Rebonded Foam Molding Machine, System, and Method

A rebonded foam molding machine comprising:

• a top mold comprising a top mold contact surface and a top mold fluid port, the top mold contact surface comprising at least one top mold flow hole;
• a middle mold comprising a first middle mold contact surface, a second middle mold contact surface, and a middle mold fluid port, wherein the first middle mold contact surface or the second middle mold contact surface comprises at least one middle mold flow hole;
• a bottom mold comprising a bottom mold fluid port and a bottom mold contact surface shaped to form at least a portion of a mold cavity, wherein the bottom mold contact surface comprises at least one bottom mold flow hole;
• a middle mold actuator assembly configured to move the middle mold into a middle mold form position within the mold cavity;
• and
• a top mold actuator assembly configured to move the top mold into a top mold form position within the mold cavity above the middle mold in the middle mold form position;
• wherein a mold space is defined by an interior space of the mold cavity between the top mold in the top mold form position, the middle mold in the middle mold form position, and the bottom mold, the mold space being configured to retain rebond foam particles for molding a seamless rebonded foam article with an internal cavity;
• wherein the middle mold fluid port is configured to inject steam and compressed air into the mold space via the at least one middle mold flow hole;
• wherein the top mold fluid port is configured to evacuate steam and compressed air from the mold space via the at least one top mold flow hole;
• wherein the bottom mold fluid port is configured to draw steam and compressed air from the mold space via the at least one top mold flow hole;
• wherein the middle mold actuator and the top mold actuator are further configured to move the middle mold and the top mold out of the mold cavity to permit removal of the seamless rebonded foam article from the middle mold disposed within the internal cavity of the seamless rebonded foam article.

A method for molding a seamless rebonded foam article with an internal cavity, the method comprising:

• 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 a first portion of rebond foam particles, the middle mold having a width that is less than a width of the mold cavity;
• 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 a 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.