shaft thereby forming a magnetic force generating part, in which the retaining member is made from a rigid synthetic resin or resin foam, and optionally having a strain absorbing groove at a portion outside of said magnetic force generating part are provided.

Abstract: A pre-shaped aluminum plate is held against the flat end wall of an inverted mold cavity by vacuum pressure communicated through bore holes in the wall leading to a vacuum chamber in the mold body. A high temperature PTFE gasket shaped to match the plate fits in an annular recess in the wall to provide a seal between the wall and plate. Polyurethane foam expands and hardens in the mold cavity to further press the plate against the wall and to form a foamed plastic water ski having a flush aluminum deck. The mold cavity has a curved side wall to produce a ski having a radiused edge about the deck.

Abstract: A water heater comprising a water tank having a component intended to be kept substantially free from contact with an expandable foam insulating material, and a method of making same, is provided. The water heater has a jacket surrounding the tank and providing an insulating space therebetween. Positioned within this space is a pair of flexible sheets forming an apron. The sheets are joined to form a seal protecting the component from contact with the foam. The apron is positioned over a part of the tank surface so that the seal surrounds the component. The sheets of the apron are substantially unsealed along their top and sides. Foam is introduced between the sheets of the apron and flows out of the unsealed sides of the apron to fill the space between the tank and the jacket.

Abstract: A body panel joint finishing method to produce a finished body panel joint by molding a bead directly to a vehicle body in a single operation without any need for secondary processing to remove excess materials. The method utilizes a foamable plastic as the bead forming material to provide greatly improved sealing property for moisture prevention in the gaps of the sheet metal body panel joints.

Abstract: A method of sealing cavities open on one side, preferably cavities of electrical equipment housings fitted with various components. A measured quantity of an encapsulant, preferably polyurethane foam, is inserted into the cavity. Thereafter the opening is covered by a permeable, absorbent fabric, preferably of polypropylene, which is covered first by an elastic and then a rigid layer. After hardening, the fabric is removed from the surface of the encapsulant.

Abstract: An insulated welded wire structural building panel and a method for making such panels are disclosed. The panel has a plurality of parallel trusses joined together with cross wires. Each truss is triangular in cross section. A layer of polyurethane foam is provided in the panel spaced from both the front side and the back side of the panel. On one surface of the foam is a layer of solidified viscous material, such as asphalt or a thermoplastic. The cross wires on opposite sides of the panel are offset from each other along the axes of the truss runner wires to which they are welded.

Abstract: A prefabricated building wall is particularly suited for residences. The wall has a metal outer frame, and inner frames of metal may be located therein for doors and windows. Non-metallic stiffening members are interconnected within the outer frame in a diagonal grid. Hardenable plastic foam is injected into the frame to serve as insulation and support. The stiffening members are I-beams with apertures along their webs to allow them to be interlaced.

Abstract: In order to facilitate the release of polyurethane from a steel or aluminium mould, the metal surface is provided with a mono-layer of an alkylmercaptan. A silver layer may be provided between the mould metal and the alkylmercaptan monolayer.The invention can be advantageously used for manufacturing a luminaire for a tubular discharge lamp.

Abstract: A medical-surgical dressing comprising a reinforced sheet of silicone elastomer foam having a thickness not exceeding 10 millimeters, one of the surfaces of the sheet having a surface layer of open cell foam and the other surface having a substantially non-cellular surface skin. The dressing may be manufactured by a process comprising depositing a liquid foamable silicone composition on an absorbent surface, allowing the composition to foam and set to an elastomer and thereafter separating the foam sheet from the substrate.The dressings are useful e.g. for the treatment of wounds, burns and as liners for plaster casts.

Abstract: A stiffener insert is incorporated into a molded composite article such as an automobile dashboard by inserting the stiffener insert between a pre-formed plastisol skin forming opposed mold walls for receiving an intermediate polyurethane foam layer therebetween and partially compressing a porous, resilient layer such as an open celled reticulated foam layer on opposite sides of the stiffener insert to an extent sufficient to exert a spring-like holding force to self-center the insert between the mold walls and yet insufficient to cause readout of the partially compressed porous insert layer through the outer plastisol skin on the final molded article. The partially compressed, porous, resilient layer on the stiffener insert permits flow of polyurethane foam therethrough to fill the mold cavity and is impregnated with the polyurethane foam to securely bond the stiffener insert in the composite article.

