Abstract: A method of making an article from a lightweight cementitious composition includes molding a castable cementitious mixture including an aqueous slurry of at least perlite and concrete into an article, such as a hollow, decorative article. The castable cementitious mixture can include a fibrous material, for reinforcing the cement and perlite, and an air entraining agent, for facilitating mixability and reducing a density of the cementitious mixture and facilitating casting. The mold can include an external mold form that contains the cementitious mixture and an internal mold form that displaces the cementitious mixture within the external mold form to cast the hollow article in various shapes and with various surface textures. The external and internal mold forms include liners made of a lightweight flexible material that can be removed, unfolded, and prepared and/or cleaned.

Abstract: A syntactic structural foam product in flat sheet form or curved three-dimensional form adaptable to such uses as a light weight structural core for composite laminates, is made of a mixture of hollow ceramic microspheres and dry resin powder, of either thermosetting or a high-temperature thermoplastic resin, distributed in the interstices of the mass of microspheres for integration of the mixture into desired form upon heating and cooling. Resin powder collected as a waste by-product from resin coating materials can be recycled in the production of the desired product.

Abstract: The present invention is for method and means by the manufacture of a product of expanded polymer, by which is obtained a weight per unit volume which is essentially lower than that of homogeneous expanded material. The starting material according to the invention can be either a specifically manufactured starting material or scrap and recovered material. The pieces of expanded polymer are supplied in controlled quantities through a feeder to a space for the application of glue drops which are sprayed into the space from one or more dies. In the space the pieces of polymer are dried by means of micro-wave energy which is obtained from an energy generator and magnetrones. The dried pieces then are discarded from the space together with the air flow through the opening. By the manufacture of a product according to the invention one starts from the pieces with glue applied to them as described above. The pieces are put into a mould wherein they are pressed against each other.

Abstract: The application relates to polyethylene and/or polypropylene foam moldings for packaging which consist of more than 50% of recycled material, and to a process for the production thereof.

Abstract: A process for the manufacture of re-bonded foam products is disclosed. The process comprises mixing a liquid comprising polyol with a liquid comprising polyisocyanate in the presence of small pieces of foam, consolidating the mixture, and causing the polyol and polyisocyanate to react and bond the coated pieces together.

Abstract: The recycling of used polyurethane foam is made possible by a process in which the starting material is first dried to a moisture content of 2 to 4% and is then filled into a multi-part mold (16, 17, 18) that defines the molded part (32). The parts of the mold (16, 17, 18) are then, with generation of the necessary compression pressure of below 20 N/mm.sup.2, pressed together and locked. These molds (16, 17, 18) that are subject to the compression pressure are heated in a tunnel furnace (20) so that the molding material reaches a temperature of approximately 130.degree. C. After a predefined holding time, the molds (16, 17, 18) can be opened under pressure and the molded parts (32) can be removed. Molded parts (32) with a thickness of 42 mm and of corresponding size have been produced successfully with this process. Instead of the molds (16, 17, 18), it is also possible that a two-part tool is used.

Abstract: Rebond polyurethane foams can be prepared by coating shredded polyurethane foam with a prepolymer binder formulation which includes toluene diisocyanate distillation bottoms, compressing the binder coated foam, and the curing the binder with steam. The toluene diisocyanate distillation bottoms can be used in place of more expensive prepolymer formulation components such as toluene diisocyanate or methylene diphenyldiisocyanate. The toluene diisocyanate distillation bottoms can also improve elongation and tear resistance properties of the resultant rebond foams prepared therewith.

Abstract: System and method for densifying expanded thermoplastic foam materials such as loose fill packing materials, larger blocks of such materials, and food and beverage service items to reduce the volume of such materials for recycling or disposal. The material is heated to soften the material and expel gas from cells within the material and thereby shrink the material to a reduced volume. In some embodiments, and the material is further densified by compacting the heat softened material to further reduce the volume.

Abstract: A method for recycling expanded polystyrene foam materials. Unexpanded virgin polystyrene beads having pentane gas contained therein are thermally expanded to produce a supply of expanded beads. Next, a supply of used expanded polystyrene foam is obtained and ground into small portions, preferably of the same size as the expanded beads. The used polystyrene foam pieces are then placed in contact with pentane gas. The expanded beads and the pentane-treated foam pieces are thereafter combined to form a mixture which preferably contains not less than about 50% by weight foam pieces. The mixture is then placed in a mold, followed by the application of heat and pressure thereto in order to produce a final product with a high degree of structural integrity. The pentane gas treatment of the foam pieces enables the fusion thereof to the expanded beads, resulting in a highly durable product.

