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 mold comprising a circumference, and further comprising a second series of second shapes arranged around the circumference of the second roller, the 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 roller and a corresponding second shape of the second roller 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 one of the parts of the strip of frangibly connected parts,
• the first shapes further comprising knives at least partially surrounding the projection portion and configured to cut the thermoplastic sheet material, and
• the second shapes further comprising anvil surfaces against which the knives of the first mold are configured to cut against,
• adjusting a temperature control system to maintain a gap between the knives and the 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;
• forming a frangible zone between adjacent parts of the strip of frangibly connected parts utilizing the knives and anvil surfaces;
• cutting the thermoplastic sheet material into the strip of frangibly connected parts utilizing the knives and anvil surfaces;
• 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 release from the continuous roll molder.