US 7,651,645 B2Granted

Method for molding three-dimensional foam products using a continuous forming apparatus

AssigneeCentury Products Company

InventorZachary R. Taylor

Life of this patent

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Abstract

A continuous forming apparatus for molding foam material into foam products that includes a first endless belt and a second endless belt that cooperates with the first endless belt to mold the foam material. The continuous forming apparatus may also include a first plurality of cleats and a second plurality of cleats opposed to the first plurality of cleats that support the first endless belt and the second endless belt respectively. The first plurality of cleats may include a three-dimensional abutment surface that provides transverse and lateral support to the first endless belt. Additionally, the continuous forming apparatus may include a first frame disposed to support the first plurality of cleats, a second frame disposed to support the second plurality of cleats, and a drive mechanism for imparting motion to the first endless belt, the second endless belt, the first plurality of cleats, and the second plurality of cleats.

Claims24

Dependent claims

A method of forming molded materials, comprising the steps of:

providing a continuous forming apparatus comprising:
at least a first endless mold belt comprising an inner surface and a outer surface;
a first endless support belt, the support belt comprising a plurality of rigid cleats, wherein the first plurality of cleats comprises an inner portion and an outer portion relative to a mold cavity, wherein each cleat of the first plurality of cleats comprises a three-dimensional abutment surface located on the inner portion of the cleat that is at least in partial contact with the outer surface of the first endless belt, wherein the abutment surface provides transverse and lateral support to the first endless belt;
a second endless support belt comprising a plurality of rigid cleats;
a first set of pulleys or sprockets, wherein the first endless belt travels around the first set of pulleys or sprockets;
a second set of pulleys or sprockets, wherein at least a portion of the first plurality of cleats is at least partially disposed on the second set of pulleys or sprockets, wherein the first plurality of cleats travels around the second set of pulleys or sprockets;
a third set of pulleys or sprockets, wherein the second plurality of cleats is at least partially disposed on the third set of pulleys or sprockets, and wherein the second plurality of cleats travels around the third set of pulleys or sprockets;
and
a drive mechanism configured to impart motion to at least the first endless belt;
introducing a material into the mold cavity defined at least in part by the inner surface of the first endless belt;
moving the material in a plane substantially parallel to the inner surface of the first endless belt;
and
curing the material.

10 more elements

A method of continuously molding a foamed material, comprising the steps of:

providing a pressure resistant, continuous mold cavity for containing the foamed material during molding, the mold cavity having an entrance and an exit, the entrance and the exit separated by a distance sufficient to permit molding;
containing the material within the mold cavity using at least an upper mold belt and a lower mold belt;
driving and supporting the upper mold belt with an upper conveyor belt and the lower mold belt with a lower conveyor belt, each conveyor belt being comprised of a series of cleats attached together by at least one linked chain belt;
separating the upper and lower mold belts by a distance to form at least a portion of the mold cavity, the separation distance defining a mold cavity gap;
adjusting the mold cavity gap to prevent binding of the conveyor belts and to adjust the pressure resistance of the mold cavity;
driving the upper and lower conveyor belts using at least one sprocket coupled to the linked chain belt;
supporting each of the upper and lower conveyor belts during at least a portion of the molding process using an upper rigid support surface and a lower rigid support surface, wherein the conveyor belts travel on the rigid support surfaces;
and
reducing frictional forces between the conveyor belts and the rigid support surfaces by use of rollers coupled to the linked chain belt;
wherein the upper and lower mold belts do not separate under the pressure of the foamed material during molding.

7 more elements

Dependencies are inferred from the claim text.

Facts

Application: 11/593,316Filed 6 Nov 2006 · continuation
Priority: 24 Jun 2004
Published: US 2007/0052128 A18 Mar 2007
Granted: 26 Jan 2010
Term ends: Not estimatedThe source records don’t support an estimate.

Classification12 codes

B29C 44/306
Expanding the moulding material between endless belts or rollers: longitudinally shaping, e.g. the belt
B29C 35/0277
Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould: apparatus with continuous transport of the material to be cured
B29C 37/0075
Using separating agents during or after moulding; Applying separating agents on preforms or articles, e.g. to prevent sticking to each other:…
B29C 39/16
For making articles of indefinite length: between endless belts

Family

Application60/582,420Us provisional application · filed 24 Jun 2004
Application11/165,071Parent of this continuation · filed 23 Jun 2005
US 2007/0052128 A1Pre-grant publication · published 8 Mar 2007
US 7,316,559 B2Parent of this continuation
US 2005/0287238 A1Published application
US 7,651,645 B2This patent

From the US filing history. Foreign family members aren’t listed.