Abstract: A method of making foam material includes a process of impregnating comminuted particles of a previously formed foam material with a first foaming reaction solution made up of polyol, catalyst and additives and with a second foaming reaction solution containing diisocyanate. The comminuted particles are also subjected to a rolling pressure when they are being impregnated with the first foaming reaction solution. The impregnated particles are transferred to a forming area provided with steam serving to accelerate the foaming reaction of the impregnated particles. The foam material so produced is provided with excellent properties.

Abstract: The present invention relates to a method of forming shaped articles having a continuous phase of an oriented thermoplastic polymer containing cross-linked polymer microbeads at least partially bordered by void space. The thermoplastic polymer in molten form is mixed with a plurality of the crosslinked polymer microbeads, and the mixture is then formed into a shaped article. The article is stretched in at least one direction to orient it. The orienting conditions and the character and quantity of crosslinked polymer microbeads is effective to form voids in the article at least bordering the microbeads on sides thereof in the direction(s) of orientation.

Abstract: A polystyrene polymer as well as an expandable polystyrene formulation comprises a polystyrene polymer having a particular molecular weight distribution. The polymer itself exhibits a polydispersity of from about 1 to less tha 2.0, a weight average molecular weight of greater than about 200,000 to about 300,000, and an M.sub.z :M.sub.n of from about 2 to less than about 3.0. Furthermore, the polystyrene polymer is branched to from 0 to less than 5 weight percent.The expandable polystyrene formulation comprises a polystyrene polymer exhibiting a polydispersity of from about 1.0 to less than 2.5, a weight average molecular weight of from greater than about 180,000 to about 300,000, an M.sub.z :M.sub.n of from about 2 to about 4.5. The polystyrene polymer is present in an amount of from about 94.5 weight percent to about 98 weight percent, based on the total weight of the formulation, and the polystyrene polymer is branched to from 0 to less than 5 weight percent.

Abstract: A flame retardant composition and process which is particularly useful for rebonded foam products. The composition of the present invention includes a solid component of magnesium sulfate, boric acid, decabromodiphenylethylene oxide (DECA) and antimony trioxide and a liquid component of halogenated phosphorous. The present invention is based upon the discovery of the synergism between boric acid and DECA. The process, according to the present invention, includes the steps of forming a dispersion of the solid portion of the flame retardant composition along with a small amount of water based adhesive to a mass of foam chips. The treated chips are then dried to permit handling and storage. The dried foam chips subsequently are mixed with a conventional urethane prepolymer binder and the liquid halogenated phosphorous flame retardant compound. After mixing the foam mass is transferred to molds and steamed to allow the binder to cure.

Abstract: A method for making low density (0.8-1.1 lb./cu.ft.) expanded polymeric products uses blowing agent in an amount of any from 2 to 4.4 weight percent and aging periods of from 1 to 80 hours after each expansion step. The process uses 2 to 5 expansion steps and a polymer having a particular polydispersity, weight average molecular weight and M.sub.z :M.sub.n, this polymer having a greater expandability than conventional polymers. The process requires only about half of the amount of blowing currently being used in commercially viable processes for making expanded polystyrene products. The process can be used with or without a molding step.

Abstract: A method for making low density (0.8-1.1 lb/cu.ft.) expanded polymeric products uses blowing agent in an amount of only from 2 to 4.4 weight percent and aging periods of from 1 to 80 hours after each expansion step. The process uses 2 to 5 expansion steps and a polymer having a particular polydispersity, weight average molecular weight and M.sub.z :M.sub.n, this polymer having a greater expandability than conventional polymers. The process requires only about half of the amount of blowing agent currently being used in commerically viable processes for making expanded polystyrene products. The process can be used with or without a molding step.

Abstract: A method for making low density (0.8-1.1 lb/cu.ft.) expanded polymeric products uses blowing agent in an amount of only from 2 to 4.4 weight percent. The process uses 2 to 5 expansion steps together with a polymer having a particular polydispersity, weight average molecular weight and M.sub.z :M.sub.n, this polymer having a greater expandability than conventional polymers. The process requires only about half of the amount of blowing agent currently being used in commercially viable processes for making expanded polystyrene products. The process can be used with or without a molding step.

