Foam product

Abstract

A foam product includes a foam core, a soft skin covering the foam core, and a base structure on which the foam core is disposed. The foam core of expanded beads has an outer surface on which some outermost beads of the expanded beads are exposed and bulging outward with different heights to form a bubbly texture. The foam skin has an inner surface attached to the outer surface of the foam core, and has at its inner surface a plurality of concave cavities each matedly surrounding a respective one of the bulging, outermost beads on the outer surface of the foam core.

What is claimed is: 
     
         1 . A foam product comprising:
 a foam core including a tightly packed cluster of expanded beads, wherein some outermost beads of the expanded beads are exposed and protruded on an outer surface of the foam core; and   a foam skin having an inner surface bonded to the outer surface of the foam core, and the inner surface of the foam skin comprising a plurality of concave cavities sized and shaped to respectively receive the protruded, outermost beads on the outer surface of the foam core, wherein the foam core and the foam skin are made of different foam materials.   
     
     
         2 . The foam product as recited in  claim 1 , further comprising a base structure on which the foam core is disposed, wherein the foam product is directed to a bicycle saddle in which the foam core serves as a padding of the bicycle saddle, the foam skin serves as an overlying layer covering the padding, and the base structure includes a saddle shell attached to the foam core, and a support rail mounted underneath the saddle shell. 
     
     
         3 . The foam product as recited in  claim 1 , wherein the expanded beads of the foam core comprises expanded polypropylene or expanded polystyrene. 
     
     
         4 . The foam product as recited in  claim 3 , wherein the foam skin comprises expanded polyethylene. 
     
     
         5 . The foam product as recited in  claim 4 , further comprising a non-foam plastic film bonded to an outer surface of the foam skin. 
     
     
         6 . The foam product as recited in  claim 5 , wherein the non-foam plastic film having a printed pattern. 
     
     
         7 . The foam product as recited in  claim 1 , wherein the foam product is directed to one of a stand up paddle board, sit on top kayak, small sail boat, windsurf board, a snow board, and a skiing board. 
     
     
         8 . A foam product comprising:
 a foam core including a tightly packed cluster of expanded beads, wherein some outermost beads of the expanded beads are exposed and protruded on a top surface of the foam core;   an upper foam skin having a bottom surface bonded to the top surface of the foam core, and the bottom surface of the upper foam skin comprising a plurality of concave cavities sized and shaped to respectively receive the protruded, outermost beads on the top surface of the foam core;   a lower foam skin with a top surface bonded to a bottom surface of the foam core;   a non-foam plastic film with a bottom surface bonded to a top surface of the upper foam skin; and   a non-foam plastic plate with a top surface bonded to a bottom surface of the lower foam skin;   wherein the foam core and the upper foam skin are made of different foam materials; the foam core and the lower foam skin are made of different foam materials.   
     
     
         9 . The foam product as recited in  claim 8 , wherein some outermost beads of the expanded beads are exposed and protruded on the bottom surface of the foam core; and the top surface of the lower foam skin comprising a plurality of concave cavities sized and shaped to respectively receive the protruded, outermost beads on the bottom surface of the foam core. 
     
     
         10 . The foam product as recited in  claim 8 , wherein the upper foam skin and the lower foam skin are made of expanded polyethylene. 
     
     
         11 . The foam product as recited in  claim 8 , wherein the non-foam plastic film having a printed pattern.