Continuous apparatus for forming products from thermoplastic polymeric material having three-dimensional patterns and surface textures

Apparatus for producing large area products having three-dimensional patterns on at least one surface thereof from thermoplastic polymeric material comprising:

• heating means for heating the thermoplastic polymeric material to a temperature above its glass transition temperature and feeding means for feeding the heated material to a wide narrow outlet having a length of at least two feet for issuing a continuous ribbon of said heated material therethrough at least two feet wide,
• a pair of endless flexible revolvable belt molds each having a front face on the outside thereof and a reverse surface on the inside thereof,
• a plurality of main rolls engaging the reverse surface of each of said belt molds for revolving said flexible belt molds,
• guide means engaging the reverse surface of each of said revolving belt molds for guiding runs of said revolving belt molds in opposed facing relationship defining a wide mold channel having a width of at least two feet and extending from an upstream end near said outlet to a downstream end which is located remotely from said outlet for receiving said ribbon of heated thermoplastic material and for advancing said material longitudinally along in said mold channel from said upstream end to said downstream end,
• at least one of said flexible belt molds including a flexible layer of flexible heat resistant material thereon forming the front face of said one belt mold and having a three-dimensional pattern form in said front face including abrupt changes in profile extending longitudinally of the belt mold and extending transversely thereof,
• a pair of said main rolls being positioned on opposite sides of said upstream end of said mold channel for pressing said belt molds against opposite surfaces of said heated material with said one belt mold travelling partially around one roll of said pair for rolling the three-dimensional pattern form in its front face against said ribbon for producing continuous progressive localized rolling pressing action against said ribbon as it enters the upstream end of said mold channel for impressing a three-dimensional pattern into at least one surface thereof,
• cooling means operatively associated with the belt molds for cooling the moving belt molds for cooling the impressed material in said mold channel into its memory retention state,
• conveyor means downstream from said mold channel for conveying the impressed material away from the downstream end of said mold channel, and
• means downstream from said mold channel for treating said impressed material to complete the large area products.

Apparatus for continuously shaping thermoplastic polymeric material for producing dissimilar three-dimensional patterns at least two feet wide on opposite sides of the material comprising:

• an opposed pair of rolls defining a nip region between them,
• means upstream from said nip region for feeding a moving ribbon of heated thermoplastic polymeric material into said nip region, said material being heated to a temperature level above its glass transition temperature for placing the material in a plastic state,
• a pair of flexible endless belt molds each at least two feet wide and being revolvable under tension,
• said flexible belt molds having dissimilar three-dimensional patterned surfaces of flexible heat resistant material, at least one of said patterned surfaces including abrupt changes in profile extending longitudinally of the belt mold and in surface contour extending transversely of the belt mold,
• drive means operatively associated with said belt molds for tensioning and moving each of said flexible belt molds at the same speed,
• each of said pair of rolls having one of said belt molds travelling partially therearound for impressing the three-dimensional patterned surfaces of said flexible belt molds in opposed relationship against the opposite sides of said moving ribbon in a continuous localized rolling squeezing action progressing along the length of the ribbon as it enters between the belt molds for impressing dissimilar three-dimensional patterns on opposite sides of the heated thermoplastic material in a plastic state,
• means engaging the moving belt molds for holding said flexible belt molds against opposite sides of the impressed thermoplastic material as the impressed material moves downstream from said nip region between the moving belt molds for retaining the impressions in opposite sides thereof,
• cooling means operatively associated with the belt molds for cooling said flexible belt molds for cooling the impressed opposite sides of the thermoplastic material to a temperature level below said glass transition temperature into the memory retention state for causing the opposite sides of the cooled material to retain said dissimilar three-dimensional patterns, and
• means engaging the moving flexible belt molds for directing the moving flexible belt molds away from the moving impressed material for continuously discharging such material with said dissimilar patterns at least two feet wide on opposite sides thereof.

Apparatus for producing large area products having a three-dimensional pattern on at least one surface thereof from thermoplastic polymeric material comprising:

• means for feeding a ribbon at least two feet wide containing thermoplastic polymeric material heated for being in a plastic state,
• a pair of endless flexible belt molds,
• a plurality of main rolls operatively associated with said belt molds for revolving said flexible belt molds in opposed relationship,
• guide means operatively associated with the belt molds for guiding said belt molds in opposed relationship defining a wide mold channel having a width of at least two feet and extending from an upstream end near said feeding means to a downstream end which is located remotely therefrom for receiving said ribbon containing heated thermoplastic material for advancing said material along said mold channel from said upstream end to said downstream end,
• at least one of said flexible belt molds including a flexible layer of rubber thereon having a three-dimensional grid pattern form in its outer surface,
• a pair of said main rolls being positioned on opposite sides of said upstream end for pressing said belt molds against opposite surfaces of said ribbon with said heated material in a plastic state for producing continuous progressive localized rolling squeezing action against said ribbon as it enters the upstream end of said mold channel for impressing a three-dimensional grid pattern into at least one surface thereof,
• said guide means holding said opposed belt molds against the impressed material being advanced along said mold channel,
• cooling means operatively associated with the belt molds for cooling the flexible belt molds for cooling the impressed material in said mold channel,
• conveyor means downstream from said mold channel for conveying the impressed material away from the downstream end of said mold channel, and
• means downstream from said mold channel for treating said impressed material to complete the large area products at least two feet wide having said three-dimensional grid pattern on at least one surface thereof.

Apparatus for continuous impression molding of products containing thermoplastic polymeric material comprising:

• a pair of flexible endless belt molds;
• each belt mold including a wide thin endless flexible metal belt having a flexible layer of flexible heat resistant material such as rubber bonded to the outer surface thereof and forming a mold surface;
• at least one of said mold surfaces having a three-dimensional pattern form including abrupt changes in profile extending longitudinally and transversely of the belt mold and having intricate surface texturing;
• said pair of belt molds being capable of defining a mold when their mold surfaces are positioned in opposed relationship;
• a plurality of rolls engaging each of said belt molds for revolving them;
• a pair of said rolls being positioned in opposed relationship defining a nip region between them;
• said revolving belt molds passing through said nip region between said pair of rolls with their mold surfaces in opposed relationship;
• said belt mold with said three-dimensional pattern form thereon curving partially around one of said pair of rolls and being flexed as it moves into said nip region;
• means upstream from said nip region for introducing a ribbon containing heated thermoplastic material in a plastic state between the mold surfaces of the belt molds in said nip region with said pair of rolls impressing said three-dimensional pattern form into the heated thermoplastic material of said ribbon in a progressive localized rolling squeezing action;
• guide means engaging the revolving belt molds downstream from said nip region for holding them in opposed relationship with the thermoplastic material therebetween for retaining the impressed three-dimensional pattern in said material;
• cooling means operatively associated with the belt molds for cooling them for cooling the impressed thermoplastic material downstream from said nip region into its memory retention state;
• and
• said revolving belt molds separating from the impressed thermoplastic material after it has been cooled sufficiently to retain said three-dimensional pattern;
• whereby impression molded products are continuously produced having high resolution three-dimensional patterns with intricate surface texturing.