Abstract: Sulfonated aromatic copolyesters and articles made therefrom, and processes for producing the sulfonated aromatic copolyesters and articles are provided. Articles that can be made from the sulfonated aromatic copolyesters include films, coatings and laminates. Some of the compositions and articles are biocompostable. The films can further be used to form shaped articles such as sheets, food packaging such as sandwich wraps, thermoformed containers, and coatings for, for example, films and other substrates. The sulfonated aromatic copolyesters contain a hydroxyalkanoic acid component.

Abstract: Embodiments of the present invention include a method for making a non-wicking liquid container material comprising providing container stock material having a first side and a second side, applying a first layer of thermoplastic material to the first side of the container stock material, compressing the container stock material such that the first layer of thermoplastic material is pressed substantially through a portion of the container stock material, applying a second layer of thermoplastic material to the first side of the container stock material, and applying a layer of foam material to the first side of the container stock material.

Abstract: A connecting member includes a metallic inner tube surrounding a flow path through which fluid flows; a polyimide resin-made outer tube covering an outer circumference of the inner tube; and a polyimide resin-made intermediate layer provided between the inner tube and the outer tube.

Abstract: A resin-molded component such as a loudspeaker diaphragm, in which rigidity is enhanced while light weight and high specific modulus of elasticity are maintained, is formed by applying carbon dioxide gas with a predetermined pressure to a thermoplastic resin in which crystallization is facilitated in the resin flowing direction to fill a mold. After the resin is filled, injection molding is performed by somewhat moving the mold to form five layers of: oriented minute-foaming layers, having approximately cylindrical foams, the length of which is twice the diameter thereof in the resin flowing direction in the mold, an unfoamed core layer positioned between both the foaming layers, and unfoamed skin layers formed on the front and rear surfaces.

Abstract: The invention is a composite pole with an integral mandrel therein and methods of making the same. A preferred embodiment is a fiberglass reinforced resin composite pole such as a utility pole or a lighting pole. The integral mandrel is preferably an expanded plastic foam such as expanded polystyrene. The integral mandrel is contoured to be in the desired inside configuration of the composite pole and fiber reinforced composite naterial is applied to the mandrel. The pole is used with the mandrel remaining therein, thus strengthening the pole. Passages may be placed into the mandrel for routing conduits and pipes as desired.

Abstract: The invention relates to a multilayer film comprising the following sequence of layers: A) a polyolefin foam base layer containing 0.5 to 25 percent by weight of at least one nucleation agent; B) a layer based on at least one polyolefin of foam layer A); C) an optional polyolefin-based connecting layer; D) an optional bonding layer; E) an optional gas-tight and/or odor-proof barrier layer; F) a bonding layer; G) an optionally sealable and/or peelable surface layer. The total thickness of layers A) and B) ranges between 0.5 and 2 mm while the thickness of layer B) ranges between one sixth and one half of the thickness of layer A).

Abstract: An object of the present invention is to provide a heat-shrinkable polyester film having a good light blocking property even when the label is not auxiliary processed by printing. The present invention provides a heat-shrinkable polyester film mainly made of a polyester resin, wherein the film has a total luminous transmittance of not more than 40%, a haze of not less than 90%, a sample film has a heat shrinkage percentage of not less than 50% in the maximum shrinkage direction and a heat shrinkage percentage of not more than 10% in a direction orthogonal to the maximum shrinkage direction, the sample film being in a size of 10 cm×10 cm cut off from the film and obtained by immerse in hot water at 95° C. for 10 seconds, subsequently in water at 25° C. for 10 seconds, and withdrawing.

Abstract: An absorbent insert for a food container can be made of a three layer expanded foam material. The expanded plastic foam material comprises bottom and top layers having a closed cell structure and a middle layer having an open cell structure. The top layer has apertures formed in it such that liquids can pass through the top layer and into the middle layer. The middle layer can have a surfactant that attracts and retains grease or other drippings. The insert can be sized to fit within a food container.

Abstract: The present invention refers to a method of producing a porous bonded fibrous sheet material comprising: (i) treating a porous fibrous substrate which is comprised of cellulosic fibers and which has a moisture content of less than 10% by weight with a gum and a cross-linkable wet strength resin both dissolved in water; (ii) removing excess water; and (iii) effecting cross-linking of the resin.

