WO2008153417A1 - Apparatus and method for expanding foams and formation of expanded foam articles - Google Patents

Apparatus and method for expanding foams and formation of expanded foam articles Download PDF

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Publication number
WO2008153417A1
WO2008153417A1 PCT/NZ2008/000136 NZ2008000136W WO2008153417A1 WO 2008153417 A1 WO2008153417 A1 WO 2008153417A1 NZ 2008000136 W NZ2008000136 W NZ 2008000136W WO 2008153417 A1 WO2008153417 A1 WO 2008153417A1
Authority
WO
WIPO (PCT)
Prior art keywords
foam
chamber
elongate
expansion
tubular chamber
Prior art date
Application number
PCT/NZ2008/000136
Other languages
French (fr)
Inventor
David Allan Roud
Original Assignee
Obie International Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Obie International Limited filed Critical Obie International Limited
Publication of WO2008153417A1 publication Critical patent/WO2008153417A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/58—Moulds
    • B29C44/586—Moulds with a cavity increasing in size during foaming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
    • B29C44/08—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles using several expanding or moulding steps
    • B29C44/083—Increasing the size of the cavity after a first part has foamed, e.g. substituting one mould part with another
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/56—After-treatment of articles, e.g. for altering the shape
    • B29C44/5627—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
    • B29C44/5654—Subdividing foamed articles to obtain particular surface properties, e.g. on multiple modules
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2201/00—Foams characterised by the foaming process
    • C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
    • C08J2201/024—Preparation or use of a blowing agent concentrate, i.e. masterbatch in a foamable composition

