Foam product and method of making the same
View Patent ↗The foam product includes a foam body, a connection block, an accessory and an adhesive layer. The foam body is formed of expandable polystyrene (EPS). The connection block is formed of a copolymer of expandable polyolefin and expandable polystyrene, and is completely or partially embedded inside the foam body. The accessory is made of non-expandable material and is completely or partially embedded inside the connection block. The accessory and the connection block are bonded by the adhesive layer.
1. A foam product comprising:
a foam body made of a first foam material, wherein the first foam material is expandable polystyrene (EPS);
a connection block made of a second foam material and completely or partially embedded inside the foam body, wherein the connection block is bonded with the foam body and the second foam material is a copolymer of expandable polyolefin and expandable polystyrene;
an accessory completely or partially embedded inside the connection block and in contact with the connection block, wherein a part of the accessory is exposed outside of a surface of the foam body; and
an adhesive layer located between the connection block and the accessory and creating a bond between the connection block and the accessory.
2. The foam product of claim 1 , wherein the connection block is more flexible and tougher than the foam body.
3. The foam product of claim 1 , wherein the expandable polyolefin is expandable polyethylene (EPE).
4. The foam product of claim 3 , wherein the copolymer contains approximately 30 percent by weight EPE and 70 percent by weight EPS.
5. The foam product of claim 1 , wherein the accessory is stiffer than the foam body and the connection block and the accessory is made of a material that differs from that of the foam body and the connection block.
6. The foam product of claim 1 , wherein the accessory is substantially made of plastic.
7. The foam product of claim 1 , wherein the exposed part of the accessory protrudes above the surface of the foam body.
8. The foam product of claim 1 , wherein the accessory is a holder to carry a component therein.
9. The foam product of claim 1 , wherein the accessory is a pole.
10. The foam product of claim 1 , wherein the connection block has a surface flush with the surface of the foam body.