Process and apparatus for producing gas pressurized foam particles
First Claim
1. A process for producing gas pressurized closed-cell foam particles suitable for secondary foaming to a lower density foam, comprising the steps of:
- (a) charging closed cell foam particles to a first stage compression tank wherein the foam particles are subjected to a pressure of from about 10 psig to about 150 psig to compress said foam particles to about 30%-40% of their original volume at atmospheric pressure;
(b) transferring the pressurized foam particles to a main gas pressurization tank maintained under a pressure of from about 40 psig to about 100 psig and a temperature of from about 30°
C. to about 90°
C., said gas pressurization tank having multi-level shelves through which individual charges of compressed foam particles sequentially pass, each shelf holding a separate charge of foam particles from the first stage compression tank and further wherein each shelf has a plurality of compartments to prevent bridging and immobilization of the foam particles; and
(c) passing the foam particles from one shelf to the next in a first-in-first-out sequence, during which said foam particles partially recover their volume without exceeding the free volume in each of said plurality of compartments;
(d) discharging the foam particles from the last shelf level of the main gas pressurization tank, said foam particles having an internal pressure greater than atmospheric pressure and suitable for secondary foaming.
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Accused Products
Abstract
Closed-cell foam particles are pressurized to produce particles useful in a process using secondary foaming to achieve a lower density foam. Closed-cell foam particles are initially compressed in a first stage compression tank and then transferred to a main gas pressurization tank. The main gas pressurization tank comprises multi-level shelves, each with a set of compartments. Charges of foam particles pass sequentially through the shelves while becoming fully pressurized. The multi-level shelves with means to move charges of foam particles from shelf to shelf are responsible for the closed cell foam particles becoming pressurized in an efficient manner.
7 Citations
18 Claims
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1. A process for producing gas pressurized closed-cell foam particles suitable for secondary foaming to a lower density foam, comprising the steps of:
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(a) charging closed cell foam particles to a first stage compression tank wherein the foam particles are subjected to a pressure of from about 10 psig to about 150 psig to compress said foam particles to about 30%-40% of their original volume at atmospheric pressure; (b) transferring the pressurized foam particles to a main gas pressurization tank maintained under a pressure of from about 40 psig to about 100 psig and a temperature of from about 30°
C. to about 90°
C., said gas pressurization tank having multi-level shelves through which individual charges of compressed foam particles sequentially pass, each shelf holding a separate charge of foam particles from the first stage compression tank and further wherein each shelf has a plurality of compartments to prevent bridging and immobilization of the foam particles; and(c) passing the foam particles from one shelf to the next in a first-in-first-out sequence, during which said foam particles partially recover their volume without exceeding the free volume in each of said plurality of compartments; (d) discharging the foam particles from the last shelf level of the main gas pressurization tank, said foam particles having an internal pressure greater than atmospheric pressure and suitable for secondary foaming. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A gas pressurization tank having multi-level shelves to hold separate charges of foam particles and alllow transfer of foam particle charges sequentially therethrough, comprising:
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(a) a main tank with charge and discharge openings through which foam particles pass; (b) multi-level shelves within the main tank characterized by having a series of at least four compartments at each shelf level with the compartment heights increasing at each shelf level from the charge opening to the discharge opening; and (c) means for gravity transferring individual charges of foam particles in compartments found at each shelf level to compartments found at a lower shelf level. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18)
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Specification