Definitions

  • the invention relates to expansion of foams and to formation of expanded foam articles.
  • Polyolefin foam is generally expanded from flat preformed sheets in a one or two stage process.
  • the flat sheets are heated in a mould, activating a decomposable, gas-releasing blowing agent. This causes the preformed sheets to expand to approximately 20 times their original volume.
  • preformed sheets are partially expanded in a first mould, before being fully expanded in a second mould.
  • the two-stage process limits the stresses caused in the foam structure during the expansion process. Unrestrained flat sheets would distort during the expansion process, so expansion must be carried out in restraining moulds.
  • Expanded foam is usually cut or further processed following the expansion process.
  • sheets of foam may be glued together and shaped, resulting in significant wastage.
  • the invention provides a method of forming an article by expanding foam, including the steps of: introducing unexpanded foam into an elongate, tubular chamber with an uninterrupted bore; partially expanding the foam in the elongate chamber; introducing the partially expanded foam into a second chamber having a shape corresponding to the desired shape of an article to be formed; expanding the partially expanded foam in the second chamber.
  • the invention provides a method of expanding foam, including the steps of: partially expanding foam in a first expansion chamber; introducing the partially expanded foam into a second expansion chamber of non- planar form; further expanding the partially expanded foam in the second expansion chamber.
  • the invention provides an apparatus for expansion of foam, including: an elongate, tubular chamber having an uninterrupted bore, a first end and a second end; a first closure configured to move into and out of the first end of the tubular chamber, to block the first end during expansion and to allow removal of expanded foam; and a second closure configured to block the second end of the tubular chamber during expansion and to move through the chamber from the second end towards the first end to push expanded foam out of the chamber at the first end.
  • the invention provides a method of forming expanded foam sheet, including: expanding foam in a cylindrical mould to form a cylinder of expanded foam; turning the expanded foam cylinder about its axis; using a blade to cut the expanded foam cylinder into expanded foam sheet as it turns.
  • Figure 1 shows a foam expansion apparatus in a closed position
  • Figure 2 shows the foam expansion apparatus of Figure 1 , in an open position
  • Figure 3 shows a cross-section of one embodiment of expansion chamber
  • Figure 4 shows a cross-section of another embodiment of expansion chamber
  • Figure 5 shows a cross-section of a further embodiment of expansion chamber
  • Figure 6 shows an expanded foam article
  • Figure 7 shows a method of forming expanded foam sheet from an expanded foam cylinder.
  • Figures 1 and 2 show a foam expansion apparatus 1.
  • the apparatus includes an elongate, tubular chamber 2, formed by an inner wall 3.
  • An outer wall 4 is also provided, and the space between the inner and outer walls contains a number of heating elements 5 for heating the chamber to a desired temperature.
  • the apparatus 1 also includes a first closure 6 which is configured to move into and out of a first end 7 of the chamber 2. This closure closes the first end 7 during expansion of foam in the chamber 2 (as shown in Figure 1 ) and opens the first end 7 when expansion is complete (as shown in Figure 2) to allow expanded foam to be removed.
  • the first closure 6 may be mounted on a first ram 8, such as a hydraulic ram or similar.
  • the apparatus 1 includes a second closure 10, which closes the second end 11 of the chamber 2 during expansion of foam, as shown in Figure 1.
  • the second closure 10 moves through the chamber 2 from the second end 11 towards the first end 7, in order to push expanded foam out of the chamber 2 through the first end 7.
  • the second closure 10 may be mounted on a second ram 12, such as a hydraulic ram or similar.
  • the first closure 6 may be moved from a position within the chamber ( Figure 1) towards the first end 7 without actually passing out of the chamber 2. This increases the effective volume of the chamber 2 during expansion, thereby controlling the expansion process. This movement may be achieved by driving the first ram 8 in an appropriate manner, or simply by making the ram 8 movable in response to the increasing pressure generated in the chamber 2. This increase in volume could also be achieved by moving the second closure, or both closures.
  • the elongate tubular chamber may have a circular cross-section (Figure 3), forming a cylindrical chamber. This shape is preferred as it has a natural strength, making it more suitable for withstanding the high pressures created during expansion.
  • tubular configurations such as chambers with elliptical ( Figure 4), square ( Figure 5) or rectangular cross-sections.
  • Figure 4 chambers with elliptical
  • Figure 5 square
  • Figure 5 rectangular cross-sections.
  • any cross- sectional shape may be used, but preferably the cross-section is uninterrupted by internal elements.
  • the elongate, tubular chamber may be used for partial expansion of foam or final expansion of foam, where a two stage expansion process is used.
  • the chamber 2 may be heated using the heating elements 5 to a temperature between about 150 to 165° Celsius, preferably about 160° Celsius.
  • This temperature may be maintained for a time period of about 30 to 60 seconds per mm of diameter of the chamber. Preferably the temperature is maintained for a time period of about 45 to 55 seconds per mm of diameter of the chamber, more preferably about 50 seconds.
  • the resulting partially expanded foam may be introduced into a second chamber for further expansion.
  • the second chamber may be of non-planar form and may have an internal shape which corresponds to the desired shape of an article to be formed.
  • a substantially finished article is produced by expanding foam in a mould. This is in contrast to previous methods, in which expanded mould was generally cut or otherwise worked after expansion.
  • the Applicant's method allows the use of recycled foam materials, since the outside surface of the article is formed during the expansion process. This means that any recycled materials are generally contained within the article and any lack of uniformity is generally concealed within the article. Prior methods did not allow this, since cutting of the expanded material would reveal any lack of uniformity caused by recycled material in the expanded foam.
  • the second chamber may be heated to a temperature about 10° Celsius higher than the temperature used for partial expansion.
  • the second chamber may be shaped to produce an article such as that shown in Figure 6.
  • This is a buoy 60, formed from foam expanded in a second chamber having a corresponding shape.
  • the buoy is roughly rugby-ball shaped in a cross- section along its length, pointed at its two ends 61 , 62, such that it has a low resistance to fluid flow along its length.
  • the second chamber may be shaped for moulding of any suitable article, including: boat fenders, exercise devices, flotation aides, buoys, impact buffers etc.
  • Figure 7 shows a cylinder 70 of expanded foam being formed into layers of foam.
  • the cylinder may be formed using either of the chambers described above.
  • the cylinder 70 is turned around its axis as indicated by arrow 71.
  • a blade 72 is mounted so as to cut a strip of the foam from the cylinder 70.
  • the blade is preferably movable as indicated by arrow 73, such that a continuous layer or a series of layers of foam can be formed from the cylinder.
  • This method enables a very long continuous stock of thin foam to be produced which is particularly suited to packaging applications etc. Where this method is used, it may be preferable to use all new materials, since any lack of uniformity will be revealed by the cutting operation.
  • the foam material may included recycled or new material, and may include polyolefin material, particularly cross-linkable polyolefin material, low density polyethylene material and/or ethylene vinyl acetate material. Other materials may also be suitable. In general these materials are mixed with an expanding blowing agent before expansion.
  • the methods and apparatus described above allow production of substantially finished articles, with very little waste. Recycled plastics may be used.
  • the expansion chamber is also a simple and strong structure.

