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

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.

1 . A method of forming molded foam materials using a continuous forming apparatus comprising the steps of:
 providing a continuous forming apparatus comprising a first endless belt comprising an inner surface and an outer surface, a first plurality of cleats and a second plurality of cleats opposed to the first plurality of cleats, wherein the first plurality of cleats comprise a three-dimensional abutment surface to provide transverse and lateral support to the first endless belt, and a drive mechanism for imparting motion to the first endless belt, the first plurality of cleats and the second plurality of cleats;   introducing a composite material into a mold cavity defined at least in part by the inner surface of the first endless belt;   moving the composite material in a plane substantially parallel to the inner surface of the first endless belt; and   curing the composite material to form a molded foam material.   
     
     
         2 . A method according to  claim 1 , wherein the continuous forming apparatus further comprises a first attachment chain connecting the first plurality of cleats together and a second attachment chain connecting the second plurality of cleats together. 
     
     
         3 . A method according to  claim 1 , wherein the continuous forming apparatus further comprises a second endless belt that cooperates with the first endless belt to mold the foam material, wherein the second endless belt is supported by the second plurality of cleats. 
     
     
         4 . A method according to  claim 3 , wherein the second plurality of cleats comprise a three-dimensional abutment surface to provide transverse and lateral support to second endless belt. 
     
     
         5 . A method according to  claim 3 , further comprising a third endless belt and a fourth endless belt that cooperates with the first endless belt and the second endless belt to mold the foam material. 
     
     
         6 . A method according to  claim 1 , wherein the continuous forming apparatus further comprises a third plurality of cleats and a fourth plurality of cleats disposed generally orthogonal to the first plurality of cleats and the second plurality of cleats. 
     
     
         7 . A method according to  claim 1 , wherein the first endless belt of the continuous forming apparatus comprises an insert support feature. 
     
     
         8 . A method according to  claim 1 , wherein the first endless belt comprises a mold cavity for molding a discrete foam part. 
     
     
         9 . A method according to  claim 1 , wherein the continuous forming apparatus further comprises a first frame disposed to support the first plurality of cleats and a second frame disposed to support the second plurality of cleats. 
     
     
         10 . A method according to  claim 1 , wherein the first endless belt is supported by the first plurality of cleats to form a curved cross sectional area for molding foam material. 
     
     
         11 . A method according to  claim 10 , wherein the first endless belt is also supported by the second plurality of cleats to form a circular cross sectional area for molding foam material. 
     
     
         12 . A method according to  claim 1 , wherein a lateral gap is disposed between each cleat of the first plurality of cleats. 
     
     
         13 . A method according to  claim 1 , wherein a transverse gap is disposed between the first plurality of cleats and the second plurality of cleats when the first plurality of cleats support the first endless belt for molding foam material. 
     
     
         14 . A method of forming molded foam materials using a continuous forming apparatus comprising the steps of:
 providing a continuous forming apparatus comprising a first endless belt comprising an inner and an outer surface, a first plurality of cleats, wherein each cleat of the first plurality of cleats comprises a base portion and a mold support portion, wherein the mold support portion is removably attached to the base portion, wherein the mold support portion comprises a three-dimensional abutment surface for supporting the endless belt, and a drive mechanism for imparting motion to the first endless belt and the first plurality of cleats;   introducing a composite material into a mold cavity defined at least in part by the inner surface of the first endless belt;   moving the composite material through the continuous forming apparatus by longitudinal movement of the first endless belt; and   curing the composite material to form a molded foam material.   
     
     
         15 . A method according to  claim 14 , wherein the first endless belt comprises an insert support feature. 
     
     
         16 . A method according to  claim 14 , wherein the first endless belt comprises a mold cavity for molding a discrete foam part. 
     
     
         17 . A method according to  claim 14 , wherein the continuous forming apparatus further comprises a first frame disposed to support the first plurality of cleats. 
     
     
         18 . A method of forming molded foam materials using a continuous forming apparatus comprising the steps of:
 providing a continuous forming apparatus comprising a first endless belt comprising an inner surface and an outer surface, a second endless belt comprising an inner surface and an outer surface, a first plurality of cleats and a second plurality of cleats opposed to the first plurality of cleats, wherein the first plurality of cleats supports the first endless belt in molding the foam material, a third endless belt and a fourth endless belt opposed to the third endless belt, wherein the third endless belt and the fourth endless belt are disposed substantially orthogonal to the first endless belt and the second endless belt, and a drive mechanism for imparting motion to the first endless belt, the second endless belt, the first plurality of cleats, the second plurality of cleats, the third endless belt, and the fourth endless belt;   introducing a composite material into a mold cavity defined at least in part by the inner surface of the first endless belt and the inner surface of the second endless belt;   moving the composite material through the continuous forming apparatus by longitudinal movement of the first endless belt and the second endless belt; and   curing the composite material to form a molded foam material.   
     
     
         19 . A method according to  claim 18 , wherein the continuous forming apparatus further comprises a first attachment chain connecting the first plurality of cleats together and a second attachment chain connecting the second plurality of cleats together. 
     
     
         20 . A method according to  claim 18 , wherein the continuous forming apparatus further comprises a third plurality of cleats and a fourth plurality of cleats that cooperate with the first plurality of cleats and the second plurality of cleats to mold the foam material, wherein the third endless belt is supported by the third plurality of cleats and the fourth endless belt is supported by the fourth plurality of cleats.