US 11,911,932 B2
System for making a rigid foam substitute
Drayton Miller, Dauphin Island, AL (US); and Paul Muncrief, Sacramento, NM (US)
Assigned to ThermoPod, Inc, Mobile, AL (US)
Filed by Thermopod, LLC, Mobile, AL (US)
Filed on Jul. 29, 2020, as Appl. No. 16/942,697.
Claims priority of provisional application 62/879,590, filed on Jul. 29, 2019.
Prior Publication US 2021/0031413 A1, Feb. 4, 2021
Int. Cl. B29C 39/00 (2006.01); D01G 7/00 (2006.01); D01G 5/00 (2006.01); B29B 7/90 (2006.01); B07B 13/00 (2006.01); B29C 39/02 (2006.01); B29C 39/38 (2006.01); B29C 39/24 (2006.01); B29B 7/24 (2006.01); B29K 105/12 (2006.01); B29K 311/10 (2006.01); B29B 7/82 (2006.01); D01B 1/14 (2006.01); D01B 9/00 (2006.01); B29K 1/00 (2006.01); B29K 31/00 (2006.01)
CPC B29C 39/003 (2013.01) [B29B 7/242 (2013.01); B29C 39/02 (2013.01); B29C 39/24 (2013.01); B29C 39/38 (2013.01); D01G 5/00 (2013.01); D01G 7/00 (2013.01); B07B 13/00 (2013.01); B29B 7/82 (2013.01); B29B 7/90 (2013.01); B29B 7/905 (2013.01); B29C 2793/009 (2013.01); B29K 2001/00 (2013.01); B29K 2003/00 (2013.01); B29K 2031/04 (2013.01); B29K 2105/12 (2013.01); B29K 2311/10 (2013.01); D01B 1/14 (2013.01); D01B 9/00 (2013.01)] 13 Claims
OG exemplary drawing
 
1. A system for making a rigid foam substitute comprising:
an opener configured to decompress compressed natural fiber material via gentle manipulation of said compressed natural fiber material using rollers of said opener,
wherein decompression of said compressed natural fiber material results in a natural fiber material,
a cleaner configured to break said natural fiber material into pieces of natural fiber material having a specific length,
wherein said rollers of said cleaner breaks said natural fiber material into said pieces of natural fiber material,
wherein trash of said natural fiber material is removed from said natural fiber material while said natural fiber material is broken into said pieces of natural fiber material,
wherein said trash of said natural fiber material comprises at least one of leaf, stone, iron particles, jute, polypropylene, colored fibers, and feather,
wherein said trash of said natural fiber material is removed by at least one of a comb and paddle of said cleaner,
a mixer configured to create a fluidic mixture from said pieces of natural fiber material, a liquid, and a natural binding material,
wherein said pieces of natural fiber material received from said cleaner and used to create said fluidic mixture differ in at least one of size, grade, source, or type,
wherein said mixer receives said pieces of natural fiber material from said cleaner, liquid, and natural binding material within at least one hopper of said mixer,
wherein said at least one hopper weighs at least one of said pieces of natural fiber material liquid, and natural binding material to a desired amount,
wherein said at least one hopper transfers said pieces of natural fiber material liquid, and natural binding material to a vat of said mixer,
wherein said mixer maintains a desired temperature range while said pieces of natural fiber material liquid, and natural binding material are mixed within said vat,
a molder configured to shape said fluidic mixture into a cast having a desired shape,
wherein said molder receives said fluidic mixture from said vat and compacts said fluidic mixture into at least one mold to create a cast,
wherein said desired shape of said cast is based on said at least one mold within said molder,
wherein said cast is pushed out of said at least one mold,
a kiln configured to cure said cast.
 
8. A system for making a rigid foam substitute comprising:
a cleaner configured to remove trash from at least two decompressed natural fiber materials that were mixed during an opening process,
wherein said cleaner breaks said at least two decompressed natural fiber materials into pieces of natural fiber material via a plurality of rollers having a specific length,
wherein trash of said at least two decompressed natural fiber materials is removed from said at least two decompressed natural fiber materials while said at least two decompressed natural fiber materials are broken into said pieces of natural fiber materials,
wherein said trash of said at least two natural fiber materials comprises at least one of leaf, stone, iron particles, jute, polypropylene, colored fibers, and feather,
wherein said trash of said at least two decompressed natural fiber materials is removed by at least one of a comb and paddle of said cleaner,
a mixer operably connected to said cleaner and configured to create a fluidic mixture within a vat using said pieces of natural fiber material, a liquid, and a natural binding material,
wherein said pieces of natural fiber material are received in a first hopper of said mixer,
wherein said natural binding material is received in a second hopper of said mixer,
wherein said pieces of natural fiber material of said first hopper and said natural binding material of said second hopper are transferred to said vat of said mixer,
wherein said pieces of natural fiber material received from first hopper and said second hopper differ in at least one of size, grade, source, or type,
wherein a specified amount of a liquid is transferred to said vat,
wherein said mixer maintains a desired temperature range while said pieces of natural fiber material, liquid, and natural binding material are mixed within said vat,
a molder operably connected to said mixer and configured to shape said fluidic mixture into a cast having a desired shape,
wherein said molder automatically receives said fluidic mixture from said mixer and compacts said fluidic mixture into at least one mold to create a cast,
wherein said desired shape of said cast is based on said at least one mold within said molder,
wherein said cast is pushed out of said at least one mold, and
a kiln operably connected to said molder and configured to cure said casts.