Abstract

According to one method an article is formed by introducing unexpanded foam into an elongate, tubular chamber with an uninterrupted bore, partially expanding the foam in the elongate chamber, introducing the partially expanded foam into a second chamber having a shape corresponding to the desired shape of an article to be formed and expanding the partially expanded foam in the second chamber. In another method foam is expanded by partially expanding foam in a first expansion chamber, introducing the partially expanded foam into a second expansion chamber of non-planar form and further expanding the partially expanded foam in the second expansion chamber. In another method foam is expanded in a cylindrical mould to form a cylinder of expanded foam, the cylinder is turned about its axis and a blade is used to cut the expanded foam cylinder into expanded foam sheet as it turns. Apparatus for performing the methods is also disclosed.

Description

APPARATUS AND METHOD FOR EXPANDING FOAMS AND FORMATION OF EXPANDED FOAM ARTICLES
FIELD OF THE INVENTION
The invention relates to expansion of foams and to formation of expanded foam articles.
BACKGROUND TO THE INVENTION
Polyolefin foam is generally expanded from flat preformed sheets in a one or two stage process. The flat sheets are heated in a mould, activating a decomposable, gas-releasing blowing agent. This causes the preformed sheets to expand to approximately 20 times their original volume.
In a two-stage process, preformed sheets are partially expanded in a first mould, before being fully expanded in a second mould. The two-stage process limits the stresses caused in the foam structure during the expansion process. Unrestrained flat sheets would distort during the expansion process, so expansion must be carried out in restraining moulds.
Previous moulds are generally planar in form. However, this requires the use of strong materials and powerful hydraulic systems in the moulds. This makes the machinery costly and inefficient.
Expanded foam is usually cut or further processed following the expansion process. To form non-planar objects, sheets of foam may be glued together and shaped, resulting in significant wastage.
It is an object of the invention to provide an improved foam expansion apparatus and/or method, or at least to provide the public with a useful choice. SUMMARY OF THE INVENTION
In a first aspect the invention provides a method of forming an article by expanding foam, including the steps of: introducing unexpanded foam into an elongate, tubular chamber with an uninterrupted bore; partially expanding the foam in the elongate chamber; introducing the partially expanded foam into a second chamber having a shape corresponding to the desired shape of an article to be formed; expanding the partially expanded foam in the second chamber.
In a second aspect the invention provides a method of expanding foam, including the steps of: partially expanding foam in a first expansion chamber; introducing the partially expanded foam into a second expansion chamber of non- planar form; further expanding the partially expanded foam in the second expansion chamber.
In a third aspect the invention provides an apparatus for expansion of foam, including: an elongate, tubular chamber having an uninterrupted bore, a first end and a second end; a first closure configured to move into and out of the first end of the tubular chamber, to block the first end during expansion and to allow removal of expanded foam; and a second closure configured to block the second end of the tubular chamber during expansion and to move through the chamber from the second end towards the first end to push expanded foam out of the chamber at the first end.
In a fourth aspect the invention provides a method of forming expanded foam sheet, including: expanding foam in a cylindrical mould to form a cylinder of expanded foam; turning the expanded foam cylinder about its axis; using a blade to cut the expanded foam cylinder into expanded foam sheet as it turns.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example only, with reference to the accompanying drawings, in which:
Figure 1 shows a foam expansion apparatus in a closed position;
Figure 2 shows the foam expansion apparatus of Figure 1 , in an open position;
Figure 3 shows a cross-section of one embodiment of expansion chamber;
Figure 4 shows a cross-section of another embodiment of expansion chamber;
Figure 5 shows a cross-section of a further embodiment of expansion chamber;
Figure 6 shows an expanded foam article; and
Figure 7 shows a method of forming expanded foam sheet from an expanded foam cylinder.
DETAILED DESCRIPTION
Figures 1 and 2 show a foam expansion apparatus 1. The apparatus includes an elongate, tubular chamber 2, formed by an inner wall 3. An outer wall 4 is also provided, and the space between the inner and outer walls contains a number of heating elements 5 for heating the chamber to a desired temperature. The apparatus 1 also includes a first closure 6 which is configured to move into and out of a first end 7 of the chamber 2. This closure closes the first end 7 during expansion of foam in the chamber 2 (as shown in Figure 1 ) and opens the first end 7 when expansion is complete (as shown in Figure 2) to allow expanded foam to be removed. The first closure 6 may be mounted on a first ram 8, such as a hydraulic ram or similar.