Abstract: A method for making low density (0.8-1.1 lb/cu. ft.) expanded polymeric products uses blowing agent in an amount of only from 2 to 4.4 weight percent. The process uses 2 to 5 expansion steps together with a polymer having a particular polydispersity, weight average molecular weight and M.sub.z :M.sub.n, this polymer having a greater expandability than conventional polymers. The process requires only about half of the amount of blowing agent currently being used in commercially viable processes for making expanded polystyrene products. The process can be used with or without a molding step.

Abstract: A method for making low density (0.8-2 lb/cu.ft.) expanded polymeric products uses blowing agent in an amount of only from 2 to 4.4 weight percent, the process emitting blowing agent during processing in an amount of from only about 0.3 to about 2.5 weight percent. The process uses 2 to 5 expansion steps together with a polymer having a particular polydispersity, weight average molecular weight and M.sub.z :M.sub.n, this polymer having a greater expandability than conventional polymers. The process requires only about half of the amount of blowing agent currently being used in commerically viable processes for making expanded polystyrene products. The process can be used with or without a molding step.

Abstract: The polymerization in aqueous suspension of at least one vinylaromatic monomer is carried out in the presence, relative to the vinylaromatic monomer, of approximately 0.01% to 0.06% by weight of at least one polyethylene wax and of approximately 0.005% to 0.1% by weight of at least one nonionic surface-active agent which has an HLB value of between 7 and 16.Materials obtained from expandable beads prepared according to this polymerization process.

Abstract: The present invention provides polypropylene resin pre-expanded beads formed by shrinking polypropylene resin pre-expanded beads originally having a bulk density of not higher than 0.0930 g/cc to give them a bulk volume ratio of 10-75% at normal temperature and normal pressure, a manufacturing method thereof and an expansion-molding method with the aforementioned pre-expanded beads. According to this invention, it is possible to greatly reduce storing and transporting costs per unit weight of pre-expanded beads.

Abstract: A two-part for reinforcing a hollow strucutral members and its method of use are provided. A method of reinforcing a structural member having a hollow cavity comprises the steps of preparing a first dough which includes a thermal setting resin, a first filler and unexpanded, thermally-expandable microspheres. A further step includes preparing a second dough which includes a curing agent, a colorant and a second filler. The curing agent is compatible with the thermosetting resin to promoter cross-linking of the thermosetting resin upon contact with the curing agent. The hollow structural member may be preheated to enhance the rate at whcih the thermosetting resin cross-links. The two dough are blended together until a reactive third dough of substantially uniform mixture is formed. The uniformity of the blending is confirmed when the reactive third dough attains a uniform color intermediate the color between the colors of the first and second doughs.

Abstract: Particulate styrene polymers containing blowing agents are prepared by a process in which an aliphatic hydrocarbon of 7 to 9 carbon atoms is added in an amount of from 0.01 to 0.5% by weight, based on the styrene polymer, before, during or after the polymerization. The particulate styrene polymers can be processed to foam blocks and moldings having a satisfactory smooth surface.

Abstract: A precast composite plastic reinforcement insert, method of making the reinforcement insert and method of reinforcing a structural member. The insert includes pellets which are formed of a mixture of a thermoplastic polymeric resin and a blowing agent. Polymeric resins disclosed include a one-part epoxy with a thermal curing system or a thermoplastic polyester resin. The pellets in one embodiment are retained within a matrix of expanded polystyrene and in combination form the insert. The insert is formed in a mold cavity which receives the pellets and unexpanded polystyrene which is expanded during the process by heating the same within the mold cavity. The insert is used to reinforce a structural member by placing it in the structural member prior to a thermal paint curing operation.

Abstract: A precast composite plastic reinforcement insert, method of making the reinforcement insert and method of reinforcing a structural member. The insert includes pellets which are formed of a mixture of a thermosetting polymeric resin and a blowing agent. Polymeric resins disclosed include a one-part epoxy with a thermal curing system or a thermoplastic polyester resin. The pellets in one embodiment are retained within a matrix of expanded polystyrene and in combination form the insert. The insert is formed in a mold cavity which receives the pellets and unexpanded polystyrene which is expanded during the process by heating the same within the mold cavity. The insert is used to reinforce a structural member by placing it in the structural member prior to a thermal paint curing operation.

