How Is Foam Board Insulation Made?
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Overview on Types of Foam Board
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There are several types of foam board insulations. Not all are strictly foam boards, some can be applied in liquid forms and sprays. The most common are MEPS (molded expanded polystyrene) boards installed in homes and buildings. Extruded expanded polystyrene boards or XEPS are similar but have a better heat rating or R value of 5, while MEPS has a 4 value. Both are made in a similar way.
Manufacturing MEPS
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MEPS boards are made from small beads of polystyrene. These beads contain a liquefied pentane. They are combined with a blowing agent in a large container and then heated so the pellets become enlarged. Using a pressurized system, the mixed product is injected into a mold and pressurized and heated until the foam forms blocks. The block is then cut to form the boards you commonly see. Different types of "finishes" or layers can also be applied to the MEPS boards.
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Manufacturing XEPS
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The XEPS boards are constructed in a similar way but the pellets are mixed with a number of chemicals in a container. When the blowing agent is added, it forms gases and the entire mixture begins foaming before it is shot into a press or cast where it returns to room temperature and hardens. With this method, the XEPS can be shaped into any form, but typically it is made into large blocks that are cut into panels.
Other Information
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Both of these types of foam board can be made to have different qualities by mixing in various chemicals and shaping them under higher or lower pressure and heat. The final result is a variety of densities that have different heat retention characteristics. These are used for a range of buildings, homes and other uses.
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