The apparatus 1 includes a second closure 10, which closes the second end 11 of the chamber 2 during expansion of foam, as shown in Figure 1. When expansion is complete, the second closure 10 moves through the chamber 2 from the second end 11 towards the first end 7, in order to push expanded foam out of the chamber 2 through the first end 7. The second closure 10 may be mounted on a second ram 12, such as a hydraulic ram or similar.
During expansion of foam, the first closure 6 may be moved from a position within the chamber (Figure 1) towards the first end 7 without actually passing out of the chamber 2. This increases the effective volume of the chamber 2 during expansion, thereby controlling the expansion process. This movement may be achieved by driving the first ram 8 in an appropriate manner, or simply by making the ram 8 movable in response to the increasing pressure generated in the chamber 2. This increase in volume could also be achieved by moving the second closure, or both closures.
The elongate tubular chamber may have a circular cross-section (Figure 3), forming a cylindrical chamber. This shape is preferred as it has a natural strength, making it more suitable for withstanding the high pressures created during expansion.
However, other tubular configurations may be used, such as chambers with elliptical (Figure 4), square (Figure 5) or rectangular cross-sections. In general, any cross- sectional shape may be used, but preferably the cross-section is uninterrupted by internal elements.
The elongate, tubular chamber may be used for partial expansion of foam or final expansion of foam, where a two stage expansion process is used.
For partial expansion of foam, the chamber 2 may be heated using the heating elements 5 to a temperature between about 150 to 165° Celsius, preferably about 160° Celsius.
This temperature may be maintained for a time period of about 30 to 60 seconds per mm of diameter of the chamber. Preferably the temperature is maintained for a time period of about 45 to 55 seconds per mm of diameter of the chamber, more preferably about 50 seconds.
Where this chamber is used for partial expansion of foam, the resulting partially expanded foam may be introduced into a second chamber for further expansion. The second chamber may be of non-planar form and may have an internal shape which corresponds to the desired shape of an article to be formed. Thus, a substantially finished article is produced by expanding foam in a mould. This is in contrast to previous methods, in which expanded mould was generally cut or otherwise worked after expansion. The Applicant's method allows the use of recycled foam materials, since the outside surface of the article is formed during the expansion process. This means that any recycled materials are generally contained within the article and any lack of uniformity is generally concealed within the article. Prior methods did not allow this, since cutting of the expanded material would reveal any lack of uniformity caused by recycled material in the expanded foam.
The second chamber may be heated to a temperature about 10° Celsius higher than the temperature used for partial expansion. The second chamber may be shaped to produce an article such as that shown in Figure 6. This is a buoy 60, formed from foam expanded in a second chamber having a corresponding shape. The buoy is roughly rugby-ball shaped in a cross- section along its length, pointed at its two ends 61 , 62, such that it has a low resistance to fluid flow along its length.
The second chamber may be shaped for moulding of any suitable article, including: boat fenders, exercise devices, flotation aides, buoys, impact buffers etc.
Figure 7 shows a cylinder 70 of expanded foam being formed into layers of foam. The cylinder may be formed using either of the chambers described above. The cylinder 70 is turned around its axis as indicated by arrow 71. A blade 72 is mounted so as to cut a strip of the foam from the cylinder 70. The blade is preferably movable as indicated by arrow 73, such that a continuous layer or a series of layers of foam can be formed from the cylinder. This method enables a very long continuous stock of thin foam to be produced which is particularly suited to packaging applications etc. Where this method is used, it may be preferable to use all new materials, since any lack of uniformity will be revealed by the cutting operation.
The foam material may included recycled or new material, and may include polyolefin material, particularly cross-linkable polyolefin material, low density polyethylene material and/or ethylene vinyl acetate material. Other materials may also be suitable. In general these materials are mixed with an expanding blowing agent before expansion.
The methods and apparatus described above allow production of substantially finished articles, with very little waste. Recycled plastics may be used. The expansion chamber is also a simple and strong structure.
While the present invention has been illustrated by the description of the embodiments thereof, and while the embodiments have been described in detail, it is not the intention of the Applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and methods, and illustrative examples shown and described. Accordingly, departures may be made from such details without departure from the spirit or scope of the Applicant's general inventive concept.