Abstract: An elongate fastener assembly comprising a flexible polymeric backing strip from which project a multiplicity of headed stems adapted to engage loops on materials pressed against the heads, and an open porous permanent attachment layer attached to the surface of the backing strip opposite the stems which has sufficient open area to receive foam to permanently attach the fastener assembly to a foamed article. The fastener assembly has a temporary attachment layer comprising granular ferromagnetic material in a polymeric binder sandwiched between the backing strip and the permanent attachment layer which is adapted to be attracted by magnets to temporarily hold the fastener assembly in position during a foaming process, and has a heat shrinkable film cover means overlaying the heads attached to the edges of the backing strip that will shrink transversely to expose the heads upon the application of heat below 125.degree. C.

Abstract: A composite sandwich formed by enclosing a central resilient layer of a soft compressible material between two plate-shaped parts of foamable synthetic material and inserting the assembly into a cavity formed from two shells of prefabricated sheet metal. The resultant composite is subjected to a heat treatment for about 10 minutes at about 200.degree. C. so that the foamable material expands to fill the cavity.

Abstract: A pre-shaped aluminum plate is held against the flat end wall of an inverted mold cavity by vacuum pressure communicated through bore holes in the wall leading to a vacuum chamber in the mold body. A high temperature PTFE gasket shaped to match the plate fits in an annular recess in the wall to provide a seal between the wall and plate. Polyurethane foam expands and hardens in the mold cavity to further press the plate against the wall and to form a foamed plastic water ski having a flush aluminum deck. The mold cavity has a curved side wall to produce a ski having a radiused edge about the deck.

Abstract: A molded insulating insert of expanded polystyrene has a central section and hingedly connected side sections which are bendable toward each other to bring the insert to a U-shaped configuration for insertion in a building block cavity. The hinges are formed to provide resistance to full ninety degree bending of the side sections so that the insert side sections are inclined slightly outwardly in a free condition. On flexing inwardly and insertion in a block cavity the side sections tend to spring outwardly and frictionally grip the walls of the cavity. Lug-notch connection means frictionally retain the inserts in the U-shaped configuration and prevent dislodgement of sections in the event of hinge rupture. In molding the inserts, a transfer process is employed with the hinges partially formed in a hot mold and thereafter fully formed in a cold mold. The polystyrene is compressed in the hinge area to a higher density for hinge integrity. Density in the hinge area is approximately doubled.

Abstract: Cushioned automotive strap handles with spring steel base strips, cushions, and wrapped and sealed covers are made by injection molding resin cladding directly onto steel base strips before assembly with the cushion and cover. The base strips 10 are cut to length with formed end regions 11 which are mounted on a mold part 15 so that a midregion of base strip 10 spans an injection mold cavity 18. Pins 21 within mold cavity 18 locate base strip 10 in a plane spaced from the cavity walls so that the cavity surrounds the midregion of the base strip. The injection molded resin cladding 25 also surrounds the midregion of base strip 10 and provides raised resin shoulders 20 extending along longitudinal side edges of the base strip. The surrounding engagement of cladding 25 secures resin shoulders 20 against transverse movement relative to the base strip.

Abstract: This invention relates to insulated pipe and methods and apparatus for making the same. There has been difficulty in placing foamable insulating materials in the narrow elongated space between a casing pipe and a core pipe. According to the instant invention, a miniaturized mix head is inserted in this elongated space. Constituents of the foamable insulating material are simultaneously mixed and disseminated by the mix head in a manner to create a moving foam front which displaces air within the elongated space and permits the formation of a layer uniform, low density insulating material therein.

Abstract: A matrix coating system and method of manufacture thereof is presented wherein the matrix coating contains chemical blowing agents which permit low pressure molding and also the formation of printing plates having deep relief. The method of manufacture is such that a foamed coating is produced which at molding temperatures is highly compressible at low pressures and which also expands into the relief or nonprinting regions of the pattern plate. The unusually low molding pressures necessary result in less distortion of rubber pattern plates or made from photo polymers. In addition, the combination of high compressibility in appropriate areas, and of volume expansion in relief areas allows the board coating to conform before and during cure to pattern plates of deep relief, so that in the cured state there results a rigid, durable high fidelity mold useful for molding numerous flexographic printing plates.

Abstract: Method for casting a base directly on an electron tube comprising a stem and stem leads sealed in and extending out from the stem includes: A. detachably coupling a mold to the leads and stem, B. producing a temporary pressure seal between the mold and the stem including applying static pressure in a direction that is substantially normal to the surface of the stem and C. injecting liquid castable material into the mold at substantial hydraulic pressure while maintaining the static pressure at the temporary seal.

