Method for Molding Recycled EPS Using Powder Adhesive and Steam

摘要

A method is provided of molding recycled EPS and other suitable expanded bead materials using a powder adhesive and steam. The method allows for molding EPS parts with over 5% and up to 100% recycled content. The method involves using an adhesive to fuse the regrind EPS particles under pressure from steam. The adhesive may be in powder form and preferably comprises small particles having a high surface area per unit weight and high static so the adhesive powder sticks to the surface of the regrind EPS particles during a dry blending step.

主权项

1. A method of making a molded article comprising the steps of:
Step 100: mixing about 95 wt % to about 99.9 wt % expanded bead foam regrind particles with about 0.1 wt % to about 10 wt % of a high static powder adhesive in a dry blend rotating mixer to obtain adhesive coated expanded bead foam regrind particles; Step 102: transferring the adhesive-coated expanded bead foam regrind particles to a mold; Step 104: bonding together the adhesive-coated regrind particles under pressure by introducing a small quantity of pressurized steam into the mold to raise the temperature above the melting point of the powder adhesive but below the melting point of the expanded foam regrind particles to create bonded regrind particles; and Step 106: cooling the bonded regrind particles in the mold for about two minutes, thereby producing a molded article having a recycled expanded bead foam content of over 5% and up to 100%.