US 12,233,583 B2
Molding of expandable polystyrene
Jonathan Godfrey, Joppa, MD (US); Saumitra Bhargava, Clarksville, MD (US); Michael W. Elliott, Aberdeen, MD (US); and Gerry Babyok, Abingdon, MD (US)
Assigned to LIFOAM INDUSTRIES, LLC, Greer, SC (US)
Filed by Lifoam Industries, LLC, Greer, SC (US)
Filed on Mar. 28, 2022, as Appl. No. 17/656,665.
Prior Publication US 2023/0302692 A1, Sep. 28, 2023
Int. Cl. B29C 44/34 (2006.01); B29C 44/42 (2006.01); B29K 25/00 (2006.01); B29K 105/04 (2006.01)
CPC B29C 44/3426 (2013.01) [B29C 44/3403 (2013.01); B29C 44/3461 (2013.01); B29C 44/354 (2013.01); B29C 44/355 (2013.01); B29C 44/42 (2013.01); B29K 2025/06 (2013.01); B29K 2105/048 (2013.01); B29K 2995/0063 (2013.01); B29K 2995/0082 (2013.01); B29K 2995/0097 (2013.01)] 23 Claims
OG exemplary drawing
 
1. A method of making a molded foam article, comprising:
(i) introducing foam particles comprising polystyrene into a mold for an article while simultaneously introducing steam into the mold;
(ii) subjecting the mold to direct steaming; and then
(iii) subjecting the mold to a negative pressure cycle, in the absence of cooling water, in which the foam particles are expanded and fused together to form the article; and then
(iv) removing the molded foam article from the mold.