Abstract: The invention relates to a factory prefabrication method for hollow panels for the on-site erection of insulated constructions.This method employs a three-dimensional framework 1 composed of thrust bars arranged in two parallel planes and of link bars linking the former. The method consists in placing said framework in a mold 13 containing a pulverulent material 16 wherein the framework is embedded by part of its thickness, in molding an insulating synthetic material 4 in the empty part of the mold so as to embed the visible parts of the framework 1, in placing above the mold a form sheet 2 so that the insulating material shall make contact with it and adhere to it during hardening, and after this hardening, in extracting the pulverulent material and in ejecting the obtained panel. The panel so manufactured can be provided after ejection with a second form sheet opposite the first.

Abstract: A pre-shaped aluminum plate is held against the flat end wall of an inverted mold cavity by vacuum pressure communicated through bore holes in the wall leading to a vacuum chamber in the mold body. A high temperature PTFE gasket shaped to match the plate fits in an annular recess in the wall to provide a seal between the wall and plate. Polyurethane foam expands and hardens in the mold cavity to further press the plate against the wall and to form a foamed plastic water ski having a flush aluminum deck. The mold cavity has a curved side wall to produce a ski having a radiused edge about the deck.

Abstract: Insulated pipeline components are produced by positioning a steel pipe in the cavity of a casting mold with the pipe ends protruding therefrom. The dimensions of the cavity are greater than those of the inner pipe, and in the space between the inner pipe and the contact surfaces of the mold cavity a plastic powder is introduced, the powder being melted by heating of the mold. The mold is then rotated in a manner well known in rotational molding technique so that centrifugal force drives the molten plastic material against the contact surfaces of the mold cavity to form a plastic jacket; and after the mold has cooled the component is removed and expandable plastic material is supplied to the space between the inner pipe and the plastic jacket and is foamed. The resulting component has an exactly centered inner pipe, lacks conventional joints and can be produced at relatively low cost in a manner complying with industrial safety requirements.

Abstract: A racket structure to be used in a tennis and the like racket and a method for producing it, where the handle section and the head frame section are made of a one-piece composite member including an inner light weight soft plastic core member having a central prestressed multifilament cord member and a glass fibers reinforced hard plastic, outer surrounding layer, anchored on said core member within the head frame section, said surrounding layer being covered on opposite faces with respective resilient flat cover members which also sheath part of the height of said head frame section on the inside face, facing the netting, defining the striking surface stretched in the oval space defined by the head frame section of the racket.

Abstract: A method of manufacturing a protective and decorative molding for an automobile, comprising the steps of: adding a foaming agent to a starting resinous material comprising a vinyl chloride polymer or copolymer or a blend thereof; kneading the foaming agent and the starting resinous material; successively forming the kneaded mixture into an elongated rod or sheet blank by means of extruder or calender rolls; shearing the rod or blank into pieces having a predetermined shape; and molding the piece in a mold having high-frequency heating electrodes to apply a high-frequency voltage to the piece so that the foaming agent contained in the piece decomposes and foams to provide a product having a predetermined shape.

Abstract: A polyamine mixture formed from formaldehyde, an ortho-alkylaniline, and an ortho,ortho-dialkylaniline. The polyamine mixture is prepared by heating one of the anilines with formaldehyde, mixing the other aniline with an acid catalyst, and slowly adding the former to the latter. The mixtures are useful as chain extenders in polyurethane processes including reaction injection molding. The novel mixtures give unexpected mold gel and set times as compared to corresponding unmixed compounds formed from a single aniline or formed by previous typical condensation reactions. Also, the proportion of polyamines made by the novel mixtures may be varied to give excellent physical characteristics.

Abstract: An applicator is provided for coating the uncovered end portions or stubs of pipe sections after they have been welded together. A belt is maintained in tension out of contact with the pipe until the pipe stubs are welded together and coating operations are to begin. The belt is then wrapped onto the pipes forming an annular cavity about the welded stubs. Chain reinforcing mesh is also applied to the exterior of the belt for support. An expanding foam which sets into a hard coating is then injected into the cavity. Once the foam hardens and fills the cavity, the belt and reinforcement are unwrapped from the coated joint and moved away from the pipe.

Abstract: A process for obtaining cellular materials from unsaturated polyester resins reinforced with fillers having a density below 0.7 kg/lt by injecting a liquid foam, made from the resins by mechanical introduction of a gas therein into a closed mold, is described. The liquid foam, obtained from polyester resins including additives and optionally a reinforcement of synthetic, artificial, vegetable or mineral fibres having a length lower than 5 mm, and optionally containing a low boiling foaming agent, is injected voluminized and cross-linked in the hot or in the cold in a closed mold containing a reinforcing agent of synthetic, artificial, vegetable or mineral fibers as a monofilament mat, a cut fibre mat, a mono or bidirectional roving woven mat, rovings, fabrics.