Abstract: The present invention provides a composite material (26) including a substrate layer (27), a porous layer (28) intermixed within the substrate material (27), and a thermoplastic layer (29) disposed upon the porous layer. The porous layer (28) is at least partially disposed within the thermoplastic layer (29). The present invention also provides a method for forming the composite material including the steps of: providing a substrate layer, providing a porous layer disposed on the substrate layer, providing a thermoplastic layer disposed on the porous layer, applying pressure and vacuum to mechanically interlock the thermoplastic layer with the porous layer; and bonding the porous layer to the substrate layer.

Abstract: A sealable food container includes a base serving member such as a plate having a generally planar central portion, a sidewall extending generally upwardly and outwardly therefrom and a base outer flange portion extending outwardly from the sidewall. The sidewall defines a sealing area with an undercut annular sealing surface disposed between the substantially planar central portion of the base serving member and the base outer flange portion. The sidewall portion of the plate defines a base stop ridge adjacent the upper edge of the undercut annular sealing surface of the sidewall as well as a laterally extending retaining shelf adjacent the lower edge of the undercut annular sealing surface of the base serving member.

Abstract: A foam thermoplastic container e.g. cup, bowl molded from expandable thermoplastic particles e.g. expandable polystyrene, has a film made of a thermoplastic resin e.g. solid polystyrene, rubber-modified polystyrene, PET, polyethylene, polypropylene, fused to its inner sidewall surface by heat and pressure to create a barrier to resist the leakage of liquid and food with oil and/or fatty components and to increase the rim strength of the container. The thermoplastic resin film can be fused to the outer surface of the container for printing purposes and/or to create a barrier and/or can be fused to the base surfaces of the container. The molding machine used to form the foam container is used to fuse the film to the container.

Abstract: A heat insulating paper cup having an improved seal. The cup can include a body member having an inside surface and an outside surface, and a bottom panel member having a upper surface and a bottom surface. The body member is coated (or in some instances partially coated) on its outside surface with a foamed low density polyethylene, and on its inside surface with an unfoamed modified low density polyethylene. The bottom panel member is coated on its upper surface with a foamed or an unfoamed low density polyethylene or foamed or unfoamed modified low density polyethylene. The body member and bottom panel member are oriented and joined to form a heat seal at an interface between a portion of the unfoamed modified low density polyethylene coated on the inside surface of the body member and a portion of unfoamed low density polyethylene or unfoamed modified low density polyethylene coated on the upper surface of the bottom panel member.

Abstract: A method for mechanically protecting a connection between at least two components forming part of an electrical and/or telecommunications network. At least one protective coating is provided, the coating being produced from an expanded polymeric material and providing the connection with a mechanical impact strength and ensuring a predetermined heat exchange between the connection and the external environment. This coating is axially and circumferentially continuous with respect to the connection. The present invention also relates to a coating for the mechanical protection of a connection between two components and to a joint thus protected.

Abstract: The present invention provides certain sulfonated copolyetherester compositions containing hydroxyalkanoic acids and processes for producing such sulfonated aromatic copolyetheresters. The invention further provides shaped articles, preferably in the shape of films, coatings and laminates, having improved thermal properties, wherein the shaped articles are produced from the certain sulfonated copolyetherester compositions. Some of these materials are also biocompostable. The sulfonated copolyetheresters are produced from a mixture of an aromatic dicarboxylic acid component, hydroxyalkanoic acid component, a sulfonate component, a poly(alkylene ether) glycol component, a glycol component, an optional other glycol component, an optional branching agent, and an optional color reducing agent.

Abstract: Recyclable multi-layer material of polyester resin suitable for the production of beverage and food containers comprising a layer of foam in polyester resin with density lower than 700 kg/m3, and a film of polyester resin adhered to the foamed sheet. On the multi-layer material a pattern is creased according to which by folding it is possible to develop the shape of a container.

Abstract: A highly absorptive open cell foam having a ratio of cell size to pore size of between about 1 and about 10. A juice absorbing food package comprising a tray having a bottom bounded by an upwardly extending lip around the perimeter of the bottom and a liquid-absorbing pad comprised of polymer foam joined to the bottom of said tray, wherein the polymer foam is a highly absorptive open cell foam having a ratio of cell size to pore size of between about 1 and about 10. The tray of the juice-absorbing package may be overwrapped with gas permeable film, and may be provided with an oxygen absorbing substance therein. Alternatively, the overwrapped tray may be placed in a sealed barrier bag that is subsequently purged with a non-oxidizing gas such as carbon dioxide.

