Continuous process for manufacturing a shaped foam article

A technology for foam and body products, which is used in the field of preparing foam products, polystyrene foam boards, and vinyl, and achieves the effects of cost saving, great flexibility and capital reduction.

Inactive Publication Date: 2011-11-16
DOW GLOBAL TECH LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

However, these methods only produce uniformly extruded or compressed foam and not shaped foam articles

Method used

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  • Continuous process for manufacturing a shaped foam article
  • Continuous process for manufacturing a shaped foam article
  • Continuous process for manufacturing a shaped foam article

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 13

[0112] Examples 13 and 14 were foam blank samples prepared from IMPAXX 300 foam planks. Example 13 was formed by the Paratus Industries twin roll forming equipment described above.

Embodiment 14

[0113] Example 14 was formed using a Chemsultants International benchtop laminator (model HL-1000). The embossing and guide rolls were each 4 inches in diameter. A 1500-Watt cartridge heater can be used to heat the upper embossing roll to 400℉, and then controlled by an Ogden digital temperature controller. The lower (ie, drive) guide roll was covered with 80-durometer silicone rubber and the roll speed could be varied from 1 to 20 fpm. Forming pressure can be controlled by using air regulators that control the sides of the embossing roll. The benchtop roll former can shape samples up to 18 inches wide.

[0114] Table 2

[0115]

[0116] * Not an embodiment of the invention

[0117] Foam blank samples measuring 300mm x 600mm x approximately 45mm were prepared from IMPAXX 300 foam panels using a Baumer abrasive wire saw such that each foam blank had either an outer (raw sample) side or a cut side. Before molding, measure and record the initial thickness (t o ). Only ...

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Abstract

The present invention is a method to manufacture shaped foam article. Specifically, the present invention is a method of extruding a styrenic polymer with a blowing agent to form a foam polymer plank having a density gradient and shaping the surface of the foam plank having the lowest density by passing the foam plank through one or more sets of rolls. Preferably, the foam has a vertical compressive balance (Rv) equal to or greater than 0.4 and more preferably, the foam has a cell gas pressure less than 1 atmosphere and / or an open cell content of equal to or less than 20 percent.

Description

[0001] cross-reference statement [0002] This application claims the benefit of US Provisional Application No. 61 / 138,302, filed December 17, 2008. Background of the invention [0003] The present invention relates to an improved continuous process for forming extruded thermoplastic foam, preferably polystyrene foam board, into shaped foam articles. [0004] Extruded thermoplastic foams, such as extruded polystyrene (XPS) foam, have been used for some time in acoustic and insulation applications. Foams are formed by continuously extruding a heated plastic resin containing a blowing agent through a die, which expands under, for example, steam or a vacuum as it exits the die. Typically, these foams are limited to applications requiring only simple or complex shapes with a thin thickness. Simple shapes include, for example, generally flat toys die-cut from sheet metal, including puzzles and imitation badges. Another method for shaping foam is to utilize a Computer Numeric Con...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B29C44/56
CPCB29C44/352B29C44/5627Y10T428/24504
Inventor 迈伦·毛雷尔蒂莫西·克尔希凯西·菲廷詹姆斯·奥布赖恩
Owner DOW GLOBAL TECH LLC
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