Patent ID: 7144534

Claim:
A method of producing rebonded foam blocks in a box mould comprising a base, a plurality of mutually adjacent mould side walls standing thereupon and a plunger movable in the direction of the base, wherein at least one of the mould side walls is swivelable about a substantially horizontal swivel axis mounted on the base between an outwardly directed position and a substantially vertical position, the method comprising: mixing foam flakes with a binder; swiveling at least one of the mould side walls outwards such that a cross-sectional area of the box mould increases from the bottom upwards; introducing foam flakes into the box mould; adjusting the at least one mould side wall so that the cross-sectional area of the box mould is substantially constant over its height; compressing the foam flakes by means of the plunger to a desired density or foam block height, thereby bonding together the foam flakes; and removing the finished foam block from the mould.