Patent ID: 9187609
Filing Date: 2015-11-17
Classification: B29C,B29K,B65D,C08J

Abstract:
1. A method of forming at least one element to float at least partially on a surface of an at least partially liquid hydrocarbon mixture, the method comprising: (a) mixing a polymer resin and a foaming agent together in preselected proportions to provide a material mixture; (b) heating the material mixture, to at least partially liquefy the material mixture; (c) injecting the at least partially liquefied material mixture into a mold cavity configured to define said at least one element's exterior surface over a predetermined first time period at a predetermined first velocity and under a predetermined first pressure; (d) at the end of the first predetermined time period, injecting the at least partially liquefied material mixture into the mold cavity over a predetermined second time period at a predetermined second velocity that is less than the first velocity, and under a predetermined second pressure that is less than the first pressure; and (e) at the end of the second predetermined time period, injecting the at least partially liquefied material mixture into the mold cavity over a predetermined third time period at a predetermined third velocity that is less than the second velocity, and under a third pressure that is less than the second pressure.