US 4,290,248 AGranted

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

AssigneeWilliam James Kemerer

InventorsWilliam J. Kemerer, Clyde W. Vassar

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Abstract

A continuous process and apparatus are disclosed for forming products from thermoplastic polymeric material having three-dimentional patterns and surface textures on one or both faces that may be similar or dissimilar with or without a continuously changing profile and with or without shaped edges, such as shake shingle panels, board and batten panels, rough barn board panels, wainscoting panels, brick panels, stone panels, patterned door panels, similar structural wall panels, roofing or siding panels, ribbed soffits, fascia board, flooring reinforced with egg crate ribs, forms for pouring contoured concrete structures, and other three-dimensional pattern and surface textured plastic products which may extend in widths up to 4 feet or more and in lengths up to 20 feet or more.

Claims24

Dependent claims

A continuous impression molding process for making three-dimensional patterns on thermoplastic polymeric material comprising the steps of:

continuously providing a heated ribbon of substantially uniform thickness of said material in a plastic state at a temperature above its glass transiton temperature,
initially pressing opposed endless flexible belt molds, at least one of which has a three-dimensional rubber pattern form with abrupt changes in profile extending longitudinally of the belt and in surface contour extending transversely of the belt, against opposite sides of said heated ribbon while its temperature is above its glass transition temperature, so as to displace at least a portion of said ribbon in a continuous progressive localized pinching nip action with sufficient initial pressure for impressing a three-dimensional pattern on the heated material of said ribbon,
moving said opposed flexible belt molds and carrying said impressed material along between said opposed molds while exerting sufficient pressure against opposite sides of the material to retain said three-dimensional pattern therein,
cooling said moving opposed molds for cooling said impressed material down to a temperature in its memory retention state to cause said cooled material to retain said three-dimensional pattern, and
removing the cooled impressed material from between the opposed molds.

2 more elements

A continuous impression molding process for making three-dimensional patterned products from thermoplastic polymeric material comprising the steps of:

continuously providing a moving heated ribbon of said material in a plastic state at a temperature in the range between its glass transition temperature and 220.degree. F. thereabove,
providing opposable endless flexible belt molds at least one of which has a three-dimensional rubber pattern form and capable of defining a mold cavity, when positioned in opposed relationship,
initially pressing said molds in opposed relationship in a continuous progressive localized rolling squeezing pinching nip action against said moving heated ribbon for forming the cavity while impressing a three-dimensional pattern on the heated material of said ribbon, said three-dimensional pattern defining areas in said thermoplastic material varying in the range of 1/8 inch to one-inch thick,
moving said molds along a predetermined path while holding the molds in opposed relationship for retaining the impressed material within the travelling mold cavity formed by the opposed moving molds,
cooling the opposed moving molds for cooling the impressed material down to a temperature level below said glass transition temperature into its memory retention state to cause the cooled material to retain said impressed three-dimensional pattern, and
removing and treating the cooled impressed material for making the three-dimensional patterned products.

3 more elements

Dependencies are inferred from the claim text.

Facts

Application: 05/639,328Filed 10 Dec 1975 · continuation in part
Priority: 6 Jan 1975
Granted: 22 Sep 1981
Term ends: Not estimatedThe source records don’t support an estimate.

Classification21 codes

B29C 43/224
Of articles of indefinite length: having a profiled section, e.g. tubes, rods
B29B 7/603
For feeding, e.g. end guides for the incoming material: in measured doses, e.g. proportioning of several materials
B29C 43/222
Of articles of indefinite length: characterised by the shape of the surface
B29C 48/001
Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor: combinations…