Importance

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Abstract

The invention is inspired by the animal bone structure which is normally hollow in the middle. The invention introduces a novel foam article and a method of manufacturing it to include cavities similar to the bone structure. The novel foam article comprises a cavity-defining structure that is placed inside a mould prior to introducing expanded polymer beads into the mould. The cavity-defining structure comprises hollow compartments or layers that create macro-cavities and hollow compartments in specific sizes and locations of the foam article during the moulding process. As a result, the foam article equipped with the cavity-defining structure uses fewer polymer beads and is lighter than foam articles made conventionally. The invention also improves the foam article in terms of its shock absorption, durability, thermal insulation, acoustic insulation, and floatation.

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First Claim