Reinforced foam articles

Abstract

Reinforcement for foamed articles is provided utilizing a matrix of fiber elements disposed within the interior or core of the article. The fiber elements are injected along with dry flowable formable beads into a mold cavity. Upon heating of the mold interior and subsequent wetting/expanding/fusing phase, the fiber elements become joined to the expanding beads to provide enhanced strength of the resulting molded article.

What is claimed is:  
     
         1 . A method of producing a reinforced foamed article comprising the steps of: 
 providing dry expandable flowable foam beads;    providing a plurality of fiber elements;    providing a mold cavity;    flowing the foam beads into the mold cavity along with discrete fiber elements; and    heating the foam beads and fiber elements within the mold cavity while allowing the foam beads to heat, expand, and fuse with one another and with the reinforcing fiber elements to form a three-dimensional foam matrix with internal reinforcing fiber elements interspersed therein.    
     
     
         2 . The method of  claim 1  further comprising the step of forming a chemical attachment between the fiber elements and the foam beads.  
     
     
         3 . The method according to  claim 2  further comprising the step of coating the fiber elements with a sizing material to enhance said chemical attachment.  
     
     
         4 . The method according to  claim 1  wherein the step of providing internal reinforcing fiber members comprises a step of providing internal reinforcing fiber members having an aspect ratio ranging between 0.001 and 0.00001.  
     
     
         5 . The method according to  claim 1  wherein the fiber elements comprise fiberglass strands.  
     
     
         6 . The method according to  claim 5  wherein said foam beads are comprised of one of said styrene and said polystyrene.  
     
     
         7 . The method of  claim 1  further comprising the step of mixing said fiber elements and said foam beads together, prior to introduction into the mold cavity.  
     
     
         8 . The method of  claim 1  further comprising the step of mixing said fiber elements and said foam beads at the time of introduction into the mold cavity.  
     
     
         9 . The method of  claim 1  further comprising the step of mixing said fiber elements and said foam beads together, prior to introduction into the mold cavity the step of providing said fiber elements includes dimensioning said fiber elements to a length ranging between 2 and 3 inches.  
     
     
         10 . The method of  claim 1  wherein the reinforced foam article is to be subjected to an applied force extending in a preselected direction, said method further comprising the step of orienting at least a majority of said fiber elements in a direction generally perpendicular to said preselected direction.  
     
     
         11 . The method of  claim 10  wherein at least 60% of said fiber elements are oriented in a direction generally perpendicular to said preselected direction.  
     
     
         12 . The method of  claim 1  wherein the foam beads are comprised of polystyrene and said fiber elements are comprised of fiberglass.  
     
     
         13 . The method of  claim 12  wherein the foam beads have a size dimension of 0.40 to 1.10 mm.  
     
     
         14 . The method of  claim 12  wherein the foam beads have a size dimension of 0.40 and 1.10.  
     
     
         15 . The method of  claim 12  wherein 50% of the foam beads have a size dimension of 0.40 mm and 50% of the foam beads have a size dimension of 1.10 mm.  
     
     
         16 . In a freestanding form module for receiving flowable materials to make a wall which includes the form module, the flowable materials exerting a force in a selected direction, the form module comprising at least two spaced-apart form members having opposed interior form surfaces, each form member including a wall portion and a rib portion extending from the wall portion toward another one of said form members; and at least one monolithic molded plastic tie member having opposed ends with a web member between the ends extending along a web axis, a bearing member at each end of the tie member, extending generally transverse to the web axis and embedded in the wall portion of a respective form member with the form member formed around so as to captively enclose the bearing member and each end of the tie member having a stabilizing member extending generally transverse to the web axis, spaced from the bearing member and embedded in the rib portion of a respective form member adjacent the interior form surface thereof with the form member formed around so as to captively enclose the stabilizing member; 
 the improvement in said form members comprising:    a reinforced foamed article including a three-dimensional foam matrix core of expanded dry flowable foam beads;    a plurality of discrete spaced-apart internal reinforcing fiber elements interspersed in the foam matrix and attached to the expanded beads of the foam matrix;    a sizing between at least some of the foam beads and the fiber elements; and    at least a majority of said fiber elements oriented in said foam matrix in a direction generally perpendicular to said preselected direction.    
     
     
         17 . The improvement of  claim 16  wherein at least 60% of said fiber elements are oriented in a direction generally perpendicular to said preselected direction.  
     
     
         18 . The improvement of  claim 16  wherein the foam beads are comprised of polystyrene and said fiber elements are comprised of fiberglass.