In-situ foam core articles

Abstract

A plastic article is recited having a plastic shell including walls defining a cavity. Within the cavity is an in-situ foam core including expanded polymer beads. A layer of the expanded polymer beads includes a layer of distorted beads adjacent to the walls. The in-situ foam core has a thermal bond to the walls.

What is claimed is: 
     
         1 . A plastic article, comprising:
 a plastic shell having opposed and spaced apart walls defining a cavity; and   an in-situ foam core including expanded polymer beads disposed in the cavity, the expanded beads including a layer of distorted beads adjacent to the walls, the layer having a thermal bond to the walls.   
     
     
         2 . The article of  claim 1 , wherein the plastic shell comprises a water-going vessel. 
     
     
         3 . The article of  claim 1 , wherein the plastic shell comprises a buoy. 
     
     
         4 . The article of  claim 1 , wherein the plastic shell comprises a spoiler. 
     
     
         5 . The article of  claim 1 , wherein the plastic shell comprises at least one of a water-containing article and a component of the water-containing article. 
     
     
         6 . The article of  claim 1 , wherein the plastic shell comprises an ironing board. 
     
     
         7 . The article of  claim 1 , wherein the plastic shell comprises an insulating precast floor support having a u-value less than 0.17. 
     
     
         8 . The article of  claim 1 , wherein the plastic shell comprises at least one of a Class VIII and a Class IX shipping container. 
     
     
         9 . The article of  claim 1 , wherein the plastic shell comprises a vehicle running board. 
     
     
         10 . The article of  claim 1 , wherein the plastic shell comprises a ramp. 
     
     
         11 . The article of  claim 1 , wherein the plastic shell comprises at least one of a surfboard, a sailboard, and a skateboard deck. 
     
     
         12 . The article of  claim 1 , wherein the plastic shell comprises a roll-around cart. 
     
     
         13 . The article of  claim 1 , wherein the plastic shell comprises a moulding for use with a building. 
     
     
         14 . The article of  claim 1 , wherein the plastic shell comprises a highway bumper system component. 
     
     
         15 . The article of  claim 1 , wherein the plastic shell comprises a playground equipment component. 
     
     
         16 . The article of  claim 1 , wherein the plastic shell includes a storage shed component. 
     
     
         17 . The article of  claim 1 , wherein the plastic shell comprises a storage shed with a DP30 rating. 
     
     
         18 . The article of  claim 1 , wherein the plastic shell comprises an oil containment flotation chamber. 
     
     
         19 . A plastic structural article, comprising:
 a plastic shell having opposed and spaced apart walls defining a cavity; and   an in-situ foam core including fully expanded beads having a composition of at least one of a polyolefin composition or an alkenyl aromatic composition disposed in the cavity, the in-situ foam core having a thermal bond to the walls, wherein the in-situ foam core density ranges from 1 lb/ft 3  to 25 lb/ft 3 .   
     
     
         20 . A plastic structural article, comprising:
 a thermoplastic shell having opposed and spaced apart walls defining a cavity; and   an in-situ foam core including fully expanded thermoplastic beads disposed in the cavity, the in-situ foam core having a thermal bond to the walls, wherein the article is recyclable.