Abstract: Described are structures comprising, successively: a first layer of high density polyethylene (HDPE), a layer of binder, a second layer of EVOH or of a mixture based on EVOH, optionally a third layer of polyamide (A) or of a mixture of polyamide (A) and polyolefin (B). Also described are devices for transferring or storing fluids and more particularly tubes, tanks, chutes, bottles and containers consisting of the above structure and in which the barrier layer (the second or the combination of the second and the third layer) is in direct contact with the fluid contained or transported.

Abstract: A compound permitting the economic production of packaging containers, which when activated produces concentrated amounts of CO2 gas for extended periods for preservation of perishable products therein, comprises a mixture including a CO2 generating portion incorporated within a polymer matrix. Preferably, the mixture includes citric acid; calcium carbonate, and polyethylene resin. More preferably, the mixture includes a mixture of a carboxylic acid (0.1–40%); a hydrogen carbonate (0.1–40%) and any polyolefin resin. Even more preferably, the mixture includes a mixture including (0.01–40%) Citric Acid; (0.01–40%); and 30–75% polyethylene resin. Most preferably, the mixture includes by weight 12% citric acid; 38% calcium carbonate; and 50% low density polyethylene resin with a melt index of 20 and a density of 0.924 g/cc. Alternatively, the carboxylic acid and hydrogen carbonate components are compounded into separate polymer matrixes, and later combined.

Abstract: A multilayer web article, including a first layer of a porous material, e.g., Tyvek® film, and a second layer overlying and sealed to the first layer. The second layer is non-porous to passage of gas therethrough and includes a peelable film, e.g., of polyethylene, in contact with the first layer of porous material. The peelable film permits peeling removal of the second layer from the first layer to expose the first layer of porous material for passage of gas therethrough. In a specific construction, the web article constitutes one of opposedly facing panels of a lay-flat bag article, in which the facing panels are bonded to one another along superposed edges thereof. After pressurization integrity testing of the bag, the peelable film is peeled away to enable steam - and/or ETO-sterilization of the bag and its contents to be carried out.

Abstract: A multi-layered pipe of arbitrary length and cross-section is produced by co-extrusion of a lower polyolefin (C2–C4) outer body over the exterior surface of a tubular core of randomly, partially randomly, or blocky chlorinated lower polyolefin, the core having a wall thickness, measured in the radial direction, in the range from about 0.025 mm to 5 mm. The tubular core is coextensive with essentially the entire length of the pipe. The tubular core comprises a major proportion by weight of the randomly chlorinated polyolefin (r-CPO), or, partially randomly chlorinated polyolefin (pr-CPO), or, a blocky chlorinated polyolefin (b-CPO), any of which may be blended with a minor proportion by weight of a blending ingredient. The r-CPO, pr-CPO or b-CPO, or a blend thereof, each has an extrusion temperature in the same range as that for the corresponding non-halogenated polyolefin, namely in the range from about 150° C. to 250° C.

Abstract: A polyester resin container with improved weatherability as well as colorlessness and heat resistance, made of a polyester resin composition comprising (A) 100 parts by weight of a polyester resin and (B) 0.01 to 10 parts by weight of a triazine ultraviolet absorber represented by formula (I): wherein R1 represents a straight-chain or branched alkyl group having 1 to 17 carbon atoms, which may have an alicyclic group at the terminal or in the chain thereof; and R2, R2?, R3, and R3? each represent a hydrogen atom or a methyl group.

Abstract: A two-layer ceramic composite material, wherein the first predominantly load-bearing layer is an oxidic, carbon-free fiber-reinforced ceramic layer which is made by a colloidal process. The second predominantly thermally insulating layer is an oxide-ceramic foam. The colloidal process produces carbon-free oxide ceramics which, because of their high purity, have low dielectric losses in the entire usage temperature range. In addition, the colloidal process provides a simple and cost-effective production method.

Abstract: The invention relates to a syntactic polyolefin composition for pipe coating, wherein the composition comprises a ?-nucleated propylene polymer and microspheres. The invention also relates to a method for the preparation of the composition for pipe coating and to an off-shore pipe coated with the syntactic polyolefin composition.

Abstract: Beverage or food containers made from sheet material, and methods of making such containers. Such container comprises a layer of paperboard and an expanded foam layer applied as a coating in a liquid carrier, and affixed to a paperboard base layer. The expanded foam has a remote surface preferably defined by intermingled peaks and valleys. The sheet material can include a protective cover layer overlying the remote surface. Such cover layer can comprise paper, plastic film, or foamed thermoplastic. The sheet material can include a heat seal layer, with the heat seal layer overlying, and in surface-to-surface contact with, the foam layer such that the foam layer is between the paperboard and the heat seal layer. Preferred composition for the foam layer is PVDC or AMM.