Abstract: A method of completely filling mines and underground cavities in such a way as to reinforce the strata and ground thereabove in order to prevent collapse or subsidence. The method comprises introduction into mines and cavities, expandable plastic materials which are incorporated into a chemically catalysed foam reaction and strongly bonded thereby. The heat required to expand foamable plastic materials many-fold is provided by the chemically exothermic polymerization reaction of polymeric isocyanate with polyols and epoxides by basic catalysis which promotes highly exothermic urethane/isocyanurate polymer formation in the presence of suitable blowing agents and surfactants.

Abstract: Method for preparing a setting foam material containing plastic material granules, which plastic material granules are prepared from beads of plastic material. After preparing a slurry of base material it is mixed with the plastic material granules. This motar is immediately pumped after which the foam is introduced.

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.

Abstract: A method for encapsulating electronic components in high acceleration and high thermal cycling environments. A liquid uncured thermal setting polyurethane formulation is mixed with a finely ground particulate foam which serves as a nucleating agent. The mixture is in accordance with the polyurethane formulation. The resultant foam contains open air pockets which allow it to be compressed and then re-expand.

Abstract: Prefoamed polypropylene-base particles have a crystalline structure featuring a high-temperature peak appeared on the higher temperature side than the peak inherent to polypropylene-base resins on a DSC curve obtained by differential scanning calorimetry upon heating 1-3 mg of the prefoamed polypropylene-base particles at a constant heating rate of 10.degree. C./min. to 220.degree. C. by means of a differential scanning calorimeter and the internal pressure decreasing velocity coefficient k of the particles is either equal to or smaller than 0.70 (k.ltoreq.0.70) at 25.degree. C. and 1 atm. The prefoamed polypropylene-base particles can be formed into an expansion-molded polypropylene-base article by imparting foamability to the particles, filling the resultant particles in a mold and then heating the particles so as to cause their expansion.

Abstract: The invention claimed here comprises a process for producing neoprene foam structures which are greater than four inches in diameter. The claimed invention also comprises a structure of neoprene with a thickness greater than about four inches composed of one continuous mass of adhesively bound neoprene particles.

Abstract: The present invention relates to a method of producing high-density PU foam material, which is characterized by its process of using comminuted waste foam material, as its primary raw material which is then dried and filtered before mixing with other chemical agents in proportion, such as Voranol 3800 polyo, Isocyanate and relatively small amount of Catalysts to make the individual particle and also those agents between particles to swell to proper size in mold. Then, the yet foamed material is compressed in a mechanical way and cooled down slowly in natural manner to produce high-density PU foam material.

Abstract: An insulating foam and a process for producing insulating foam, wherein a foamable first component may be made of alkyl sulfate, half ester of maleic anhydride and acrylic resin in an aqueous solution is mechanically foamed with air, and to that foam is added an aqueous solution of magnesium oxide, dispersant, acrylic resin, perlite and/or precipitated calcium carbonate. To those components is added an aqueous solution of at least one of aluminum chloride, magnesium sulfate, magnesium chloride, zinc chloride, sulfamic acid, sodium silicate, zinc oxide, barium metaborate, vinyl alcohol, magnesium carbonate, calcium chloride and vinyl acetate. In another embodiment a polyvinyl alcohol and dispersant first portion is foamed with air and mixed with a second cementitious portion comprising magnesium oxide and barium metaborate.

Abstract: A tool for use in a latex dip process for producing a latex skin in a given configuration, the tool being formed by producing an electro-formed female mold from a sculpture of the desired configuration, casting a vinyl skin from the electro-formed female mold, removing the vinyl skin to expose a hollow interior, and stuffing the vinyl skin with a composition of materials, having the characteristics of providing rigidity to the vinyl skin and approximately zero buoyancy in a latex bath.

Abstract: Expandable phenolic resin-coated composite beads comprise an aggregate having coated thereon a solid, expandable resin composition comprising a solid, phenolic resin initial condensation product, a foaming agent and, if necessary, a hardening agent. The expandable phenolic resin-coated composite beads provide composite cellular moldings in which the aggregates are uniformly dispersed in a phenolic resin-expanded layer and are firmly adhered to the expanded layer. The composite cellular moldings can be adhered to a face plate to form integral laminates.

Abstract: Fibrillated films or flat netlike structures made of synthetic polymers and having a specific surface area of more than 12 m.sup.2 /g. the thickness thereof in microns are disclosed, as is use of said films or flat netlike structures as reinforcement for hydrosetting binders such as cement. A method of preparing the fibrillated films or flat netlike structures is also disclosed.