Claims

1. A method of forming an article by expanding foam, including the steps of: i. introducing unexpanded foam into an elongate, tubular chamber with an uninterrupted bore; ii. partially expanding the foam in the elongate chamber; iii. introducing the partially expanded foam into a second chamber having a shape corresponding to the desired shape of an article to be formed; and iv. expanding the partially expanded foam in the second chamber.
2. A method as claimed in claim 1 wherein the elongate, tubular chamber is a cylindrical chamber.
3. A method as claimed in claim 1 wherein the elongate, tubular chamber has an oval cross-section.
4. A method as claimed in any preceding claim, including: v. closing the elongate, tubular chamber before partially expanding the foam, using a first closure at a first end of the elongate, tubular chamber and a second closure at a second end of the elongate, tubular chamber; vi. opening the elongate, tubular chamber at its first end after partially expanding the foam, by removing the first closure; and vii. forcing the partially expanded foam from the elongate, tubular chamber by moving the second closure through the elongate, tubular chamber from its second end towards its first end.
5. A method as claimed in claim 4 including operating the second closure using a ram.
6. A method as claimed in claim 4 or 5 including operating the first closure using a ram.
7. A method as claimed in any one of claims 4 to 6 including moving at least one of the closures during the partial expansion so as to increase the operating volume of the elongate, tubular chamber.
8. A method as claimed in any preceding claim' including heating the elongate, tubular chamber to a temperature between about 150 to 165° Celsius during partial expansion of the foam.
9. A method as claimed in any claim 8 including heating the elongate, tubular chamber to a temperature of about 160° Celsius during partial expansion of the foam.
10. A method as claimed in any preceding claim including partially expanding the foam over a time period of about 30 to 60 seconds per mm of diameter of the elongate, tubular chamber.
11. A method as claimed in any claim 10 including partially expanding the foam over a time period of about 45 to 55 seconds per mm of diameter of the elongate, tubular chamber.
12. A method as claimed in any claim 11 including partially expanding the foam over a time period of abcut 50 seconds per mm of diameter of the elongate, tubular chamber.
13. A method as claimed in any preceding claim wherein the unexpanded foam includes recycled material.
14. A method as claimed in any preceding claim wherein the unexpanded foam includes crosslinkable polyolefin material.
15. A method as claimed in any preceding claim wherein the unexpanded foam includes low density polyethylene material.
16. A method as claimed in any preceding claim wherein the unexpanded foam includes ethylene vinyl acetate material.
17. A method as claimed in any preceding claim wherein the second chamber is shaped to produce a finished article shaped for low resistance to fluid flow.
18. A method of expanding foam, including the steps of:
I. partially expanding foam in a first expansion chamber; introducing the partially expanded foam into a second expansion chamber of non-planar form; and iii. further expanding the partially expanded foam in the second expansion chamber.
19. A method as claimed in claim 18 wherein the second expansion chamber has a shape corresponding to the desired shape of an article to be formed.
20. A method as claimed in claim 18 or 19 wherein the second chamber is shaped to produce a finished article shaped for low resistance to fluid flow.
21. A method as claimed in any one of claims 18 to 20 wherein the first expansion chamber is an elongate, tubular chamber with an uninterrupted bore.
22. A method as claimed in any one of claims 18 to 21 wherein the unexpanded foam includes recycled material.
23. A method as claimed in any one of claims 18 to 22 wherein the unexpanded foam includes crosslinkable polyolefin material.
24. A method as claimed in any one of claims 18 to 23 wherein the unexpanded foam includes low density polyethylene material.
25. A method as claimed in any one of claims 18 to 24 wherein the unexpanded foam includes ethylene vinyl acetate material.
26. An apparatus for expansion of foam, including: i. an elongate, tubular chamber having an uninterrupted bore, a first end and a second end; ii. a first closure configured to move into and out of the first end of the tubular chamber, to block the first end during expansion and to allow removal of expanded foam; and iii. a second closure configured to block the second end of the tubular chamber during expansion and to move through the chamber from the second end towards the first end to push expanded foam out of the chamber at the first end.
27. An apparatus as claimed in claim 26 wherein the elongate, tubular chamber is a cylindrical chamber.
28. An apparatus as claimed in claim 26 wherein the elongate, tubular chamber has an oval cross-section.
29. An apparatus as claimed in any one of claims 26 to 28 including a first ram configured to move the first closure into and out of the first end of the elongate, tubular chamber.
30. An apparatus as claimed in any one of claims 26 to 29 including a second ram configured to move the second closure through the chamber from the second end towards the first end.
31. An apparatus as claimed in any one of claims 26 to 30 wherein at least one of the closures is configured to move during the expansion so as to increase the operating volume of the elongate, tubular chamber.
32. An apparatus as claimed in any one of claims 26 to 31 including a heater for heating the chamber, thereby causing expansion of foam within the chamber.
33. A system for forming an article by expanding foam, including an apparatus as claimed in any one of claims 26 to 32 and a second chamber for receiving foam partially expanded in the elongate, tubular chamber and having a shape corresponding to the desired shape of an article to be formed.
34. A method of forming expanded foam sheet, including: expanding foam in a cylindrical mould to form a cylinder of expanded foam; turning the expanded foam cylinder about its axis; using a blade to cut the expanded foam cylinder into expanded foam sheet as it turns.
35. A method as claimed in claim 1 or 18 substantially as herein described.
36. An apparatus as claimed in claim 26 substantially as herein described.
37. An apparatus for expansion of foam substantially as herein described with reference to any embodiment shown in Figures 1 to 5 of the accompanying drawings.
PCT/NZ2008/000136 2007-06-14 2008-06-11 Apparatus and method for expanding foams and formation of expanded foam articles WO2008153417A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NZ55588007 2007-06-14
NZ555880 2007-06-14

