Continuous forming system utilizing up to six endless belts
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B29C-043/48
B29C-043/44
출원번호
US-0417385
(2006-05-04)
등록번호
US-7491351
(2009-02-17)
발명자
/ 주소
Taylor,Zachary
Brown,Wade H.
출원인 / 주소
Century Board USA LLC
대리인 / 주소
Knobbe, Martens, Olson & Bear, LLP
인용정보
피인용 횟수 :
14인용 특허 :
67
초록▼
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
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.
대표청구항▼
What is claimed is: 1. A system for providing shape, surface features, or both, to a moldable material, comprising: at least two opposed endless belts spaced apart a distance and attached to a first set of rollers, each having an inner surface and an outer surface relative to a mold cavity; at leas
What is claimed is: 1. A system for providing shape, surface features, or both, to a moldable material, comprising: at least two opposed endless belts spaced apart a distance and attached to a first set of rollers, each having an inner surface and an outer surface relative to a mold cavity; at least two endless opposing mold belts attached to a second set of rollers, each having an inner and an outer surface relative to the mold cavity, each mold belt being at least partially in contact with the inner surfaces of the at least two opposed endless belts; the mold cavity defined at least in part by the at least two opposed endless mold belts; each mold belt being generally symmetrical and substantially identically shaped with one another and opposing one another to form, at least in part, the mold cavity, each mold belt comprising a backing, the backing having at its ends a pair of integral shoulders, the shoulders being substantially thicker than the backing and abutting and compressed against the shoulders of the other opposed belt to form a cavity mating line to resist separation of the cavity due to internal pressure of the moldable material, a support surface, wherein the support surface is separate from the at least two endless belts and the at least two mold belts, wherein the support surface supports the shoulders, and wherein the support surface is configured to move with the at least two mold belts along substantially the length of the mold cavity; and a drive mechanism for imparting motion to the at least two opposed endless belts. 2. The system of claim 1, wherein the mold belts are adapted to shape, or mold surface features, or both, into a moldable material. 3. The system of claim 1, wherein each of the at least two endless opposing mold belts has a profile. 4. The system of claim 1, wherein the outer surface of at least one of the at least two opposed endless belts is supported by a rigid supporting surface. 5. The system of claim 1, wherein the at least two opposed endless belts comprise 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 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, and wherein the holes and plenum chamber are adapted to provide pressurized air film lubrication between the outer surface of the at least one of the at least two opposed endless belts and the rigid supporting surface. 9. The system of claim 1, wherein the at least two opposed endless belts are adjustable such that the distance can be varied. 10. The system of claim 1, wherein at least one of the mold belts comprises an elastomeric face layer adapted to contact a moldable material, and the backing is adapted to contact a surface of one of the opposed endless belts. 11. The system of claim 1, further comprising a plurality of mold belt tensioners, adapted to maintain the mold belts in tension. 12. The system of claim 11, wherein the plurality of mold belt tensioners comprises one or more pulleys disposed such that the mold belt encloses at least a portion of the drive mechanism. 13. The system of claim 1, wherein the opposed endless belts and the mold belts are oriented substantially horizontally. 14. The system of claim 1, wherein the at least two endless belts comprise flat conveyors. 15. The system of claim 1, wherein the backing is reinforced. 16. The system of claim 1, wherein the mold cavity is rectangular. 17. The system of claim 1, further comprising at least one side support, wherein the at least one side support is disposed adjacent to the mold cavity and cooperates with the support surface to support the shoulders of the at least two mold belts. 18. The system of claim 17, wherein the at least one side supports comprises compressed air. 19. The system of claim 18, wherein the at least one side support comprises an endless loop. 20. The system of claim 1, wherein the support surface comprises a belt. 21. A method of continuously forming a moldable material to have a desired shape or surface feature or both, comprising: providing at least two opposed mold belts in contact with a first set of returns, wherein the mold belts comprise shoulders on each side and a backing, wherein the shoulders of a first of the at least two opposed mold belts are configured to abut and compress against the shoulders of a second of the at least two opposed mold belts to form a mold mating line; providing at least two opposed support belts in contact with a second set of returns; contacting the at least two opposed mold belts with the at least two opposed support belts; forming a mold cavity by abutting and compressing the shoulders of the first mold belt against the shoulders of the second mold belt; providing a support surface configured to move with the mold belts along the length of the mold cavity; introducing the moldable material into an end of the mold cavity; transferring the moldable material along the mold cavity by longitudinal movement of the first mold belt and the second mold belt; applying pressure to the moldable material via the at least two opposed mold belts; applying pressure to the shoulders of the mold belts via the support surface; and removing a molded material from the mold cavity after sufficient time has passed for the moldable material to cure or harden into a molded configuration and thereby form the molded material. 