초록 ▼

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 p

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.

대표청구항 ▼

What is claimed is: 1. A method of forming molded materials, comprising the steps of: providing a continuous forming apparatus comprising: at least a first endless mold belt comprising an inner surface and a outer surface; a first endless support belt, the support belt comprising a plurality of rig

What is claimed is: 1. A method of forming molded materials, comprising the steps of: providing a continuous forming apparatus comprising: at least a first endless mold belt comprising an inner surface and a outer surface; a first endless support belt, the support belt comprising a plurality of rigid cleats, wherein the first plurality of cleats comprises an inner portion and an outer portion relative to a mold cavity, wherein each cleat of the first plurality of cleats comprises a three-dimensional abutment surface located on the inner portion of the cleat that is at least in partial contact with the outer surface of the first endless belt, wherein the abutment surface provides transverse and lateral support to the first endless belt; a second endless support belt comprising a plurality of rigid cleats; a first set of pulleys or sprockets, wherein the first endless belt travels around the first set of pulleys or sprockets; a second set of pulleys or sprockets, wherein at least a portion of the first plurality of cleats is at least partially disposed on the second set of pulleys or sprockets, wherein the first plurality of cleats travels around the second set of pulleys or sprockets; a third set of pulleys or sprockets, wherein the second plurality of cleats is at least partially disposed on the third set of pulleys or sprockets, and wherein the second plurality of cleats travels around the third set of pulleys or sprockets; and a drive mechanism configured to impart motion to at least the first endless belt; introducing a material into the mold cavity defined at least in part by the inner surface of the first endless belt; moving the material in a plane substantially parallel to the inner surface of the first endless belt; and curing the 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 material, wherein the second endless belt is supported by the second plurality of cleats. 4. A method according to claim 3, further comprising a third endless belt and a fourth endless belt that cooperate with the first endless belt and the second endless belt to mold the material. 5. 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. 6. A method according to claim 1, wherein the first endless belt of the continuous forming apparatus comprises an insert support feature. 7. A method according to claim 1, wherein the first endless belt comprises a mold cavity for molding a discrete foam part. 8. A method according to claim 1, wherein a lateral gap is disposed between each cleat of the first plurality of cleats. 9. 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 the material. 10. A method according to claim 1, wherein the first endless belt and the first plurality of cleats are supported by and travel around at least one common pulley or sprocket. 11. A method according to claim 1, wherein the first and second sets of pulleys or sprockets share at least one common pulley or sprocket. 12. A method according to claim 1, further comprising the step of providing heat to the mold cavity. 13. A method according to claim 12, wherein the step of providing heat to the mold cavity comprises heating the mold cavity via a heat lamp. 14. A method of continuously molding a foamed material, comprising the steps of: providing a pressure resistant, continuous mold cavity for containing the foamed material during molding, the mold cavity having an entrance and an exit, the entrance and the exit separated by a distance sufficient to permit molding; containing the material within the mold cavity using at least an upper mold belt and a lower mold belt; driving and supporting the upper mold belt with an upper conveyor belt and the lower mold belt with a lower conveyor belt, each conveyor belt being comprised of a series of cleats attached together by at least one linked chain belt; separating the upper and lower mold belts by a distance to form at least a portion of the mold cavity, the separation distance defining a mold cavity gap; adjusting the mold cavity gap to prevent binding of the conveyor belts and to adjust the pressure resistance of the mold cavity; driving the upper and lower conveyor belts using at least one sprocket coupled to the linked chain belt; supporting each of the upper and lower conveyor belts during at least a portion of the molding process using an upper rigid support surface and a lower rigid support surface, wherein the conveyor belts travel on the rigid support surfaces; and reducing frictional forces between the conveyor belts and the rigid support surfaces by use of rollers coupled to the linked chain belt; wherein the upper and lower mold belts do not separate under the pressure of the foamed material during molding. 15. A method according to claim 14, wherein at least one of the mold belts comprises a pair of integral shoulders adapted to form at least a portion of the mold cavity. 16. A method according to claim 14, wherein the rigid support surfaces comprise at least one rail. 17. A method according the claim 16, further comprising the step of guiding the conveyors along the rigid support surfaces by engaging at least some of the rollers with the at least one rail. 18. A method according to claim 14, further comprising the steps of mounting the upper rigid support surface on an upper frame element and the lower rigid support surface on a lower frame element, and wherein the step of adjusting the mold cavity gap comprises the step of adjusting at least one of the frame elements. 19. A method according to claim 14, wherein at least one of the upper and lower conveyor belts comprises a series of cleats comprising a three-dimensional abutment surface adapted to provide transverse and lateral support to at least one of the mold belts during at least a portion of the molding process. 20. A method for the continuous molding of a product, comprising: providing a continuous mold cavity comprising at least an upper mold belt and a lower mold belt, the mold cavity having an entrance and an exit; containing a material within the mold cavity using at least the mold belts; supporting the upper mold belt with an upper conveyor belt and the lower mold belt with a lower conveyor belt, each conveyor belt being comprised of a series of cleats attached together by an attachment chain; and supporting each of the upper and lower conveyor belts during at least a portion of the molding process using an upper rigid support surface and a lower rigid support surface, wherein the conveyor belts travel on the rigid support surfaces. 21. A method according to claim 20, wherein at least one of the mold belts comprises a pair of integral shoulders adapted to form at least a portion of the mold cavity. 22. A method according the claim 20, wherein at least one of the upper and lower conveyor belts comprises a series of cleats comprising a three-dimensional abutment surface adapted to provide transverse and lateral support to at least one of the mold belts during at least a portion of the molding process. 23. A method according to claim 20, wherein a lateral gap is disposed between each cleat in the series of cleats. 24. A method according to claim 20, wherein at least one of the upper and lower conveyor belts comprises a series of cleats comprising a flat abutment surface adapted to support at least one of the mold belts during at least a portion of the molding process.