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Extruded Polystyrene Foam
Carl Munters had shown that polystyrene heated with methyl chloride under pressure puffs into a closed-cell foam when let out of the vessel (US 2,023,204) - but only in small pieces; with larger outlets the mass collapsed into brittle, irregular lumps. Otis Ray McIntire at Dow found the fix: keep the mass BELOW the critical temperature of methyl chloride, about 143 °C, so the gas stays dissolved, and let its own evaporation cool the foam fast enough to freeze the cells.
**US 2,450,436**, "Manufacture of cellular thermoplastic products", McIntire, assigned to Dow Chemical, filed 26. July 1947, granted 5. October 1948. Its drawing is the pressure vessel with the bottom valve the foam flows out of. Dow sold the result as blue insulation board; the white bead foam of packaging is a later process.
**Methyl chloride is toxic; you start from foam board.** You build a hot-wire cutter, cut an insulated box, and measure how long it keeps ice.
初学者
3 hours plus an ice test
说明
1
1
The cutter
The cutter
Base on two feet, a post and an arm; the wire runs from the arm tip down through the base to a spring underneath.
2
2
Build the frame
Build the frame
From 18 mm plywood cut a 300 x 300 mm base, two 300 x 40 mm feet, a 280 x 50 mm post and a 200 x 50 mm arm. Glue and screw the post to the back edge and the arm square on top.
此步骤所需材料：
胶合板1 个
木螺钉10 个
木工胶20 毫升所需工具：
手锯
充电式电钻
螺丝刀套装
钢直尺3
3
String the wire
String the wire
Drill 2 mm through the arm tip and the base directly below. Fix the wire to an eye bolt on top of the arm, run it down through the base, and tie it to a spring under the base so it stays taut when it expands hot. Check it is square to the table.
此步骤所需材料：
镍铬丝 80/20，0.64 毫米1 米
吊环螺栓1 个
压缩弹簧套件1 套所需工具：
充电式电钻
盒装钻头组4
4
Power it
Power it
Clip leads to the wire at the arm and below the base. Set the bench supply to 1.5 V with a 4 A limit and raise it slowly (notebook) until the wire slides through a scrap cleanly. Ventilate.
所需工具：
可调式台式电源
Alligator to Alligator Cables
N95 防颗粒物口罩
透明安全眼镜5
5
Cut the box
Cut the box
From 25 mm foam board cut a base and lid 200 x 200 mm, two sides 200 x 150 mm and two 150 x 150 mm. Feed slowly - let the wire do the work. Tape the box together.
此步骤所需材料：
Extruded Polystyrene Foam Board1 张
美纹纸胶带1 卷所需工具：
钢直尺6
6
Weigh a cube
Weigh a cube
Cut a 50 mm cube from an offcut and weigh it for the notebook.
所需工具：
数字厨房秤7
7
The ice test
The ice test
Put 500 g of ice in a bag in the foam box and another 500 g in a cardboard box of the same size, side by side in the same room. Note the room temperature and check both every hour until the ice is gone.
此步骤所需材料：
冰块1000 克
瓦楞纸箱1 个所需工具：
数字厨房秤
室温计8
8
Wire, density, heat leak
Wire, density, heat leak
正在加载 Jupyter 笔记本…
9
9
History & Context
History & Context
**What the patent specifies:** polystyrene with methyl chloride dissolved under pressure below the gas's critical temperature, released through an outlet so evaporation expands and cools it into uniform closed cells, in blocks 2 inches thick or more. **Modern build (derived):** commercial extruded foam board, today made with other blowing agents.
The patent names its target plainly: blocks big enough to cut into insulating panels for refrigerators. Its limits: it melts at low heat, burns unless treated, dissolves in many solvents (and in some glues and paints), and breaks down in sunlight.
材料
10- 1 个占位符
- 10 个占位符
- 20 毫升占位符
- 占位符
- 1 个占位符
- 1 套占位符
- 1 卷占位符
- 1000 克占位符
- 1 个占位符
所需工具
11- 占位符
- 1 vendor sell this, none ship to you yet占位符
- 占位符
- 占位符
- 占位符
- 占位符
- $3.58
- 占位符
- 占位符
- 占位符
- 占位符
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