Silk-screen printable foam product

Abstract

A molded product is made comprising a low-density product having a porous volume including cells and an essentially non-porous layer adjacent an external surface of the product. Essentially none of the cells are exposed at the external surface. The external surface is sufficiently tough, smooth, strong and durable to be suitable as a substrate for silk-screen printing.

That which is claimed is:  
     
         1 . A low-density product, which comprises: 
 a porous volume including cells; and    an essentially non-porous layer adjacent an external surface of the product, essentially none of the cells being exposed at the external surface.    
     
     
         2 . The product of  claim 1  in which the porous volume and the essentially non-porous layer have been formed from the same body of material.  
     
     
         3 . The product of  claim 1 , which has the appearance of having been formed from non-porous material.  
     
     
         4 . The product of  claim 1 , which has a non-uniform thickness, the porous volume and the essentially non-porous layer having been formed from the same sheet of foam of substantially uniform thickness.  
     
     
         5 . The product of  claim 1  in which the porous volume and the essentially non-porous layer are integral with each other.  
     
     
         6 . The product of  claim 1 , which has a non-uniform thickness and in which the porous volume and the essentially non-porous layer are integral with each other.  
     
     
         7 . The product of  claim 1 , which has a decorative coating on the external surface, the coating formed by applying a liquid material to the external surface.  
     
     
         8 . The product of  claim 1 , which has a decorative, silk-screen print on the external surface.  
     
     
         9 . The product of  claim 1 , which is composed essentially of polyethylene or ethylene vinyl acetate copolymer.  
     
     
         10 . The product of  claim 1 , wherein the porous volume is composed essentially of a resiliently deformable foam material.  
     
     
         11 . A low-density product, which comprises: 
 a porous volume including cells; and    an essentially non-porous layer adjacent an external surface of the product, the external surface being sufficiently tough, smooth, strong and durable to be suitable as a substrate for silk-screen printing.    
     
     
         12 . The product of  claim 11  in which the porous volume and the essentially non-porous layer have been formed from the same body of material.  
     
     
         13 . The product of  claim 11 , which has the appearance of having been formed from non-porous material.  
     
     
         14 . The product of  claim 11 , which has a non-uniform thickness, the porous volume and the essentially non-porous layer having been formed from the same sheet of foam of substantially uniform thickness.  
     
     
         15 . The product of  claim 1   1  in which the porous volume and the essentially non-porous layer are integral with each other.  
     
     
         16 . The product of  claim 11 , which has a non-uniform thickness and in which the porous volume and the essentially non-porous layer are integral with each other.  
     
     
         17 . The product of  claim 11 , which has a decorative coating on the external surface, the coating formed by applying a liquid material to the external surface.  
     
     
         18 . The product of  claim 11 , which has a decorative, silk-screen print on the external surface.  
     
     
         19 . The product of  claim 11 , which is composed essentially of polyethylene or ethylene vinyl acetate copolymer.  
     
     
         20 . The product of  claim 11 , wherein the porous volume is composed essentially of a resiliently deformable foam material.