U.S. patent application number 12/661111 was filed with the patent office on 2010-07-29 for article employing expanded thermoplastic elements and methods for making same.
Invention is credited to Buddy Harry Bussey, III, Harry Bussey, JR..
Application Number | 20100189505 12/661111 |
Document ID | / |
Family ID | 37910485 |
Filed Date | 2010-07-29 |
United States Patent
Application |
20100189505 |
Kind Code |
A1 |
Bussey, JR.; Harry ; et
al. |
July 29, 2010 |
Article employing expanded thermoplastic elements and methods for
making same
Abstract
A drainage element is made by filling a container with expanded
thermoplastic elements that are in a non-cured state and that
possess a degree of latent foaming ability. After filling the
container with the non-cured elements, the elements are allowed to
cure under ambient conditions during which the blowing agent
remaining in the elements in a vapor state condenses allowing air
to be drawn in while the elements expand. This expansion of the
elements distends and rigidifies the container where the container
is allowed to expand
Inventors: |
Bussey, JR.; Harry; (Marco
Island, FL) ; Bussey, III; Buddy Harry; (Atlantic
Highlands, NJ) |
Correspondence
Address: |
Francis C. Hand, Esq.,;c/o Carella, Byrne, Bain, Gilfillan, Cecchi,
Stewart & Olstein, 5 Becker Farm Road
Roseland
NJ
07068
US
|
Family ID: |
37910485 |
Appl. No.: |
12/661111 |
Filed: |
March 11, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11248753 |
Oct 12, 2005 |
7708350 |
|
|
12661111 |
|
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Current U.S.
Class: |
405/43 |
Current CPC
Class: |
A47C 7/18 20130101; Y10S
5/911 20130101; A47C 7/20 20130101; Y10S 297/01 20130101; Y10T
428/1376 20150115 |
Class at
Publication: |
405/43 |
International
Class: |
E02B 11/00 20060101
E02B011/00 |
Claims
1. A drainage element comprising a tubular netting having a pair of
closed ends; and a mass of expanded loose fill discrete elements
within said netting characterized in having been expanded from an
initial state to an expanded state after filling of said netting
therewith and in imparting a degree of rigidity to the drainage
element in said expanded shape sufficient to maintain an expanded
three dimensional shape of said netting.
2. A drainage element as set forth in claim 1 further comprising a
pipe passing through said mass of elements and extending outwardly
of said closed ends of said netting.
3. A drainage element as set forth in claim 2 wherein said pipe is
perforated.
4. A drainage element as set forth in claim 2 wherein said pipe is
corrugated.
5. A drainage element as set forth in claim 1 wherein said loose
fill elements have a bulk density of less than 1.0 pounds per cubic
foot.
6. A drainage element as set forth in claim 1 having a length of
ten feet, a diameter of ten inches, and a degree of rigidity
characterized in that when supported in a horizontal plane at a
mid-point with at least one end extending therefrom in a cantilever
manner, said one end has a deflection of two inches or less
relative to said horizontal plane.
7. A drainage element comprising a container of flexible material
characterized in having been expanded from a collapsed state into
an expanded three dimensional shape; and a mass of expanded loose
fill discrete thermoplastic elements within said container
characterized in having been placed in said container in a
non-cured expanded initial state and thereafter expanded from said
initial state to a further expanded cured state without external
manipulation while in said container and in imparting a degree of
rigidity to said container in said expanded shape thereof
sufficient to maintain said expanded three dimensional shape of
said container.
8. A drainage element as set forth in claim 7 wherein said
container is a tube made of plastic flexible screen.
Description
[0001] This is a Division of U.S. Ser. No. 11/248,753, filed Oct.
12, 2005.
[0002] This invention relates to articles made of expanded
thermoplastic elements and methods for making the same. More
particularly, this invention relates to a drainage element using
expanded thermoplastic elements.
[0003] As is known, expanded thermoplastic materials such as
expanded polystyrene (EPS) have been used for many years as
packaging elements, filling elements, padding and the like.
Typically, the thermoplastic elements were made by extruding a
homogeneous mixture of thermoplastic material and blowing agent
through a die having an opening with a cross section suited to the
shape of the desired element, for example a C-shaped opening. As
the homogeneous mass is extruded through the die, a smooth skin
forms on the outside peripheral surfaces of the extrudate. In some
cases, equipment is provided for cutting the extrudate into
individual discrete elements that are then directed into a
container.
[0004] It has also been known that the initially expanded
thermoplastic elements contain some residual hydrocarbon in a
liquid state. Thus, the elements can be subsequently heated in a
chamber in order to bring about a further expansion of the
elements. It has also been known that the elements can be subjected
to a third stage of expansion.
