Molded Expanded Polystyrene Foam Core Board Used For Foam Board Insulation

Molded Expanded Polystyrene Foam Core Board Used For Foam Board Insulation

Together with Extruded Expanded Polystyrene (XEPS) foam, they are the most used materials derived from polystyrene that are used in the production of insulating boards.

Out of the two, Molded Expanded Polystyrene foam is the most basic, cheapest and easiest to produce.

Before becoming "Molded", Polystyrene is transformed into a foam trough an elaborate process.

The first step in creating the foam board insulation material is called "pre-expansion", and has the purpose of expanding the polystyrene beads in order to achieve the density needed for the final polystyrene foam.

The process of "pre-expansion" consists of heating the raw, unexpanded polystyrene beads, commonly using steam, or as is the case with beads used for high density foams, using hot air. This process takes place in a vessel where an "agitator" stops the beads from fusing and because the expanded beads become lighter, the constant movement makes the expanded beads exit trough the top of the vessel. The pre-expansion" makes the beads become up to three percent less dense and gives them a smooth surface. After they are expanded, the beads are allowed to "age" for at least 24 hours in special mesh containers, letting the air cool the beads and increase their hardness.

The next step is feeding the expanded beads into a mold shaped as desired and pumping low pressure steam or hot air into the mold in such a way that it gets between them, expanding the beads event more and making them "stick" together, taking the shape of the mold.

After the process is complete, the mold must be cooled to allow the foam be taken out. The cooling is done trough several methods, like circulating water trough the mold or spraying it on the outside surface. The excellent insulating properties of the polystyrene foam make this step quite difficult as the foam itself makes the mold harder to cool.

After the mold is cooled, the foam, now in the shape of a block, or in whatever shape was molded, is taken out and cut in foam core boards according to the specifications of the foam board insulation needed.

Want to find out ways to make your home more energy efficient? If so you'll need to learn more about Foam board insulation and Foam core board

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