Abstract: An insulating ceramic made up of a plurality of partially filled shapes (e.g., 101), such as oblate spheroids, spheres, and shapes free of corners, is provided. Each partially filled shape may include an inner skeleton (e.g., 102) and an outer skin (e.g., 104). The inner skeleton may be stabilized at a higher temperature relative to the outer skin. The shapes may be disposed in a binding matrix. The thickness of the outer skin may be very thin in view of the support provided by the inner skeleton, thereby improving the abradability characteristics of the ceramic.

Abstract: A resin composition having a high adhesion between a resin layer and a metallic layer as well as an excellent durability, a process for producing the same, and an electrophotographic fixing member are provided. In the resin composition, a metallic layer is provided on a surface of a resin layer having a porous structure at least on the surface.

Abstract: A trauma mitigation device is provided which includes, an enclosure having a fluid impervious barrier, a crushable matrix disposed within said enclosure, and a viscous fluid disposed within said enclosure. Both the matrix and the fluid absorb energy when subjected to an impact force. A composition to be used in the device is also provided. The composition includes a viscous fluid in an amount of about 60–80% by weight of the composition and a plurality of macrosphere particles, in an amount of about 20–40% by weight of the total composition, disposed within said viscous fluid.

Abstract: A pulp molded container comprising a pulp molded article (2) having on the inner surface and/or the outer surface thereof a resin layer (3) with a thickness of 5 to 300 ?m formed by applying a coating, wherein the thickness ratio of the resin layer (3) to the molded article (2) (former/latter) is 1/2 to 1/100, and the surface roughness profile of the outer or inner surface of the pulp molded article is such that a centerline average roughness (Ra) is 0.5 to 20 ?m.

Abstract: Multipurpose fancy goods having a plurality of sheets connected to each other to form a polyhedron. The multipurpose fancy goods including a first regular square-shaped sheet, a second regular square-shaped sheet, a first regular triangle-shaped sheet, and a second regular triangle-shaped sheet each being made of a polypropylene foam sheet. Each of the first and second regular square-shaped sheets has four regular square-shaped sheet coupling parts each protruded outwardly from one side of each edge. Each of the first and second regular square-shaped sheets has four regular square-shaped sheet coupling through holes each formed around each corner. Each of the first and second regular triangle-shaped sheets has three regular triangle-shaped sheet coupling through holes each formed around each corner.

Abstract: Single layer and multilayer polyolefin foam pipes with improved compression resistance have a polyolefin foam layer which consists of mixtures of modified propylene polymers having strain hardening behaviour or propylene homopolymers with a stereospecifity index >98% or propylene copolymers with a stereospecifity index of the homopolymer matrix of >96%. The polyolefin foam pipes are coated steel pipes for transporting crude oil or gas products or district heating applications, single layer pipes for insulation purposes and for non- or low-pressure applications and multilayer plastic pipes for the transportation of hot or cold fluids.

Abstract: A charge roller that includes a metal core, an elastic member configured wrapped around the metal core, and film members is disclosed. Each of the film members is wrapped around each end of the elastic member in a circumferential direction of the metal core such that at least a part of each of the film members exists at every position around the ends of the elastic member in an axial direction of the metal core. Portions of the film members do not overlap each other in an radial direction of the metal core.

Abstract: A catheter balloon formed of a polymeric material such as expanded polytetrafluoroethylene (ePTFE) bonded to a second layer formed of a low tensile set polymer and/or impregnated with a low tensile set polymer. In a presently preferred embodiment, the low tensile set polymer is a silicone-polyurethane copolymer elastomer or a diene polymer elastomer. The low tensile set polymer has high strength, low modulus, high elongation, and low tensile set. The diene or silicone-polyurethane has a low tensile set, which facilitates deflation of the balloon to a low profile deflated configuration. One aspect of the invention provides improved attachment of the diene to the ePTFE. In one embodiment, the second layer is formed of a diene mixed with a bonding promoter such as a vulcanizing agent which is covalently bonded to the diene.