[0005] Typically, expansion of the loose fill elements occurs in
two or three stages followed by a curing step. This curing step
typically subjects the thermoplastic elements to a cooling off
period of time such as from 12 to 24 hours. During this time, the
heated blowing agent, typically pentane, cools from a vapor state
to a liquid state thereby allowing the elements to contract in
size. Also, once the hydrocarbon has cooled, air is able to pass
from outside the elements into the cells of the elements causing
the elements to expand.
[0006] It is object of this invention to utilize non-cured expanded
thermoplastic elements to make articles of manufacture that can be
rigidified upon curing and expansion of the thermoplastic
elements.
[0007] It is another object of the invention to be able to package
articles within containers in a tight fit manner.
[0008] It is another object of the invention to provide a process
of packaging articles in an efficient tight fit manner.
[0009] Briefly, the invention utilizes a mass of discrete non-cured
thermoplastic elements to make articles of manufacture and to
package articles within a container.
[0010] In one embodiment, an article of manufacture is made from a
porous container of flexible material and a mass of the non-cured
filled plastic elements. In this respect, the porous container is
made of a suitable flexible material that is characterized in being
expandable from a collapsed state into an expanded
three-dimensional shape. For example, the container may be in the
form of a pouch or a bag having an open end through which the pouch
can be filled and with means for selectively closing the open end
in order to seal the contents of the pouch.
[0011] In accordance with the invention, a mass of the non-cured
elements is filled through the open end of the pouch or bag to an
extent that the bag is completely or almost filled and then the bag
or pouch closed using the means provided therefor.
[0012] Once the container, i.e. pouch or bag, has been filled and
closed, the container is set aside to allow the thermoplastic
elements to cure in an atmosphere of ambient temperature.
Typically, the curing time will be a twelve hour period during
which the blowing agent within the discrete elements cools followed
by swelling of the elements as air enters through the porous
container into the cells of the elements. Typically, the amount of
expansion of the elements is from 5% to 15% of the initial state,
i.e. the state in which the elements are placed in the container.
As a rule of thumb, the ultimate or final size of an element within
a container is the size just after the element expands and before
the element shrinks. Generally, the thermoplastic elements have a
bulk density of 1.0 pounds or less per cubic foot when in
place.
[0013] The thermoplastic elements within the container are thus
characterized in having been expanded from an initial state to an
expanded state after filling of the container as well as being
characterized in imparting a degree of rigidity to the container in
the expanded shape sufficient to maintain the expanded
three-dimensional shape of the container. The thermoplastic
elements are in a non-cured state and possess a degree of latent
foaming ability.
[0014] Whether the container is a pouch or a bag, the resulting
article may be used as a cushion or pillow. In this respect, the
material of the bag or pouch is pervious to a flow of air, for
example, being provided with holes or perforations to allow air to
enter into the curing thermoplastic elements.
[0015] The container is such that the discrete elements are tightly
packed together and are resistant to migration within the
container.
[0016] The container may also have several sections to form
different shapes. For example, the container may have a first
section forming a seat cushion and a second section forming a back
cushion so that the resulting structure provides a cushioned chair
for seating an occupant.
[0017] In another embodiment, an article of manufacture may be made
in tubular form with a wall of flexible material that defines a
confined space filled with thermoplastic elements that are cured
after filling of the space. Such an article may be used as a
flotation device, a drainage element and the like.
[0018] The non-cured thermoplastic elements can be used in the hull
or hollow seats of a boat for flotation purposes. When the elements
cure, a tight flotation aid is presented.
[0019] In still another embodiment, the non-cured thermoplastic
elements can be used for packaging articles in containers in a
tight-fit economical manner. For example, a layer of discrete
non-cured thermoplastic elements may be placed in the bottom of a
container within the article placed on top of the layer.
Thereafter, the container would be filled with further non-cured
thermoplastic elements and the container closed to contain the
article therein. Thereafter, the thermoplastic elements would be
subjected to a curing stage at an ambient temperature sufficient to
cure the thermoplastic elements and to effect expansion of the
thermoplastic elements from within so that the cured and expanded
thermoplastic elements rigidify the container and tightly hold the
article within the container. In this respect, since the curing
stage requires air to pass into the thermoplastic elements, the
container would be provided with holes or openings to permit the
inflow of air into the interior of the container.
[0020] The flexible container or rigid container can be used to
make any suitable item such as a round ball for beach or flotation
purposes, a buoyant cylinder for use in pools, life preservers,
life jackets, floating mats, seat cushions for stadium seating,
drainage mats, fillers for hollow doors, roof panels, side panels
and the like. Plastic containers that are filled with the cured
thermoplastic elements may be used for safety bumpers, highway
abutments and dividers, cushions for football field goal posts.
