METHOD FOR MOLDING THREE-DIMENSIONAL FOAM PRODUCTS USING A CONTINUOUS FORMING APPARATUS
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 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.