Method of forming fire retardant insulating material from plastic foam scrap and the resultant product
OwnerBenjamin Mosierinventor
Life of this patent
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Abstract
Fire retardant polystyrene insulating material is manufactured from expandable polystyrene scrap in admixture with a phenol-formaldehyde or melamine-formaldehyde resin in resole form, the resin containing a blowing agent and a surfactant. The insulating material is formed from the scrap-resin mix by applying dielectric heating to foam the resin, and cure the foamed resin to a closed cell structure.
Claims14
The method of forming fire retardant insulation material from rigid plastic foam scrap, comprising:
- (a) comminuting said scrap to obtain pieces having maximum dimensions of less than one inch;
- (b) preparing a moldable mixture of said comminuted scrap with a heat-foamable thermosetting resin composition, the resin component of said composition being selected from the class consisting of phenol-formaldehyde and melamine-formaldehyde resins, said resin being in resole form and containing a blowing agent and a surfactant, from 10 to 150 parts by volume of said resin being present per 100 parts of said scrap in said mix;
- and
- (c) applying dielectric heating to said moldable mixture in enclosed molds to obtain integrated molded bodies composed of resin-encapsulated scrap pieces, said dielectric heating being effective for rapidly foaming said resin and curing it to a predominately closed cell structure surrounding said scrap pieces.
The method of forming fire retardant insulation material from foamed polystyrene scrap obtained as trimmings in the manufacture of foamed polystyrene board by the integration of expandable polystyrene beads without a binder, comprising:
- (b) preparing a moldable mixture of said comminuted scrap with a heat-foamable thermosetting resin composition, the resin component of said composition being selected from the class consisting of phenol-formaldehyde and melamine-formaldehyde resins, said resin being in resole form and containing a blowing agent and a surfactant, from 10 to 150 parts by volume of said resin being present per 100 parts of said polystyrene scrap in said mix;
- and
- (c) applying dielectric heating to said moldable mixture in enclosed molds to obtain integrated molded bodies composed of resin-encapsulated scrap pieces, said dielectric heating being effective for rapidly foaming said resin and curing it to a predominately closed cell structure surrounding said scrap pieces.
Dependencies are inferred from the claim text.