[0021] Further uses include insulation in housing construction,
mobile homes, trailers and airplanes.
[0022] Typically, the curing temperature should be 50.degree. F. or
above. However, the temperature may be lower than 50.degree. F. but
such would result in a much slower curing process and would result
in a lower degree of expansion.
[0023] These and other objects and advantages of the invention will
become more apparent from the following detailed description taken
in conjunction with the accompanying drawings wherein:
[0024] FIG. 1 illustrates a perspective view of a cushion
constructed in accordance with the invention;
[0025] FIG. 2 schematically illustrates a partial cross-sectional
side view of a chair constructed in accordance with the
invention;
[0026] FIG. 3 illustrates a front view of the chair of FIG. 2;
and
[0027] FIG. 4 illustrates a partial cross-sectional view of a
container with a packaged article in accordance with the
invention.
[0028] Referring to FIG. 1, the cushion 10 is formed of a pouch 11
of plastic material that is provided with a plurality of openings
12 sufficient to enable air to pass into and out of the interior of
the pouch 11. The pouch 11 is typically made with one open end that
is close by a heat seal 13 or by any other suitable means.
Alternatively, by way of example, the means for closing the pouch
may be in the form of two plastic rails having mating
cross-sections so that when the two rails are mated together, the
rails interlock. A slider is also provided to move along the rails
in order to move the rails together into interlocking relation.
Movement of the slider in a reverse direction allows the rails to
unlock from each other thereby opening the pouch.
[0029] The cushion 10 also has a mass of discrete thermoplastic
elements 14 contained within the pouch 11.
[0030] In order to make the cushion 10, the pouch 11 is opened and
a mass of non-cured thermoplastic elements 14, for example expanded
polystyrene elements (EPS), are poured into the pouch 11. When the
pouch 11 has been filled to capacity or near to capacity, the open
end of the pouch 11 is closed, for example, by heat sealing of
mouth of the pouch 11 or by using mating rails as described
above.
[0031] The non-cured thermoplastic elements 14 are obtained from
elements that have been extruded in a conventional manner using a
suitable extruder and subjected to two stages of expansion, i.e. a
conventional first stage expansion with curing thereafter and a
second stage expansion without curing. After the second stage
expansion and before further curing, the elements 14, i.e. the
"non-cured elements" are poured into the pouch 11 before the
elements 14 have had time to cure in the expanded second stage
state. Thus, the term "non-cured elements" used herein defines
thermoplastic elements that have passed through a first stage
expansion with curing thereafter and a second stage expansion
without curing.
[0032] After closing, the pouch 11 is set aside for a period of
time and at an ambient temperature to allow the thermoplastic
elements 14 to cure. By way of example, the curing stage occurs
over a 12 to 24 hour period during which time the blowing agent
within the elements 14 cools and air enters into the elements 14 to
swell the elements 14. The amount of swelling is 5% to 15% of the
initial state of the elements 14 as poured into the pouch 11. Thus,
the pouch 11 is expanded by 5 to 15%. This, in turn, rigidifies the
pouch 11 to a degree sufficient to maintain the expanded shape of
the cushion 10.
[0033] Referring to FIGS. 2 and 3, wherein like reference numerals
indicate like parts as above, the non-cured thermoplastic elements
14 may also be used to make a chair 15 having a first section 16
that forms a seat cushion and a second section 17 that forms a back
cushion. The chair 15 is made from a container 18 that is of a
material suitable for use in a chair and, as above, has one or more
openings (not shown) to permit the filling of the two sections
16,17 with the non-cured expanded polystyrene elements 14. The
container also has a plurality of holes 19 for the passage of air
into the interior or may be made of an air-permeable material, such
as a woven textile material, that allows the passage of air.
[0034] As above, after the sections 16,17 of the container 18 have
been filled and closed in a suitable manner by suitable means (not
shown), the container 18 is subjected to a curing stage during
which time the expanded polystyrene elements 14 swell so as to
rigidify each of the two sections 16,17 of the chair 15.
[0035] Referring to FIG. 4, wherein like reference numerals
indicate like parts as above, the non-cured expanded polystyrene
elements 14 may also be used for packaging purposes. For example, a
layer of the non-cured thermoplastic elements 14 may be poured into
the bottom of a cardboard container 20 and thereafter an article 21
to be shipped or stored is placed on the layer of elements 14. The
remainder of the container is then filled with additional non-cured
thermoplastic elements 14 and the flaps 22 of the container 20
closed and sealed to contain the article 20 therein. One or more
walls 23 of the container 20 are provided with openings 24 to allow
the passage of air into the interior of the container 20.
