Continuous forming system utilizing up to six endless belts

Abstract

A system for providing shape and/or surface features to a moldable material includes, in an exemplary embodiment, at least two first opposed flat endless belts spaced apart a first distance, with each having an inner surface and an outer surface. The system also includes at least two second opposed flat endless belts disposed substantially orthogonal to the first two opposed endless belts and spaced apart a second distance. A mold cavity is defined at least in part by the inner surfaces of the at least two opposed flat endless belts. The system further includes a drive mechanism for imparting motion to at least two of the opposed flat endless belts.

1 . A system for providing shape, surface features, or both, to a moldable material, comprising:
 at least two opposed flat endless belts spaced apart a distance, each having an inner surface and an outer surface;   a mold cavity defined at least in part by the inner surfaces of the at least two opposed flat endless belts; and   a drive mechanism for imparting motion to the at least two opposed flat endless belts.   
     
     
         2 . The system of  claim 1 , further comprising two endless opposing profile mold belts, each adapted to fit within the mold cavity, and each having
 an inner surface adapted to shape, or mold surface features, or both, into a moldable material, and   an outer surface in contact with the inner surface of at least one of the at least two opposed flat endless belts.   
     
     
         3 . The system of  claim 1 , wherein the outer surface of at least one of the at least two opposed flat endless belts is supported by a rigid supporting surface. 
     
     
         4 . The system of  claim 3 , wherein the rigid supporting surface comprises a slider bed or platen. 
     
     
         5 . The system of  claim 3 , wherein the outer surface comprises a coating of a friction reducing substance. 
     
     
         6 . The system of  claim 5 , wherein the friction reducing substance comprises a fluoropolymer or ultra-high molecular weight polyethylene. 
     
     
         7 . The system of  claim 4 , further comprising an air-film lubrication system adapted to reduce friction between at least one of the at least two opposed flat endless belts and the rigid supporting surface. 
     
     
         8 . The system of  claim 7 , wherein the rigid supporting surface comprises a plurality of holes therein, in fluid communication with a plenum chamber located near the slider bed or platen, and wherein the holes and plenum chamber are adapted to provide pressurized air film lubrication between the flat endless belt and the rigid supporting surface. 
     
     
         9 . The system of  claim 1 , wherein the at least two opposed flat endless belts are adjustable such that the distance can be varied. 
     
     
         10 . The system of  claim 2 , wherein at least one of the profile mold belts comprises an elastomeric face layer adapted to contact the moldable material, and a reinforced backing layer adapted to contact the inner surface of one of the opposed flat endless belts. 
     
     
         11 . The system of  claim 2 , further comprising a plurality of a profile mold belt tensioners, adapted to maintain the profile mold belts in tension. 
     
     
         12 . The system of  claim 11 , wherein the profile mold belt tensioner comprises one or more pulleys disposed such that the profile mold belt encloses at least a portion of the drive mechanism. 
     
     
         13 . The system of  claim 2 , wherein the opposed flat endless belts and the profile mold belts are oriented substantially horizontally. 
     
     
         14 . A method of continuously forming a moldable material to have a desired shape or surface feature or both, comprising:
 introducing the moldable material into an end of a mold cavity formed at least in part by the inner surfaces of opposed flat belts;   exerting pressure on the moldable material through the opposed flat belts;   transferring the moldable material along the mold cavity by longitudinal movement of the opposed flat belts;   removing the molded material from the mold cavity after sufficient time has passed for the material to cure or harden into the molded configuration and thereby form molded material.   
     
     
         15 . The method of  claim 14 , wherein the mold cavity is at least partly defined by the inner surfaces of two opposed profiled mold belts disposed inside the opposed flat belts, and having outer surfaces in contact with the inner surfaces of the opposed flat belts. 
     
     
         16 . The method of  claim 14 , wherein the moldable material comprises a filled thermoset plastic. 
     
     
         17 . The method of  claim 14 , wherein the moldable material comprises a foamed or foaming material. 
     
     
         18 . The method of  claim 15 , wherein the profile mold belts form the moldable material into a shape having a cross-section at least approximately corresponding to that of the mold cavity. 
     
     
         19 . The method of  claim 15 , wherein the profile mold belts impart a surface pattern to the moldable material. 
     
     
         20 . A forming apparatus for forming a moldable material, said apparatus comprising:
 a first belt;   a second belt opposed to said first belt, said first and second belts spaced apart a distance, each of said first and second belts comprising an inner surface and an outer surface;   a mold cavity defined by said inner surfaces of said first and second belts; and   a belt drive mechanism operationally coupled to said first and second belts.