Abstract: A structural reinforcement for a hollow member comprising a rigid reinforcing member having a shape that substantially conforms to the cross section of the hollow member to be reinforced with an expandable adhesive material over at least a portion of the surface of the structural reinforcement having one or more extensions on its external surface which control and direct the direction in which the adhesive material expands to bond the reinforcing member to the internal surface of the hollow member, some of the extensions also provide improved reinforcement.

Abstract: In a method of manufacturing a resin molded article, resin including a foaming agent is injected into a cavity defined in a mold assembly. Then, a movable mold of the mold assembly is moved to partly expand the cavity so that the foaming is promoted at the part where the cavity is expanded. Therefore, a high foamed portion having voids therein and a low foamed portion having an expansion ratio less than that of the high foamed portion are integrally formed in the resin molded article.

Abstract: A protective member primarily for use as an energy absorbing pad for incorporation into garments to protect the wearer against accidental impacts. The member comprises a putty-like energy absorbing material (2) encapsulated in a flexible envelope (3, 4). The energy absorbing material is normally soft and flexible but changes to become temporarily rigid when an impact force is applied thereto, thereby absorbing the impact energy, the material returning to its normal flexible condition after the impact. The energy absorbing member preferably comprises a series of connected corrugations to increase its energy absorbing properties.

Abstract: A container constructed from a laminate structure that includes a layer of foamed polymer. The layer of foamed polymer replaces the paperboard layer of known laminate structures. A preferred embodiment of the laminate structure is comprised of a layer of foamed polymer, a first layer of low density polyethylene, a second layer of low density polyethylene, a layer of aluminum foil, a tie layer, and a third layer of low density polyethylene. The container has a non-polar homogeneous heat seal that may be created by conventional equipment at a temperature ranging from about 250 degrees Fahrenheit to about 500 degrees Fahrenheit.

Abstract: An object of the present invention is to provide a foamed polyolefin resin sheet which exhibits a high adhesive strength when laminated with a layer formed of a saponified ethylene-vinyl ester copolymer and which still exhibits a high adhesive strength even when laminated with a layer of a thermoplastic resin having relatively low polarity such as a polyolefin resin. This object is attained by a foamed polyolefin resin sheet including a foamed polyolefin resin layer and a non-foamed surface layer formed of a thermoplastic resin composition having an A1/A2 ratio falling within a range between 1×10?8 and 1×10?1, wherein A1 is a maximum absorbance of the infrared absorption spectrum of the thermoplastic resin composition within an infrared ray wave number region of from 1700 to 1750 cm?1 and A2 is a maximum absorbance of the infrared absorption spectrum of the thermoplastic resin composition within an infrared ray wave number region of from 1455 to 1465 cm?1.

Abstract: An insulating paper container's body has a low m.p. thermoplastic synthetic resin film laminated on its outer wall surface and a compatibly expansile ink applied to the outer surface either as a primer or as indicia to provide stock material improved in its printability for bar codes or the like as well as in its insulating property. In addition there is provided a process for making such stock material.

Abstract: A structural reinforcement for a hollow member comprising a rigid reinforcing member having a shape that substantially conforms to the cross section of the section of the hollow member to be reinforced with an expandable adhesive material over at least a portion of the surface of the rigid reinforcing member sufficient to bond the reinforcing member to at least two nonparallel internal surfaces of the structure.

Abstract: Methods of making articles are provided in which a self-supporting structure formed of natural polymer has a self-adherent, moisture resistant thermoplastic film comprising gelatinized starch and a hydroxy-functional polyester on the structure surface. The self-supporting structure preferably is a starch and polyvinyl alcohol blend in an expanded form. The articles typically do not delaminate even when soaked in water, and are biodegradable.

Abstract: A sealing member for a cap featuring excellent cap performance as well as excellent safety and environmental friendliness, and a metallic cap. A foamed polyurethane elastomer having a JIS A hardness of from 15 to 65 and a foaming magnification of from 1.1 to 10 times is used as the sealing member so as to obtain excellent sealing performance, durability, safety and environmental friendliness. The sealing member is provided for a metallic cap shell that has a polyester film formed on the inner surface of the cap, thereby to obtain a cap featuring excellent sealing performance, durability, safety and environmental friendliness.