[0036] Thereafter, the closed container 20 is subjected to a curing
stage wherein the non-cured thermoplastic elements 14 are cured
under ambient conditions in a manner as described above without the
need of any external means, such as a heater. As the elements 14
swell within the container 20, the elements 14 rigidify the
container 20 and tightly hold the article 21 within the container
20.
[0037] It has been known to employ cured thermoplastic elements to
package articles within cartons. Typically, a layer of
thermoplastic elements is first laid in the container, the article
placed on top of the layer and then additional thermoplastic
elements are filled into the carton in an over-fill manner.
Thereafter, the flaps of the carton are folded over into a closed
position while pressing down on the overfilled thermoplastic
elements in order to compress the elements and to lock the article
in place within the carton. This technique, however, requires an
effort to be made to press down the flaps of the carton when
closing the carton. The invention provides a technique that avoids
this effort.
[0038] The container employed by the invention may be made of any
suitable material. For example, the container may be in the form of
a paper envelope into which an article can be inserted along with a
mass of non-cured thermoplastic elements. After closing of the
envelope and subsequent curing, the expanded thermoplastic elements
will expand the paper envelope and tightly hold the article in
place and prevent migration of the article. Such an envelope may be
used in place of a conventional paper envelope lined with bubble
wrap. If the paper is not permeable, an opening may be allowed
within the envelope for the passage of air into the elements during
the curing stage.
[0039] By way of example, a mass of (EPS) elements were extruded in
a conventional manner and expanded twice in an expander to a bulk
density of 0.3 pounds per cubic foot and allowed to contract while
cooling to a temperature of 83.degree. F. The elements were then
almost immediately put into two separate tubular containers of
mesh/plastic film and allowed to cure to a temperature of
68.degree. F. while re-expanding to a bulk density of less than 0.3
pounds per cubic foot.
[0040] Each container was a tube made of plastic flexible screen
with square holes of 0.5 inches and strands of 0.020 inches and was
tied at one end prior to packing with the elements. Each packed
tube was fully packed with the thermoplastic elements and, after
tying off the open end, measured 10 foot long with a diameter of 10
inches.
[0041] One tube was laid flat on a floor during curing and took on
a cylindrical cross-section. During re-expansion and curing of the
elements with the tube, the tube became rigid with the elements
becoming tightly packed.
[0042] The second tube was laid flat on a floor with a board
weighing 10 pounds on the top and along the entire length causing
the packed tube to deform into an oblong cross-sectional shape.
When the elements were fully cured, the tube maintained the oblong
cross-sectional shape due t the tight packing.
[0043] The two packed tubes were then laid in a horizontal plane
transversely of and on a conventional 2.times.4 board on a floor in
a symmetric manner to determine the deflection of each end of the
tubes. The cantilevered length of each end of each tube was thus
about 5 feet less one half the thickness of the 2.times.4 board.
The amount of deflection of each end of each tube was less than one
inch. Thus, for these tubes, the degree of rigidity can be
characterized in that when supported in a horizontal plane at a
mid-point with at least one end extending therefrom in a cantilever
manner, the end of the packed tube has a deflection relative to the
horizontal plane of two inches or less.
[0044] The non-cured thermoplastic elements may also be used to
make the drainage elements described in U.S. patent application
Ser. No. 11/106,108, filed Apr. 14, 2005, now U.S. Pat. No.
7,600,308 issued Oct. 13, 2009, the disclosure of which is
incorporated herein. For example, a drainage element may be made of
a tubular netting having a pair of closed ends and a mass of
expanded loose fill discrete elements within the netting wherein
the elements are characterized in having been expanded from an
initial state to an expanded state after filling of the netting
therewith and in imparting a degree of rigidity to the drainage
element in the expanded shape sufficient to maintain an expanded
three dimensional shape of the netting. The drainage element may
also be made with or without a pipe that may itself be corrugated
or not and perforated or not. In any case, the pipe would extend
beyond the closed ends of the netting to be able to connect with
other pipes or components of a drainage system.
[0045] The rigidity of the drainage tubes made in accordance with
the invention allows the tubes to be easily handled and put into
place in the field as compared to drainage tubes that are readily
flexible and that may snag on equipment in the field.
[0046] The invention thus provides a technique for using expandable
thermoplastic elements for making articles of three-dimensional
shape that have a rigid construction. The method of the invention
may be used to make drainage tubes, flotation devices, lateral
tubes for a septic system, bumpers for divided highways and toll
booths, packing, decorative roofing, recreational floats, toys and
the like.
[0047] The invention also provides a technique for packaging
articles within containers in a tight-fit manner.
* * * * *