US 12,472,664 B2
Rebonded foam molding machine, system, and method
David Murphy, High Point, NC (US); Michael Heyn, Hickory, NC (US); and Alex Wesley, Huntersville, NC (US)
Assigned to HICKORY SPRINGS MANUFACTURING COMPANY, Hickory, NC (US)
Filed by Hickory Springs Manufacturing Company, Hickory, NC (US)
Filed on Jul. 13, 2023, as Appl. No. 18/221,503.
Prior Publication US 2025/0018622 A1, Jan. 16, 2025
Int. Cl. B29C 43/56 (2006.01); B29C 43/00 (2006.01); B29C 43/02 (2006.01); B29C 43/36 (2006.01); B29C 43/52 (2006.01); B29K 75/00 (2006.01); B29K 105/00 (2006.01); B29K 105/04 (2006.01); B29K 105/26 (2006.01); B29L 31/00 (2006.01)
CPC B29C 43/56 (2013.01) [B29C 43/003 (2013.01); B29C 43/02 (2013.01); B29C 43/36 (2013.01); B29C 43/52 (2013.01); B29C 2043/561 (2013.01); B29K 2075/00 (2013.01); B29K 2105/0026 (2013.01); B29K 2105/04 (2013.01); B29K 2105/251 (2013.01); B29K 2105/26 (2013.01); B29L 2031/771 (2013.01)] 11 Claims
OG exemplary drawing
 
1. A method for molding a seamless rebonded foam article with an internal cavity, the method comprising:
loading a mold cavity, formed at least partially by a bottom mold, with a first portion of rebond foam particles to a first threshold volume, the rebond foam particles comprising an adhesive;
moving a middle mold, via a middle mold actuator assembly controlled by mold system control circuitry, to a middle mold form position within the mold cavity to press into the first portion of rebond foam particles, the middle mold having a width that is less than a width of the mold cavity;
loading the mold cavity with a second portion of rebond foam particles to a second threshold volume that covers the middle mold;
moving a top mold, via a top mold actuator assembly controlled by the mold system control circuitry, to a top mold form position within the mold cavity to press into the second portion of rebond foam particles, the top mold having a complementary shape to the mold cavity to compress the first and second portions of rebond foam particles;
injecting steam into the mold cavity at a middle mold fluid port interface of the middle mold, the steam passing into the mold cavity to interact with the first and second portions of rebond foam particles via at least one middle mold flow hole in the middle mold;
evacuating the steam from the mold cavity via a vacuum source coupled to a bottom mold fluid port interface and a top mold fluid port interface, the bottom mold fluid port interface being fluidly coupled to the mold cavity via at least one bottom mold flow hole in the bottom mold and the top mold fluid port interface being fluidly coupled to the mold cavity via at least one top mold flow hole in the top mold;
subsequent to injecting steam for a steaming duration to cure the first and second portions of rebond foam particles into a seamless article, discontinuing the injection of the steam and injecting compressed air into the mold cavity via the middle mold fluid port interface to remove the steam; and
moving the middle mold and the top mold out of the mold cavity for removal of the seamless rebonded foam article by removing the middle mold from the internal cavity of the seamless rebonded foam article.