Abstract:
The invention relates to an improved method of extracting a shaped foam article from a mold cavity after being formed, specifically by imparting a vacuum sufficient enough to hold the shaped foam article to one side of the mold, preferably the core half of the mold, when the mold opens.
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.
Abstract:
The invention relates to an improved method of cold forming a shaped foam article from a foam having a vertical compressive balance equal to or greater than 0.4 and one or more pressing surface and articles thereof. The improvement comprises the use of a stamping press to form the shaped foam article. Preferably, the stamping press is operated by mechanical or hydraulic means. The shaped foam article may be shaped on one or more surfaces.
Abstract:
The invention relates to an improved method of cold forming a shaped foam article having a shape with a high degree of draft with improved surface aesthetics, specifically reduced surface cracking and articles made therefrom. The improvement is using a mold with a reduced-slip cavity surface, preferably a textured cavity surface.
Abstract:
The present invention is a method to manufacture one or more shaped foam article. Specifically, the present invention is a method of extruding a thermoplastic polymer with a blowing agent to form a foam polymer plank having a density gradient. Preferably, shaped articles are prepared from the surface of the foam plank having the lowest density. The article is shaped by a mold comprising one or a plurality of cavities wherein the periphery of each cavity is defined by a trimming rib, said mold concurrently shapes the foam article and trims the resulting shaped foam article from the surrounding continuous unshaped foam plank. 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.
Abstract:
The invention relates to an improved method of cold forming a shaped foam article wherein the improvement is using a near net-shaped foam blank cut from a foam plank having a vertical compressive balance equal to or greater than 0.4 to produce the shaped foam article.