Method of molding a composite foamed plastic article utilizing airless spraying of an outer film formed from heat curable materials

Claim 1

THE METHOD OF FORMING A COMPOSITE ARTICLE HAVING AN IMPREVIOUS RESINOUS FILM OF A PRESLECTED CONTOUR ON THE EXTERIOR THEREOF AND A CORE TEACIOUSLY BONDED TO THE INNER SURFACE OF SAID FILM WHICH COMPRISES THE STEPS OF PROVIDING A VINYL POLYMER PLASTISOL HAVING A VISOCITY RANGING FROM ABOUT 1000 CENTIPOISES TO ABOUT 15,000 CENTIPOISES, FRAGMENTING SAID PLASTISOL INTO A PLURALITY OF FINESIZED DROPLETS BY FORCING SAID PLASTISOL THROUGH A NOZZLE UNDER A PRESSURE RANGING FROM ABOUT 1200 P.S.I. TO ABOUT 2000 P.S.I., DIRECTING THE FRAGMENTED SAID PLASTISOL AGAINST A MOLD SURFACE OF A PRESELECTED CONTOUR, SAID MOLD SURFACE HAVING A TEMPERATURE IN THE RANGE OF ABOUT 180*F. TO ABOUT 400*F. FORMING THEREBY A SUBSTANTIALLY UNIFORMLY GELLED FILM THEREON, CONTROLLING THE QUANTITY OF THE FRAGMENTED SAID PLASTISOL DIRECTED TOWARD SAID MOLD SURFACE SO AS TO ACHIEVE THE DESIRED THICKNESS OF SAID FILM, HEATING SAID GELLED FILM AT A TEMPERATURE BELOW THAT AT WHICH THERMAL DEGRADATION OF THE FILM WILL OCCUR FOR A PERIOD OF TIME SUFFICIENT TO EFFECT SUBSTANTIALLY COMPLETE FUSION OF SAID PLASTISOL FORMING THEREWITH A SUBSTANTIALLY INTEGRAL HOMOGENEOUS FILM, AND THEREAFTER TENACIOUSLY BONDING A CORE MATERIAL TO THE INTERIOR OF SAID FILM FORMING THEREWITH SAID COMPOSITE ARTICLE.

Claim 2

THE METHOD OF FORMING A COMPOSITE ARTICLE HAVING AN IMPREVIOUS RESINOUS FILM OF A PRESLECTED CONTOUR ON THE EXTERIOR THEREOF AND A CORE TEACIOUSLY BONDED TO THE INNER SURFACE OF SAID FILM WHICH COMPRISES THE STEPS OF PROVIDING A VINYL POLYMER PLASTISOL HAVING A VISOCITY RANGING FROM ABOUT 1000 CENTIPOISES TO ABOUT 15,000 CENTIPOISES, FRAGMENTING SAID PLASTISOL INTO A PLURALITY OF FINESIZED DROPLETS BY FORCING SAID PLASTISOL THROUGH A NOZZLE UNDER A PRESSURE RANGING FROM ABOUT 1200 P.S.I. TO ABOUT 2000 P.S.I., DIRECTING THE FRAGMENTED SAID PLASTISOL AGAINST A MOLD SURFACE OF A PRESELECTED CONTOUR, SAID MOLD SURFACE HAVING A TEMPERATURE IN THE RANGE OF ABOUT 180*F. TO ABOUT 400*F. FORMING THEREBY A SUBSTANTIALLY UNIFORMLY GELLED FILM THEREON, CONTROLLING THE QUANTITY OF THE FRAGMENTED SAID PLASTISOL DIRECTED TOWARD SAID MOLD SURFACE SO AS TO ACHIEVE THE DESIRED THICKNESS OF SAID FILM, HEATING SAID GELLED FILM AT A TEMPERATURE BELOW THAT AT WHICH THERMAL DEGRADATION OF THE FILM WILL OCCUR FOR A PERIOD OF TIME SUFFICIENT TO EFFECT SUBSTANTIALLY COMPLETE FUSION OF SAID PLASTISOL FORMING THEREWITH A SUBSTANTIALLY INTEGRAL HOMOGENEOUS FILM, AND THEREAFTER TENACIOUSLY BONDING A CORE MATERIAL TO THE INTERIOR OF SAID FILM FORMING THEREWITH SAID COMPOSITE ARTICLE.