US 10,889,035 B2
Method for molding three-dimensional foam products using a continuous forming apparatus
Zachary R. Taylor, Murrieta, CA (US)
Assigned to CENTURY-BOARD CORPORATION, Moorseville, NC (US)
Filed by Century-Board Corporation, Mooresville, NC (US)
Filed on Aug. 28, 2018, as Appl. No. 16/115,360.
Application 16/115,360 is a continuation of application No. 15/424,397, filed on Feb. 3, 2017, granted, now 10,086,542.
Application 15/424,397 is a continuation of application No. 15/213,275, filed on Jul. 18, 2016, abandoned.
Application 15/213,275 is a continuation of application No. 14/967,052, filed on Dec. 11, 2015, abandoned.
Application 14/967,052 is a continuation of application No. 14/180,630, filed on Feb. 14, 2014, abandoned.
Application 14/180,630 is a continuation of application No. 13/681,222, filed on Nov. 19, 2012, abandoned.
Application 13/681,222 is a continuation of application No. 13/366,136, filed on Feb. 3, 2012, abandoned.
Application 13/366,136 is a continuation of application No. 12/692,241, filed on Jan. 22, 2010, abandoned.
Application 12/692,241 is a continuation of application No. 11/593,316, filed on Nov. 6, 2006, granted, now 7,651,645, issued on Jan. 26, 2010.
Application 11/593,316 is a continuation of application No. 11/165,071, filed on Jun. 23, 2005, granted, now 7,316,559, issued on Jan. 8, 2008.
Claims priority of provisional application 60/582,420, filed on Jun. 24, 2004.
Prior Publication US 2019/0054670 A1, Feb. 21, 2019
This patent is subject to a terminal disclaimer.
Int. Cl. B29C 44/30 (2006.01); B29C 39/16 (2006.01); B29C 35/02 (2006.01); B29C 44/58 (2006.01); B29C 37/00 (2006.01); B29L 7/00 (2006.01); B29K 105/04 (2006.01)
CPC B29C 44/306 (2013.01) [B29C 35/0277 (2013.01); B29C 37/0075 (2013.01); B29C 39/16 (2013.01); B29C 44/585 (2013.01); B29K 2105/04 (2013.01); B29L 2007/002 (2013.01)] 14 Claims
OG exemplary drawing
 
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 second 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 support to the first endless belt, wherein the second plurality of cleats comprise a three-dimensional abutment surface to provide support to the second endless belt, and wherein the cleats are positioned with a transverse gap of about 0.1 inches between the first plurality of cleats and the second plurality of cleats, a first support surface supporting the first plurality of cleats, a second support surface supporting a 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;
introducing a composite material into a mold cavity defined at least in part by the inner surface of the first endless belt and the inner surface of the second endless belt;
moving the composite material in a plane substantially parallel to the inner surface of the first endless belt and the inner surface of the second endless belt; and
curing the composite material to form a molded foam material.