Continuous roll molding system and method; frangible cap strip and method of making using continuous roll molding

A method of forming a strip of frangibly connected parts comprising:

• providing a thermoplastic sheet material;
• and
• conveying the thermoplastic sheet material through a continuous roll molder comprising a first roller and an opposing second roller,
• the first roller comprising a circumference, and further comprising a first series of first shapes arranged around the circumference of the first roller,
• the second roller comprising a circumference, and further comprising a second series of second shapes arranged around the circumference of the second roller, the first and the second rollers configured so that the first series of first shapes opposes the second series of second shapes to form the strip of frangibly connected parts comprising a three dimensional shape on both sides of the strip of frangibly connected parts,
• a first shape of the first series of first shapes and a corresponding second shape of the second series of second shapes are configured to form a first part of the strip of frangibly connected parts,
• at least one of the first shapes and the second shapes comprising a projection portion projecting radially from the circumference of the respective first and second roller and is configured for imparting a three-dimensional shape on a surface of the first part of the strip of frangibly connected parts,
• the first shape of the first series of first shapes further comprising one or more knives configured to cut the thermoplastic sheet material,
• the second shape of the second series of second shapes further comprising one or more anvil surfaces against which the one or more knives of the first shape of the first series of first shapes are configured to cut against,
• adjusting a temperature control system to maintain a gap between the one or more knives and the one or more anvil surfaces, wherein the continuous roll molder further comprises one or more channels configured to receive a temperature-controlled fluid of the temperature control system;
• cutting the thermoplastic sheet material into the strip of frangibly connected parts utilizing the one or more knives of the first shape of the first series of first shapes and the one or more anvil surfaces of the second shape of the second series of second shapes;
• forming a frangible zone between adjacent parts of the strip of frangibly connected parts utilizing the one or more knives of the first shape of the first series of first shapes and the one or more anvil surfaces of the second shape of the second series of second shapes;
• separating the strip of frangibly connected parts from a waste thermoplastic sheet material such that the strip of frangibly connected parts and the waste thermoplastic sheet material are separated after cutting the thermoplastic sheet material into the strip of frangibly connected parts.