Systems and methods for improving adhesion of an insulating foam to a molded polymeric insulating structure through use of ozone gas for functionalization of molded polymeric surfaces of an internal cavity of the insulating structure.

Methods of making molded polystyrene articles are described. The methods include introducing steam into a mold simultaneous to filling the mold with foam particles, and cooling the mold without the use of cooling water. The method can be performed faster and with a lower temperature differential than conventional molding processes, permitting faster turn-around to the production of subsequent molded articles. The molded articles produced by the method can have thicker side walls, improved foam particle fusion, and improved compression properties as compared to conventional EPS molding processes.

A method of reducing the number or size of voids in a polyurethane comprises reacting the formulation components in a container having an inner surface, or having a liner that has an inner surface, that has been modified to reduce the shear forces that normally accompany introduction of such components into a container. This is done by modifying the inner container's or container liner's surface by profiling and/or engraving it, or by including as a liner a mesh. The profiling and/or engraving or mesh serves to alter the formulation's flow dynamics such that the polyurethane has fewer and/or smaller voids, i.e., has a more uniform density, than polyurethanes formed without the modification.

An apparatus for manufacturing panels made of expanded plastic material comprising at least one perimetric confinement frame clamped between a pair of pressing surfaces of a press in order to delimit laterally at least one expansion cavity for an expanding mixture. At least one portion of the perimetric frame defines internally, along its extension, at least one air passage channel that is connected to at least one air intake port, which is defined in the surface of the perimetric frame that is directed toward the inside of the expansion cavity, and to at least one connection port, which is defined in the surface of the perimetric frame that is directed toward the outside of the expansion cavity and adapted to be connected to at least one air suction device.

The present invention is related to a method for the production of polyurethane foam, comprising the steps of: (1) providing an isocyanate-reactive component A comprising a polyol component A1 which further comprises a physical blowing agent T; (2) combining at least the isocyanate-reactive component A and an isocyanate component B, thereby obtaining a polyurethane reaction mixture; (3) providing the polyurethane reaction mixture in a cavity (11); and (4) reducing the pressure within the cavity (11) to a pressure lower than ambient pressure. The method is characterized in that the cavity (11) is ventilated to ambient pressure before the gel time of the polyurethane reaction mixture is reached.

An apparatus including: (a) a steam generator having a power output of less than or equal to about 6 boiler horsepower; (b) a steam conduit in fluid communication with the steam generator; (c) a fluid material conduit in fluid communication with a source of a fluid material, wherein the fluid material includes unexpanded, expandable polymeric microspheres; (d) a treatment zone in fluid communication with the steam generator via the steam conduit, and with the fluid material conduit, such that the fluid material is contacted by steam within the treatment zone; and (e) a back pressure generator in fluid communication with the treatment zone, capable of increasing pressure in the treatment zone, which results in expansion of the expandable polymeric microspheres when the fluid material exits the treatment zone.

Insulating unit are disclosed which are prepared by a cavity-filling, fast-gelling rigid polyurethane foam based on a formulation comprising a polyol component which contains at least 5 weight percent of an amine-initiated polyols and 1.4 to 4 parts by weight of a catalyst package whereby the catalyst package contains at least one amine catalyst and the weight percent nitrogen present in the amine-initiated polyol to weight percent nitrogen present in the catalyst system is from 2 to 8. The formulation is injected into the cavity and the pressure in the cavity is subjected to reduced atmospheric pressure to achieve the rigid foam having a thermal conductivity of less than about 19 mW/mK at 10 C. average plate temperature.

A method for producing a High Internal Phase Emulsion foam is provided that comprises forming a first High Internal Phase Emulsion from an oil phase comprising monomer, crosslinking agent, emulsifier; and an aqueous phase. The High Internal Phase Emulsion is pumped into a water bath. The High Internal Phase Emulsion cures in the bath.

Methods of making molded polystyrene articles are described. The methods include introducing steam into a mold simultaneous to filling the mold with foam particles, and cooling the mold without the use of cooling water. The method can be performed faster and with a lower temperature differential than conventional molding processes, permitting faster turn-around to the production of subsequent molded articles. The molded articles produced by the method can have thicker side walls, improved foam particle fusion, and improved compression properties as compared to conventional EPS molding processes.

A method for producing a foam component includes providing a particulate starting material in a mold, softening the starting material, inducing a pressure change within the mold to cause foaming in at least a portion of the softened starting material without the use of a blowing agent, and solidifying the foamed starting material.