Reinforced foam articles

• US 20040177580A1
• Filed: 03/10/2003
• Published: 09/16/2004
• Est. Priority Date: 03/10/2003
• Status: Abandoned Application

• Current Assignee: Innovative Construction Technologies, Inc.
• Original Assignee: Innovative Construction Technologies, Inc.
• Inventors: Tremelling, Tim
• Application Number:
  US10/385,070
• Publication Number:
  US 20040177580A1
• Time in Patent Office: Days
• US Class Current: 52/426
• CPC Class Codes: E04B 2/8617 with spacers being embedded in both form leaves
• CPC Class Codes: E04B 2/8635 with ties attached to the inner faces of the forms E04B2/8611 and E04B2/8623 take precedence
• CPC Class Codes: E04B 2002/0206 of rectangular shape
• CPC Class Codes: E04B 2002/0226 with tongues and grooves next to each other on the end surface
• CPC Class Codes: E04C 1/40 built-up from parts of different materials, e.g. composed of layers of different materials or stones with filling material or with insulating inserts

Abstract

Reinforcement is provided for foam articles made from dry flowable expanding beads. The reinforcement includes a net work of elements, preferably woven or roving type. The net work is positioned within the foam matrix at a location remote from an applied force so as to impart increased bursting strength to the foam matrix.

Claims

1. In a freestanding form module for receiving flowable materials to make a wall which includes the form module, the flowable materials exerting a force in a selected direction, the form module comprising at least two spaced-apart form members having opposed interior form surfaces, each form member including a wall portion and a rib portion extending from the wall portion toward another one of said form members;

and at least one monolithic molded plastic tie member having opposed ends with a web member between the ends extending along a web axis, a bearing member at each end of the tie member, extending generally transverse to the web axis and embedded in the wall portion of a respective form member with the form member formed around so as to captively enclose the bearing member and each end of the tie member having a stabilizing member extending generally transverse to the web axis, spaced from the bearing member and embedded in the rib portion of a respective form member adjacent the interior form surface thereof with the form member formed around so as to captively enclose the stabilizing member;

the improvement in said form members comprising;

a reinforced foamed article including a three-dimensional foam matrix core of expanded dry flowable foam beads;

an internal reinforcing openwork reinforcing member disposed in the foam matrix and attached to the expanded beads of the foam matrix;

a sizing between at least some of the foam beads and the openwork reinforcing member; and

at least a majority of said openwork reinforcing member oriented in said foam matrix in a direction generally perpendicular to said preselected direction.

2. The improvement of claim 1 wherein at least 97% of said openwork reinforcing member is oriented in a direction generally perpendicular to said preselected direction.

3. The improvement of claim 1 wherein the foam beads are comprised of polystyrene and said openwork reinforcing member is comprised of fiberglass.

4. The improvement of claim 3 wherein 50% of the foam beads have a size dimension of 0.40 mm and 50% of the foam beads have a size dimension of 1.10 mm.

5. The improvement of claim 1 wherein the openwork reinforcing member is comprised of openwork members having openings ranging in size between 0.4 mm and approximately 3 inches.

6. A method of producing a reinforced foamed article comprising the steps of:

providing dry expandable flowable foam beads;

providing an openwork reinforcing member;

providing a mold cavity;

placing the openwork reinforcing member in the mold cavity;

flowing the foam beads into the mold cavity and around the openwork reinforcing member; and

heating the foam beads and the openwork reinforcing member within the mold cavity while allowing the foam beads to expand and fuse with one another to form a three-dimensional foam matrix with the openwork reinforcing member disposed therein.

7. The method of claim 6 further comprising the step of forming a chemical attachment between the openwork reinforcing member and the foam beads.

8. The method according to claim 7 further comprising the step of coating the openwork reinforcing member with a sizing material to enhance said chemical attachment.

9. The method according to claim 6 wherein the step of providing internal reinforcing fiber members comprises a step of providing internal reinforcing fiber members having an aspect ratio ranging between 0.001 and 0.00001.

10. The method according to claim 6 wherein the openwork reinforcing member comprises a fiberglass mesh.

11. The method according to claim 10 wherein said foam beads are comprised of one of said styrene and said polystyrene.

12. The method of claim 6 wherein the reinforced foam article is to be subjected to an applied force extending in a preselected direction, said method further comprising the step of providing a rigid bearing plate disposed in said foam matrix, said rigid bearing plate having a major surface facing in the preselected direction.

13. The method of claim 12 further comprising the step of attaching a portion of said openwork reinforcing member to said bearing plate.

14. The method of claim 12 further comprising the step of attaching a portion of said openwork reinforcing member to said bearing plate with a pressure sensitive adhesive.

15. The method of claim 6 wherein the reinforced foam article is to be subjected to an applied force extending in a preselected direction, said method further comprising the step of orienting at least a majority of said openwork reinforcing member in a direction generally perpendicular to said preselected direction.

16. The method of claim 15 wherein at least 97% of said openwork reinforcing member is oriented in a direction generally perpendicular to said preselected direction.

17. The method of claim 6 wherein the foam beads are comprised of polystyrene and said openwork reinforcing member is comprised of fiberglass.

18. The method of claim 17 wherein the foam beads have a size dimension of 0.40 mm to 1.10 mm.

19. The method of claim 17 wherein 50% of the foam beads have a size dimension of 0.40 mm and 50% of the foam beads have a size dimension of 1.10 mm.