A method of manufacturing includes providing a continuous flat cover to an assembly line, where the assembly line includes a conveying means. The method also includes applying a flowable reaction material continuously to the flat cover, where the reaction mixture is configured to expand within the flat cover. The method also includes welding the continuous flat cover around the reaction mixture to form an initial profile element. The method also includes cutting the initial profile element, continuously along the assembly line, to form one or more profile elements. Each of the one or more profile elements is a portion of the initial profile element, and each of the one or more profile elements includes a geometry for conforming with a construction component.

The present invention relates to a tool (W) having at least one first inlet opening (E1) and at least one second inlet opening (E2), and also at least one first outlet opening (A1), at least one second outlet opening (A2) and at least one third outlet opening (A3), wherein the second outlet opening (A2) and the third outlet opening (A3) alternate with the first outlet opening (A1). The present invention further relates to a process for producing a fiber/foam composite by extruding through the tool (W) and to the use of the tool (W) for production of a fiber/foam composite by extrusion.

A method of manufacturing includes providing a continuous flat cover to an assembly line, where the assembly line includes a conveying means. The method also includes applying a flowable reaction material continuously to the flat cover, where the reaction mixture is configured to expand within the flat cover. The method also includes welding the continuous flat cover around the reaction mixture to form an initial profile element. The method also includes cutting the initial profile element, continuously along the assembly line, to form one or more profile elements. Each of the one or more profile elements is a portion of the initial profile element, and each of the one or more profile elements includes a geometry for conforming with a construction component.

The present invention relates to a tool (W) having at least one first inlet opening (E1) and at least one second inlet opening (E2), and also at least one first outlet opening (A1), at least one second outlet opening (A2) and at least one third outlet opening (A3), wherein the second outlet opening (A2) and the third outlet opening (A3) alternate with the first outlet opening (A1). The present invention further relates to a process for producing a fiber/foam composite by extruding through the tool (W) and to the use of the tool (W) for production of a fiber/foam composite by extrusion.

An elongated structural article, having a continuous profile extrusion with spaced apart layers defining a portion of a cavity filed filled with thermoplastic pre-expanded beads expanded with steam in-situ causing the beads to securely bond together and to the profile extrusion. The article is cut to a length forming ends having an exposed foam core. A system for manufacturing the article is also disclosed having a profile extrusion die for forming an axially profile defining a wall surrounding a cavity, a tubular shaping mold located axially downstream of the extrusion die sized to support a length of the profile as it passes there through. A bead dispenser is oriented to introducing pre-expanded beads into the profile cavity while within the shaping fixture and a steam tube is oriented downstream of the introduction of pre-expanded beads. Control valves regulate the flow of pre-expanded beads and steam into the profile cavity.