Apparatus and method for compression molding a chair mat

An apparatus for compression molding a chair mat, said apparatus comprising:

• an extruder for extruding a quantity of accurately weighed melted polymer;
• a polymer transfer tray disposed adjacent said extruder for receiving said quantity of accurately weighed melted polymer thereon;
• a forming press disposed downstream from said extruder for compression molding said quantity of accurately weighed melted polymer;
• a conveyor for moving said polymer transfer tray with said quantity of melted polymer thereon from said extruder to said press;
• said forming press including:
• a first mold for molding an upper impression of the chair mat;
• a second mold for molding a lower impression of the chair mat, said first and second molds being movable relative to each other from an open disposition thereof for permitting loading of said quantity of accurately weighed melted polymer between said molds to a closed disposition of said molds in which said molds are moved towards each other for compression molding said quantity of weighed melted polymer between said molds;
• said first mold including:
• a movable platen;
• said first mold defining said upper impression of the chair mat;
• a plurality of guides extending from said movable platen to said second mold for guiding said movable platen and said first mold between said open and closed dispositions of said molds;
• and
• a ram for moving said movable platen between said open and closed dispositions of said molds such that when said quantity of accurately weighed polymer is disposed between said molds, said movable platen is urged by said ram towards said second mold, said guides guiding said movable platen and said first mold into register with said second mold so that said quantity of polymer disposed between said first mold and said second mold is compression molded between said molds.

A method for compression molding a chair mat, said method comprising the steps of:

• extruding a quantity of accurately weighed melted polymer through an extruder;
• receiving the quantity of accurately weighed melted polymer onto a polymer transfer tray disposed adjacent to the extruder;
• conveying the polymer transfer tray with the quantity of melted polymer thereon from the extruder to a forming press;
• and
• moving a first and a second mold of the press relative to each other from an open disposition of the molds for permitting loading of the quantity of accurately weighed melted polymer between the molds to a closed disposition of the molds in which the molds are moved towards each other for compression molding the quantity of weighed melted polymer between the molds.