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.

What is claimed is: 
     
         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 the transverse gap disposed between the first plurality of cleats and the second plurality of cleats is about 0.1 inches. 
     
     
         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 and a second 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 to provide transverse and lateral support to the endless belt, and the second plurality of cleats, 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.