Abstract: A multi-layer expansion-molded article of a polypropylene resin, which is obtained by molding a multi-layer parison comprising a foamed resin layer and a resin layer provided on the outer side of the foamed resin layer in a mold in such manner that at least part of the opposed inner surfaces of foamed resin layer in the parison are fusion-bonded to each other, and has a polypropylene resin layer on the surface of a foamed polypropylene resin layer, wherein a melt tension, MTfr (gf) and a melt flow rate, MFRfr (g/10 min) obtained by measurement to a polypropylene resin forming the foamed resin layer in the expansion-molded article satisfy the relationship [log MTfr>?0.74 log MFRfr+0.66], and a melt tension, MTur (gf) and a melt flow rate, MFRur (g/10 min) obtained by measurement to a polypropylene resin forming the resin layer on the surface of the foamed resin layer satisfy the relationship [log MTur>?1.02 log MFRur+0.47].

Abstract: A packaging system having a container, a first radiant barrier covering the exterior of the container, an insulator covering the interior of the container, a second radiant barrier positioned in the container within the insulator for surrounding a payload, a payload surrounded by the second radiant barrier, a first phase change material having a preselected phase change temperature surrounding the payload in close proximity therewith, and a second phase change material having a phase change temperature higher than the first phase change temperature surrounding the first phase change material in close proximity therewith and being in close proximity with the second radiant barrier.

Abstract: A hollow, reinforced, molded automotive hard top is made using a sheet of thermoplastic material with nanoparticles dispersed therein. The particles comprise less than 15% of total volume of the plastic sheet, at least 50% of the particles have a thickness less than about 20 layers, and at least 99% of the particles have a thickness of less than about 30 layers. The sheet is preheated and molded in an assembly having mold surfaces corresponding to the hard top configuration. Vacuum is applied to one side of the assembly and pressurized gas is applied to the opposite side of the assembly to force the sheet into conformity with the mold surfaces. After cooling, the conformed sheet is transferred to another mold assembly, where a reinforced plastic melt having a blowing agent is applied. Together, the solidified melt and the conformed plastic sheet form the hard top.

Abstract: Disclosed are porous polymer/carrier solid phase reactants which consist of a polymer that consists of fine particles and is situated in the pore space of porous carrier materials. Reactive groups are bound to the polymer. Said groups act as reactants in organic-chemical syntheses. Said solid phase reactants can be produced as bulk material or tubes, plates or rods, can be built in pressure sealed housings and can be used in flow-through apparatuses or microtitration fields for the synthesis of organic products. Potential active agents can be produced at high speed by using the inventive porous polymer/carrier solid phase reactants that can be flown through convectively, whereby production requires only little isolation and cleaning.

Abstract: A water-based coating composition suitable for preparing hydrophilic surfaces on various articles is provided which includes a supporting polymer having functional moieties capable of undergoing crosslinking reactions, said supporting polymer soluble in or emulsified in an aqueous based medium; and a hydrophilic polymer, said hydrophilic polymer associated with the supporting polymer. The composition is characterized in that, when crosslinked at the functional moieties, the supporting polymer forms a three-dimensional network which substantially minimizes disassociation of the hydrophilic polymer.

Abstract: An insulating beverage or food container or sleeve is produced with a foam layer disposed on an inner surface of a paper stock. A polymer shrink film layer is arranged in a position along an inside surface of the beverage container. The foam layer is sandwiched between the polymer shrink film layer and the paper stock and decreases the energy transfer between the beverage and the user's hands allowing the user to hold onto the container for an extended period of time without causing user discomfort or pain. The polymer shrink film layer is produced from a shrink film polymer having a percent shrink in the range of 30% or less, and more particularly a percent shrink range of 5 to 10%.

Abstract: Composite fence and decking components, for example, rails, posts and planks, are provided which generally include a weatherable outer layer, a core layer made of a thermoplastic polymeric composition and a wood component in an amount effective as a filler, and an inner layer made of a thermoplastic material. The layers are configured so as to form a generally central hollow space. The components are light weight and inexpensive to manufacture. The components can be manufactured by using a single coextrusion process to produce a cylindrical form. The cylindrical form is passed through a reshaping die to form a composite having a desired cross sectional form, for example, a composite with a substantially square or rectangular cross section.

Abstract: The present invention relates to light weight molded plastic articles and methods of making same. More specifically, the present invention relates to a method of manufacturing a hollow-core, foamed-plastic, film-laminate article utilizing convention gas assisted molding apparatus with corresponding high production rate capabilities. The resulting film-laminate, hollow-core, foamed-plastic part comprises a class A show-face surface. The method comprises formation of a porous mass of molten plastic in the mold cavity containing the laminate. The molten plastic is cored out or hollowed by injection of gas into the mold cavity.