How to Make Encapsulated Styrofoam

Info

Styrofoam is the common name for polystyrene and a trademark of the Dow company. It is a plastic used often in food containers and padding. However, also has environmental implications, since it is made from petroleum, is highly flammable and is made from benzene -- a known carcinogen. To reduce its impact, Styrofoam has been adapted for a variety of applications, including as a marine flotation material and a laser target encapsulator so that it can be recycled safely. Encapsulate expanded polystyrene in high-density polyethylene plastic and use in floating docks and marine floating devices. Use cellulose acetate extrusion in small-scale laboratory applications.

Large-scale Encapsulation

Encapsulating styrofoam prevents natural breakdown and environmental impact.

  • Create a hard, plastic exterior surface on your Styrofoam using high-density polyethylene. In the marine industry, during fresh-water flotation construction, you will need 1 cubic foot of Styrofoam to create 55 lbs. of lift and, in ocean water, 1 cubic foot of Styrofoam for 62 lbs. of lift, as explained by Envirofloat.

  • Unhitch your existing dock from it's mooring chains. Tie a buoy or fender to the chain so that it doesn't sink. Drag the buoy up on shore. Jack one side of the dock up and install new floats, or replace old ones. Use galvanized steel-truss frames to bolt the encapsulated foam into place using a wrench.

  • Aim to create a durable, sealed, odorless flotation device that is resistant to deformation, breakdown and attack from marine animals and plants such as barnacles and nesting otters.

    • Small-Scale Encapsulation

  • Perform small-scale laboratory encapsulation in, for example, laser target technology. Suspend fusion fuel-filled shells in a solution of cellulose acetate. Extrude the suspension through a small opening into a bath of ice water in a beaker. Soak the shell containing cellulose acetate gel in water to extract impurities.

  • Freeze-dry the gel to cause sublimation of water and solvent and gel structure solidification into a low-density microcellular foam containing one or more encapsulated fuel-filled shells.

  • Cut and mount on a support to provide laser fusion targets containing a fuel-filled shell surrounded by foam having a thickness of 10 to 60 μm (micrometers), according to Free Patents Online.

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