Patent ID: 9456655
Filing Date: 2016-10-04
CPC Classification: A43B,B29C,B29D,B29K,B29L

Claim Text:
1. A manufacturing method for stabilizing a phylon article that is produced utilizing a heat process, the method comprising: generating at least one pre-formed phylon biscuit from pelletized phylon in a first molding process, the at least one pre-formed phylon biscuit comprising an unexpanded phylon material; preheating an interior of the at least one pre-formed phylon biscuit until a first threshold temperature is reached at a core of the at least one pre-formed phylon biscuit; transferring the at least one preheated pre-formed phylon biscuit to a molding cavity of a mold, during a second molding process; heating the mold containing the at least one preheated pre-formed phylon biscuit to a second threshold temperature, the heating to the second threshold temperature causing the unexpanded phylon material of the at least one pre-heated pre-formed phylon biscuit to expand, forming the phylon article; removing the phylon article from the molding cavity of the heated mold after the phylon article is formed; upon removal from the molding cavity, transferring the phylon article to a first fluid contained in a first tank via a conveyor coupled to a basket-type container to carry the phylon article, the first fluid being maintained at a first temperature; withdrawing the phylon article from the first tank; transferring the phylon article to a second fluid contained in a second tank, the second fluid being maintained at a second temperature that is less than the first temperature of the first fluid in the first tank; and withdrawing the phylon article from the second tank, such that the sequential placement of the heated phylon article into the first fluid of the first tank and the second fluid of the second tank thereby causes the temperature of the phylon article to controllably and gradually ramp down, as well as cause the phylon article to exhibit an incremental decrease in volume.