Direct forming of non-textile fabric elements from plastic pellets

A method for manufacturing a non-textile fabric comprising an array of interconnected elements forming a flexible or bendable web, including the acts of:

• forming at least one first element having at least one cam surface enabling it to interconnect to a second element, said at least one first element is a plate structure and said cam surface being sloped relative to the plane of the non-textile fabric;
• forming said second element by molding said second element in the form of a plate structure and molding it against said at least one cam surface of said first element;
• and
• forming a third element by molding said third element against at least one of said first and said second elements such that said first, second and third elements are intimately mechanically connected to one another such that the first element and the second element can move relative to one another;
• wherein forming said first element includes the act of solid phase forming said first element by positioning a polymer pellet in a first mold cavity and forcing said polymer pellet to adapt the shape of said first mold cavity;
• wherein forming said second element includes the act of solid phase forming said second element by positioning a second polymer pellet in a second mold cavity and forcing said second polymer pellet to adapt the shape of said second mold cavity;
• and
• wherein forming said third element includes the act of solid phase forming said third element by positioning a third polymer pellet in a third mold cavity and forcing said third pellet to adapt the shape of the third mold cavity and be operably connected with said first and second elements.

A method of making a non-textile fabric comprising the acts of:

• providing a first roller, a second roller, a third roller, and a first nip region between said first and second rollers, and a second nip region between said second and third rollers, said rollers having work surfaces;
• forming at least a first element at said first nip region;
• and
• forming at least a second element at said second nip region by using at least a portion of said first element, said second element being formed in an interconnected manner with said first element;
• wherein the two forming steps are performed by:
• applying a first plastic pellet to said work surface on said first roller;
• aligning said work surface on said second roller with said work surface on said first roller in said first nip region to form a first mold cavity;
• solid phase forming said plastic pellet in said mold cavity in said first nip region to form said first element;
• applying a second plastic pellet to said work surface on said second roller;
• aligning said work surface on said third roller with said work surface on said second roller in said second nip region to form a second mold cavity;
• and
• solid phase forming said second plastic pellet in said second mold cavity in said second nip region to form said second element in an interconnected manner with said first element.

A method of making a non-textile fabric comprising the acts of:

• providing a first roller, a second roller, third roller, and a fourth roller, and a first nip region between said first and second rollers, a second nip region between said second and third rollers, and a third nip region between said third and fourth rollers, said rollers having work surfaces;
• forming at least a first element at said first nip region;
• forming at least a second element at said second nip region by moving against at least a portion of said first element, said second element being formed in an inter-engaging manner with said first element;
• and
• forming at least a third element at said third nip region;
• said third element being formed so as to interconnect said inter-engaging first and second elements;
• wherein the three forming steps are performed by:
• applying a first plastic pellet to said work surface on said first roller;
• aligning said work surface on said second roller with said work surface on said first roller in said first nip region to form a first mold cavity;
• solid phase forming said plastic pellet in said mold cavity in said first nip region to form said first element;
• applying a second plastic pellet to said work surface on said second roller;
• aligning said work surface on said third roller with said work surface on said second roller in said second nip region to form a second mold cavity;
• solid phase forming said second plastic pellet in said second mold cavity in said second nip region to form said second element in an inter-engaged manner with said first element;
• applying a third plastic pellet to said work surface on said third roller;
• aligning said work surface on said fourth roller with said work surface on said third roller in said third nip region to form a third mold cavity;
• and
• solid phase forming said third plastic pellet in said third mold cavity in said third nip region to form said third element to interconnect said first and second elements.

A method for manufacturing a non-textile fabric including the acts of:

• forming a first element;
• and
• forming a second element in operable connection with said first element by molding said second element against said first element wherein:
• forming said first element includes the act of solid phase forming said first element;
• and
• forming said second element includes the act of solid phase forming said second element, forming said first element includes the acts of positioning a plastic pellet in a first mold cavity;
• forcing said plastic pellet in said first mold cavity to adapt the shape of said first mold cavity;
• forming said second element includes the acts of positioning a plastic pellet in a second mold cavity;
• forcing said plastic pellet in said second mold cavity to adapt the shape of said second mold cavity and be operably connected with said first element.

A method for manufacturing a non-textile fabric including the acts of:

• forming a first element;
• forming a second element by molding said second element against said first element;
• and
• forming a third element by molding said third element against at least one of said first and said second elements such that said first, second and third elements are operably connected to one another wherein:
• forming said first element includes the act of solid phase forming said first element;
• forming said second element includes the act of solid phase forming said second element;
• and
• forming said third element includes the act of solid phase forming said third element, and wherein:
• forming said first element includes the acts of
• positioning a plastic pellet in a first mold cavity;
• forcing said plastic pellet to adapt the shape of said first mold cavity;
• forming said second element includes the acts of
• positioning a second plastic pellet in a second mold cavity;
• forcing said second plastic pellet cavity to adapt the shape of said second mold cavity;
• forming said third element includes the acts of
• positioning a third plastic pellet in a third mold cavity;
• forcing said third plastic pellet to adapt the shape of the third mold cavity and be operably connected with said first and second elements.