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 first linked chain belt connecting the first plurality of cleats together, and a second plurality of cleats opposed to the first plurality of cleats and a second linked chain belt connecting the second plurality of cleats together, wherein the first plurality of cleats comprise a three-dimensional abutment surface to provide transverse and lateral support to the first endless belt, a drive mechanism for imparting motion to the first endless belt, the first plurality of cleats wherein the drive mechanism for imparting motion to the first plurality of cleats uses at least one sprocket coupled to the first linked chain belt and the second plurality of cleats, wherein the drive mechanism for imparting motion to the second plurality of cleats uses at least one sprocket coupled to the second linked chain belt, supporting the first linked chain belt using a first rigid support surface; supporting the second linked chain belt using a second rigid support surface; and reducing frictional forces between the first linked chain belt and the first rigid support surface or the second linked chain belt and the second rigid support surface by coupling rollers to the first and second linked chain belts;   coupling rollers to the first or second linked chain belt to reduce frictional forces between the first or second linked chain belts   introducing a composite material into a mold cavity defined at least in part by the inner surface of the first endless belt, wherein the mold cavity is pressure resistant;   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 . (canceled) 
     
     
         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 the 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 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . (canceled) 
     
     
         17 . (canceled) 
     
     
         18 . A method according to  claim 3 , wherein the second plurality of cleats comprise a flat abutment surface to provide transverse and lateral support to the second endless belt. 
     
     
         19 . A method according to  claim 3 , wherein the first endless belt and second endless belt do not separate under the pressure of the foamed material during molding.