Abstract: A mold for producing a padding member having side by side portions of different hardnesses integral with each other, and a method of producing the padding member using such mold. The mold has a lower half with partition walls movably extending upwardly through the bottom of the lower mold half into the interior of the lower mold half to define a plurality of cavities into which moldable materials of which the padding member is to be formed and having different hardnesses from each other can be contained. The upper mold half is placed over the lower mold half, and has pressing members extending downwardly which engage the edges of the partition walls and force the partition walls downwardly. The pressing members are spaced from each other along the partition walls, so that the materials on the opposite sides of the partition walls can contact each other and, while molding is being carried out, become integrally joined to each other.

Abstract: A method and apparatus or system for the continuous manufacture of building element consisting of a self-supporting framework of tightly compressed solid particles and a foaming material in the shape of a foamed plastic material, includes the use of a filling station where mold bottoms are placed in series on a roller conveyor, assembled with sidewalls and passed along a guide section, wherein particle-shaped filler is supplied from a silo while premixed foam material is injected into the material through nozzle tubes and the components are mixed before being injected into the mold and compressed. After placing of a top wall on each of the molds, these are passed under a roller conveyor, and while the molds are moved ahead between the roller conveyors and possibly roller conveyors outside the sidewalls, the foam material binds the particles together to form a monolithic unit which will set before the molds leave the roller conveyors.

Abstract: Fire retardant polystyrene insulating material is manufactured from expandable polystyrene beads 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 bead-resin mix by applying dielectric heating to foam the resin, expand the beads, and cure the foamed resin to a closed cell structure.

Abstract: An improved method for manufacturing a foam-filled polyurethane foam bun from foam particles having uniformly dispersed therewith large amounts of solid material bonded together with new polyurethane foam is described. The method comprises uniformly applying a liquid flexible polyurethane foam-forming material to a dispersion of foam particles and solid material to provide a blend, distributing the blend within a mold, and foaming and curing the foam-forming material by a plurality of steaming steps wherein the mold is flipped from a first to second position between steaming steps. The foam buns have a uniform density gradient. Foam buns are disclosed having a variation in density across the foam bun. There is also disclosed an improved char-forming foam obtained as a result of using boric acid in the foam-forming formulation.

Abstract: Loose, substantially sphere-shaped particles of a foamed plastic material, e.g., polystyrene, are blended with a binder consisting of a solution of 75-85% by weight of coal-tar pitch having a ring and ball softening point of 50.degree.-65.degree. C. in 15-25% by weight of phenol-free coal-tar oil having a distillation range of 150.degree.-275.degree. C. and 20-35% by volume of an epoxy resin. The resulting sticky mass is then blended with dry cement to produce a mass of loose particles of foamed plastic material coated with a film of dry cement. A second portion of dry cement and sufficient water to harden the cement are added and the moist mixture is pressed into the desired shape.

Abstract: The aim of the invention was to find a method of producing a sorptive body, to be used especially with objectives such as the elimination of odors and air freshening. In the invented process a granular or powdered solid component consisting of a sorptive material, e.g. active carbon, or a compound containing such a material, is mixed with a binding agent, by which it is generally fixed to a carrier substance. The essence of the invention is that at least part of the finely-ground solid component is mixed with a liquid sorbate; only then it is combined with the dissolved binding agent. In a subsequent operation heat is applied to the mixture, thereby expelling the sorbate. The heat causes pores and capillaries to form within the binding agent, thus enabling air to enter into the sorptive substances deposited in the binding agent and so effecting an increase in the active area of the surface of the body.

Abstract: An apparatus for making a foam pad for carpets has features to improve the quality of the pad. The apparatus has a hopper section for receiving foam particles coated with heat activated bonding agent. An extruder section compresses the particles as they are moved continuously along a conveyor belt. A heat section heats the particles after being compressed. A raking device in the hopper section rakes the top of the body of particles prior to entering the extruder section. The raking device rakes in a direction opposite to the movement of the body of particles. The raking device can be raised and lowered to change the level of the particles, and thus the density. The raking device also forms the top of the body of particles with upwardly tapered corners. A plate located below the hopper and extruder sections supports the lower conveyor belt. The heat section uses steam chambers with a perforated top, which also serves to support the conveyor belt.

