Patents Assigned to Lifoam Industries, LLC
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Patent number: 12233583Abstract: 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.Type: GrantFiled: March 28, 2022Date of Patent: February 25, 2025Assignee: LIFOAM INDUSTRIES, LLCInventors: Jonathan Godfrey, Saumitra Bhargava, Michael W. Elliott, Gerry Babyok
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Patent number: 11213980Abstract: A method of making molded foam articles and the articles produced. A molded foam article is produced by heating or preheating the mold to a temperature at or above the glass transition or melt temperature of the particles to be molded. Foamed particles are then introduced into the mold. The particle filled mold is then subjected to a vacuum to stabilize the molded article, without application of any additional heating or cooling. The molded article is then removed from the mold at a temperature at or below the glass transition temperature of the particles, and the cycle repeated to form multiple molded articles.Type: GrantFiled: June 22, 2020Date of Patent: January 4, 2022Assignee: LIFOAM INDUSTRIES, LLCInventors: Saumitra Bhargava, Jonathan Dean Godfrey, James H. Brakebill
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Patent number: 10688698Abstract: A method of making molded foam articles and the articles produced. A molded foam article is produced by heating or preheating the mold to a temperature at or above the glass transition or melt temperature of the particles to be molded. Foamed particles are then introduced into the mold. The particle filled mold is then subjected to a vacuum to stabilize the molded article, without application of any additional heating or cooling. The molded article is then removed from the mold at a temperature at or below the glass transition temperature of the particles, and the cycle repeated to form multiple molded articles.Type: GrantFiled: March 27, 2015Date of Patent: June 23, 2020Assignee: LIFOAM INDUSTRIES, LLCInventors: Saumitra Bhargava, Jonathan Dean Godfrey, James H. Brakebill
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Publication number: 20200130241Abstract: The present invention describes compostable or biobased foams that are useful for fabricating foamed articles and methods for producing the same. The foams are produced using a compound comprising a compostable or biobased polyester and a blowing agent. Additives including plasticizers and chain extenders are optionally included in the compostable or biobased composition. These foams can be produced using conventional melt processing techniques, such as single and twin-screw extrusion processes. In one embodiment, foamed strand profiles are cooled and cut using conventional strand pelletizing equipment. In another embodiment, foamed beads are produced by cutting the foamed strand at the face of the extrusion die and the foamed bead or strand is subsequently cooled. The resulting compostable or biobased foamed bead has a density less than 0.15 g/cm3 and the foam is compostable, as determined by ASTM D6400.Type: ApplicationFiled: December 24, 2019Publication date: April 30, 2020Applicant: Lifoam Industries, LLCInventors: Adam R. Pawloski, Jeffrey J. Cernohous, Kent Kaske
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Patent number: 10518444Abstract: The present invention describes compostable or biobased foams that are useful for fabricating foamed articles and methods for producing the same. The foams are produced using a compound comprising a compostable or biobased polyester and a blowing agent. Additives including plasticizers and chain extenders are optionally included in the compostable or biobased composition. These foams can be produced using conventional melt processing techniques, such as single and twin-screw extrusion processes. In one embodiment, foamed strand profiles are cooled and cut using conventional strand pelletizing equipment. In another embodiment, foamed beads are produced by cutting the foamed strand at the face of the extrusion die and the foamed bead or strand is subsequently cooled. The resulting compostable or biobased foamed bead has a specific gravity less than 0.15 g/cm3 and the foam is compostable, as determined by ASTM D6400.Type: GrantFiled: December 19, 2016Date of Patent: December 31, 2019Assignee: Lifoam Industries, LLCInventors: Adam R. Pawloski, Jeffrey J. Cernohous, Kent Kaske
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Patent number: 9988175Abstract: A corrugated sleeve comprising an upper panel forming the top of the sleeve, a lower panel forming the bottom of the sleeve, at least two height panels forming the front and back of the sleeve, respectively, and at least two side panels forming the left and right of the sleeve, respectively. The upper, lower, height, and side panels thereby form the external structure of the sleeve. The sleeve may also include at least one pack assembly which extends from one of the panels, and for example from the end height panel. Each pack assembly may include at least one pack divider, which can be positioned between adjacent thermal packs when such thermal packs are contained within the sleeve.Type: GrantFiled: July 13, 2016Date of Patent: June 5, 2018Assignee: Lifoam Industries, LLCInventors: Mahmudul Hasan, Casey E. Coleman, Jr.
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Publication number: 20170182696Abstract: A mobile platform including an extruder for melting and extruding materials for producing lightweight, compostable or biobased foams for various expandable materials. A mobile platform is described including a screw extruder for processing poly meric material, a housing with a longitudinal bore in which an extruder screw is coaxially fitted for rotation around an axis of the screw to advance the polymeric material through the bore by threads on the screw. A feed hopper, PLA hoist/feeder, standard EPS machine equipped with electric heating and related equipment are also provided on the mobile platform. Distributed manufacturing of low density protective packaging, insulation panels and thermal insulators is also described.Type: ApplicationFiled: March 24, 2015Publication date: June 29, 2017Applicant: LIFOAM INDUSTRIES, LLCInventors: John CANTLIN, Saumitra BHARGAVA
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Publication number: 20160325472Abstract: A method of making foam beads, dies to make such beads, the resultant beads, and molding methods and molded articles utilizing such beads. A method of forming polymer foam beads is described by forming a plastic melt of a polymer, adding a blowing agent to the melt to form a polymer-blowing agent mixture, forcing the mixture through a capillary die, and pelletizing the mixture as it exits the die. The capillary die has a non-circular cross-section and shorter length than conventional circular cross-section dies, while maintain the same pressure drop across the die, resulting in polymer foam beads with very thin walls and substantially uniform expansion properties.Type: ApplicationFiled: May 6, 2015Publication date: November 10, 2016Applicant: LIFOAM INDUSTRIES, LLCInventor: Saumitra BHARGAVA
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Patent number: 8962706Abstract: The present invention enables the secondary expansion of lightweight foamed beads. The foamed beads are produced using a compound comprising a compostable or biobased polyester and a physical blowing agent as well as a chemical blowing agent. Secondary expansion can be used either to lower the density of the foamed bead further or to enable expansion of the beads during molding to promote fusion. The foam beads can be produced using conventional melt processing techniques, such as single and twin-screw extrusion processes.Type: GrantFiled: September 12, 2011Date of Patent: February 24, 2015Assignee: Lifoam Industries, LLCInventors: Adam R. Pawloski, Jeffrey J. Cernohous, Kent Kaske, Garrett Van Gorden
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Patent number: D804543Type: GrantFiled: June 29, 2016Date of Patent: December 5, 2017Assignee: Lifoam Industries, LLCInventors: Roberto Carvajal, Aaron Jones, Michael Flanagan