Abstract: The method comprises a masking step of closing by masking tapes a gap formed between a roof rail member provided at the inner periphery of an existing roof panel and the roof panel, a linear joint portion between the roof rail and pillar inner panels, and holes provided for securing parts to the roof rail. The method also includes a step of arranging a wire harness assembly at predetermined position a lining skin member below the roof panel by securing and fitting welts provided around the periphery of the lining skin member to the roof panel. A foaming mold setting step is then carried out by mounting a foaming mold having the same shape as a final shape of the lining skin member from a compartment of the vehicle. A heating step is then performed to preheat the whole ceiling portion to a predetermined temperature and a foaming composition injecting step of injecting a foaming composition into a spaced formed between the roof panel and the lining skin member is carried out.

Abstract: A fishing lure having a minnow-shaped foamed plastic body and a one-piece wire located in the central longitudinal vertical plane of the body. The wire has a nose loop at the forward end of the body, a body loop at the lower mid-section of the body, and a tail loop at the rear end of the body. Treble hooks are connected with rings to the body and tail loops. A generally flat lip projects forwardly and downwardly from the nose section of the body. The body is made with a mold assembly having two plates with a plurality of body cavities and loop grooves for supporting the wire along the longitudinal central plane of each cavity. The mold assembly has a plastic material inlet passage leading to the nose section of each cavity and a vent passage open to the tail sections of each cavity. A gun is used to pressure inject plastic materials into the inlet passage which reacts in the body cavity to form the foamed plastic body.

Abstract: Process for producing foam moldings with an insert executed in a mold for foam molding consisting of a core block and a cavity block. The process comprises steps of: (a) having a film adhering to and covering the insert on one side thereof where a foam layer is formed; (b) letting the skirt portion of the film to be pinched or sandwiched by the uniting portion of the two blocks while the foaming process is executed on a foamable material; and (c) forming integrally the foam layer on that side of the insert, with the film being retained between the insert and the foam layer to be obtained.

Abstract: A method for manufacturing a heat-insulating member, such as e.g. a door or housing of a refrigerator, including a shell and a foamed heat-insulating material filled in the shell and a jig used therefor. The jig is intended to hold the shell lest the shell of the heat-insulating member to be manufactured should be deformed when a foamable liquid composition is foamed in the shell. In the jig of this invention, a jig body is formed of a heat-insulating material. The method of this invention comprises the steps of holding the shell in a hollow state by means of two jigs, injecting the foamable liquid composition into the shell to foam the same in the shell. Since the jig body of the jig of this invention is made of a heat-insulating material, the necessity of external heating, which is essential to the conventional method, is substantially obviated.

Abstract: A stylized cover having a surface element and foam substrate is adhered to a steel or plastic base through said foam. Examples of plastic base materials include polyurethanes, polyamides, epoxies and structural foams of polycarbonates or polyesters such as polybutylene terephthalate. The plastic base may be solid or reinforced. The surface element may be highly decorated with chromeplating, metal, plastic, or the like. The syntactic foam substrate has unexpectantly good heat resistance, high compression strength, impact resistance, and is lightweight, and thus results in an excellent balance of property for lightweight application. A preferred use is the stylized cover such as a wheel cover.

Abstract: A thermal and acoustic insulating plate comprising an aminoplastic resin and a fiber reinforcement embedded therein in the form of a non-woven body of glass fibers extending uniformly throughout the entire volume of the plate. In preparing the plate a non-woven body of glass fibers is impregnated with aminoplastic resin, whereafter the resulting structure is expanded and cured in a mould by supplying heat energy thereto.

Abstract: A pull strap handle meeting all the standards of the automotive industry is formed economically with molding operations. The handle is formed with a strip 15 of strong resilient material with high tensile strength that serves as a support element. Support element 15 is enclosed within a molded cover having a firm outer side 17 and a soft inner side 18. Soft side 18 is molded of foamed resin material directly onto support element 15 to form a secure bond. Firm side 17 can be molded in a single operation with soft side 18 or can be molded separately, attached to support element 15, and located in a cavity mold that forms soft side 18. The cover can also be molded to support element 15 within a cavity mold that forms both cover sides 17 and 18 or the cover can be extruded onto support element 15 in a continuous operation.