Abstract: A cushion material and method of making the same, in which a soft polyurethane foam is cut into a slab in a predetermined form; applied to or injected into this polyurethane foam slab at a predetermined portion thereof a bonding agent or forming keeping binder which has a property to be solidified in reaction under certain conditions; said slab is shaped as compressed in a pair of forming dies into a predetermined cubic form, or integrally bonded on a cushion layer constituted by said slab of polyurethane foam another cushion layer made of polyurethane foam chips shaped in a predetermined cubic form by chopping or comminuting soft polyurethane foam scrap into chips, applying a bonding agent to them, and compressing them in a pair of forming dies.

Abstract: A rigid, shaped, mass support system, such as support or seating appliances for disabled or handicapped persons, is provided by charging a flexible container (2) made of elastic polymeric film with a uniform mixture of rigid particles of a mesh size relatively small compared to the size of the system and a curable adhesive polymeric binder material. The charged container (2) and its contents are molded to adapt to or fit the shape of the mass, such as the contour of that portion of the body to be supported, and evacuated to remove volatiles and fix the shape of the contents of the container. The adhesive binder is then cured to solidify the molded contents of the container to form a composite, from which the polymeric film can be stripped away, after which an adhesive paint is applied to seal and protect the surface.

Abstract: A method for making light weight concrete and building elements thereof with an aggregate of foamed expanded plastic beads, e.g. polystyrene. The beads are foamed and let rest before mixing with the other concrete aggregates and forming of the concrete elements but mixing and forming processes take place before a setting of the plastic beads due to aging has taken place.

Abstract: A lightweight concrete float having a concrete shell surrounding either a hollow or buoyant foam core. The shell includes a deck surrounded by integrally formed, downwardly projecting side walls of sturdy but relatively heavy standard aggregate concrete and a bottom surrounded by integrally formed, upwardly projecting uniform or tapered side walls of lightweight but relatively weak foam aggregate concrete. Reinforcing rods are embedded along the edges of the deck, and a reinforcing mesh extends around the reinforcing rods and through the deck, side walls and bottom. The float may be formed by first pouring a layer of foam aggregate concrete into a form having a rectangular bottom surrounded by four sides. A block of buoyant foam is then placed on the bottom layer of concrete with the sides of the block spaced apart from the sides of the form. The space between the sides of the form and the sides of the block is partially filled with foam aggregate concrete.

Abstract: A composite foamed material and a process for the production thereof are disclosed herein, the process comprising premixing expandable or expanded polystyrene beads, a binder and fragments of resilient, open-celled neoprene. The materials are combined in the proportions of about 4-15% polystyrene beads, about 6-25% binder and about 60-90% open-celled neoprene. The combined materials are preferably compressed to a density of about 5-30 lbs. per cubic foot, more preferably 5-17 lbs. per cubic foot, and steam is applied to the compressed materials to cure the binder, and in certain embodiments to expand the polystyrene beads, thereby producing the desired composite foamed material.

Abstract: An improved lightweight cementitious product consisting essentially of an aqueous cementitious mixture and reclaimed polystyrene beads in which the reclaimed polystyrene beads are bonded to the cementitious material. The cementitious product is prepared by dispensing reclaimed polystyrene beads in an aqueous cementitious mixture, such as hydraulic cement and water, to form a resulting mixture, placing the resulting mixture in a mold, and compressing the resulting mixture in the mold until setting of the resulting composition occurs. The volume of the resulting mixture in the mold is reduced during compression by approximately fifteen percent of the original volume and substantially no water is exuded from the resulting mixture during compression. The reclaimed polystyrene beads are substantially spherical in configuration and have a particle size substantially larger than "virgin" polystyrene beads.

Abstract: A composite foamed material and a process for the production thereof are disclosed herein, the process comprising premixing expandable or expanded polystyrene beads, a binder and fragments of resilient, open-celled neoprene. The materials are combined in the proportions of about 4-15% polystyrene beads, about 6-25% binder and about 60-90% open-celled neoprene. The combined materials are preferably compressed to a density of about 5-30 lbs. per cubic foot, more preferably 5-17 lbs. per cubic foot, and steam is applied to the compressed materials to cure the binder, and in certain embodiments to expand the polystyrene beads, thereby producing the desired composite foamed material.

Abstract: Fire retardant polystyrene insulating material is manufactured from expandable polystyrene beads in admixture with a phenol-formaldehyde or melamine-for-maldehyde resin in resole form, the resin containing a blowing agent and a surfactant. The insulating material is formed from the bead-resin mix by applying dielectric heating to foam the resin, expand the beads, and cure the foamed resin to a closed cell structure.