22. The method of claim 21, further comprising supporting the at least two opposed support belts with a rigid supporting surface. 23. The method of claim 21, wherein the moldable material comprises a filled thermoset plastic. 24. The method of claim 21, wherein the moldable material comprises a foamed or foaming material. 25. The method of claim 21, wherein the at least two opposed mold belts form the moldable material into a shape having a cross-section at least approximately corresponding to that of the mold cavity. 26. The method of claim 21, wherein the at least two opposed mold belts impart a surface pattern to the moldable material. 27. The method of claim 21, wherein the molded material comprises a synthetic lumber, roofing tiles, molded trim profiles, or siding. 28. The method of claim 21, wherein the step of providing a support surface comprises the step of providing a side belt that is contactable with the mold belts along the mold cavity. 29. A forming apparatus for forming a moldable material, said apparatus comprising: a first belt attached to a first set of returns and comprising a rigid supporting surface; a second belt attached to a second set of returns and comprising a rigid supporting surface, the second belt being opposed to said first belt, said first and second belts spaced apart a distance; a first mold belt attached to a third set of returns, wherein the first mold belt is at least partially in contact with the first belt; a second mold belt attached to a fourth set of returns and opposed to the first mold belt, wherein the second mold belt is at least partially in contact with the second belt, and wherein each of the first and second mold belts comprises a backing and substantially symmetrical side shoulders; a mold cavity defined in part by the first and second mold belts, wherein the side shoulders of the first mold belt are contactable with the side shoulders of the second mold belt along the mold cavity to form a cavity mating line and resist separation of the cavity, and wherein the side shoulders provide lateral support for the mold cavity; a support surface, wherein the support surface provides lateral support for the mold cavity, and wherein the support surface is configured to move with the first mold belt and the second mold belt; and a belt drive mechanism. 30. The forming apparatus of claim 29, wherein each of said first and second mold belts comprises at least one of a profile, surface features, and texture that is molded into a moldable material. 31. The forming apparatus of claim 29, wherein each said rigid supporting surface comprises a friction reducing substance. 32. The forming apparatus of claim 31 wherein said friction reducing substance comprises at least one of a fluoropolymer and an ultra-high molecular weight polyethylene. 33. The forming apparatus of claim 29, wherein each said rigid support surface comprises a plurality of air passage openings in fluid communication with a pressurized air source. 34. The forming apparatus of claim 29, wherein each said mold belt comprises an elastomeric face layer for contacting the moldable material, and wherein the backing comprises a reinforced backing layer for contacting said first or said second belt. 35. The apparatus of claim 29, wherein the first belt and the second belt are configured to press the side shoulders of the mold belts together. 36. The apparatus of claim 29, wherein the support surface comprises an endless loop. 37. The apparatus of claim 29, wherein the belt drive mechanism is operationally coupled to the first belt and the second belt. 38. The apparatus of claim 29, wherein the belt drive mechanism is operationally coupled to the first mold belt and the second mold belt. 39. The apparatus of claim 29, wherein the first belt, the second belt, the first mold belt and the second mold belt are driven. 40. A continuous forming apparatus for forming a moldable material, said apparatus comprising: a pair of opposed closed loop conveyors spaced apart a distance and comprising a rigid supporting surface, the pair of opposed closed loop conveyors attached to a first set of returns; a pair of mold belts attached to a second set of returns and being at least partially in contact with the pair of opposed closed loop conveyors, wherein each of the mold belts comprises a backing and substantially identically shaped side walls, wherein the side walls are substantially thicker than the backing, and wherein at least a portion of the side walls of one mold belt are contactable along at least a portion of the side walls of another mold belt; a mold cavity at least partially defined by an area between the pair of mold belts and the side walls, wherein the side walls resist separation along the mold cavity; side belt supports, wherein the supports are configured to support the side walls and move with the mold belts; and a belt drive mechanism. 41. A continuous forming apparatus in accordance with claim 40 wherein the pair of mold belts comprises at least one of a mold profile, surface features, and texture. 42. The apparatus of claim 40, wherein the first set of returns is positioned internal to the second set of returns. 43. The apparatus of claim 40, wherein the pair of opposed closed loop conveyors are adjustable such that the distance can be varied. 44. The apparatus of claim 40, wherein at least one of the pair of mold belts comprises an elastomeric face layer adapted to contact the moldable material.
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