Polymeric foam powder processing techniques, foam powders products, and foam produced containing those foam powders

Abstract

This relates variously to techniques for comminuting polymeric foams, to techniques for preparing polymeric foams containing that comminuted foam, and to the resulting comminuted foam powder and polymeric foams. The procedures may be used on foams containing production contaminants such as polyolefins, paper, and foam skins and on other foams containing consumer contaminants such as wood, metal, leather, etc. The comminuted foam powder, with or without contaminants, preferably is screened or sifted to obtain a foam powder having a particle size of about 2 mm or less.

1 . A device for collecting foam powder from a mill having a first roll including a first cylindrical surface and a second roll including a second cylindrical surface, the device comprising: 
 a) a first side wall having a first edge, wherein the first edge is adapted for positioning proximal the first cylindrical surface and substantially parallel to the first cylindrical surface,    b) a second side wall having a second edge, wherein the second edge is adapted for positioning proximal the second cylindrical surface and substantially parallel to the second cylindrical surface,    c) a bottom joining the first side wall and the second side wall,    d) a first end wall joining the bottom and the first and second side walls, wherein the first end wall includes a first end wall edge that is adapted for positioning proximal the first and second cylindrical surfaces and substantially perpendicular to the first cylindrical surface,    e) a second end wall opposing the first end wall and joining the bottom and the first and second side walls, wherein the second end wall includes a second end wall edge that 
 is adapted for positioning proximal the first and second cylindrical surfaces and substantially perpendicular to the first cylindrical surface,  
   f) a gaseous flow inlet; and    g) a gaseous flow outlet.    
   
   
       2 . The device of  claim 1  additionally comprising at least one scraper blade adapted for positioning proximal a first of the first and second cylindrical surfaces and substantially parallel to the first cylindrical surface.  
   
   
       3 . The device of  claim 1  additionally comprising an auger positioned inside the chamber for discharging foam powder from the chamber.  
   
   
       4 . The device of  claim 1  wherein the first and second side wall edges include a material softer than the first and second cylindrical surfaces.