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WO2008153417A1 true WO2008153417A1 (en) 2008-12-18

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102941646A (en) * 2012-11-06 2013-02-27 航天材料及工艺研究所 Evaluation mould for foaming ratio of foamed plastic
US10118443B2 (en) 2014-06-24 2018-11-06 Gecko Rubber Limited Expanded rubber articles

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4671910A (en) * 1984-08-16 1987-06-09 Dynamit Nobel Aktiengesellschaft Process for the production of closed-cell foam molded articles of crosslinked polyolefin
WO1996011096A1 (en) * 1994-10-10 1996-04-18 Tarocal Kirk No.7 Limited Two-stage process for making foam mouldings from tube blanks
AU5452796A (en) * 1995-05-26 1996-12-05 Raydy Pty. Ltd. Synthetic polymeric mouldable composition, product and method
US6413454B1 (en) * 2000-03-28 2002-07-02 Cheng-Hsian Chi Method for manufacturing E.V.A. foamed sports equipment
US20050282920A1 (en) * 2004-06-21 2005-12-22 Microcell Composite Company High multiple foam manufacturing method for thermoplastic elastomers composites

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4671910A (en) * 1984-08-16 1987-06-09 Dynamit Nobel Aktiengesellschaft Process for the production of closed-cell foam molded articles of crosslinked polyolefin
WO1996011096A1 (en) * 1994-10-10 1996-04-18 Tarocal Kirk No.7 Limited Two-stage process for making foam mouldings from tube blanks
AU5452796A (en) * 1995-05-26 1996-12-05 Raydy Pty. Ltd. Synthetic polymeric mouldable composition, product and method
US6413454B1 (en) * 2000-03-28 2002-07-02 Cheng-Hsian Chi Method for manufacturing E.V.A. foamed sports equipment
US20050282920A1 (en) * 2004-06-21 2005-12-22 Microcell Composite Company High multiple foam manufacturing method for thermoplastic elastomers composites

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102941646A (en) * 2012-11-06 2013-02-27 航天材料及工艺研究所 Evaluation mould for foaming ratio of foamed plastic
US10118443B2 (en) 2014-06-24 2018-11-06 Gecko Rubber Limited Expanded rubber articles
US10486469B2 (en) 2014-06-24 2019-11-26 Gecko Rubber Limited Expanded rubber articles

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