Abstract: Continuous 3-D forming machine using upper and lower revolving endless, flexible, forming belts produces three-dimensional patterned products from heated thermoplastic material. The mold belts revolve synchronously in elongated oval paths around their respective carriages moving in opposed face-to-face relationship defining one or more travelling mold channels progressing from an entrance to an exit. Formable heated thermoplastic material feeds into the entrance, and attractive 3-D products proceed from the exit. Revolving mold surfaces are operated at least 25.degree. F. above room temperature, for example in a range of 110.degree. F. to 140.degree. F., for providing aesthetic surface qualities on products having content which may be foamed to densities in the range of about 0.9 to about 0.4. Thermoplastics in such travelling mold channels are appropriately chilled when differentials .DELTA.

Abstract: Continuous impression forming of three-dimensional products from heated, formable thermoplastic materials between top and bottom mold carriages each having a three-dimensional forming belt mold revolvable around the carriage. Each three-dimensional forming belt mold includes a flexible silicone rubber mold adhered to a multi-ply woven fabric belt. A surface of desired shape on one revolving rubber mold mates with the desired shape of an opposed revolving rubber mold forming a continuously moving mold channel between the mold belts into which is fed hot thermoplastic material at moldable temperature. After discharging molded plastic product from the exit of the moving mold channel, localized surface heat in the rubber molds resulting from contact with hot plastic is removed by air blown directly onto the rubber mold surfaces. Each carriage frame includes a back-up plate coated with low friction coefficient material over which slides a continuously moving belt mold.

Abstract: Continuous impression forming of three-dimensional products from heated, formable thermoplastic materials between top and bottom mold carriages each having a three-dimensional forming belt mold revolvable around the carriage. Each three-dimensional forming belt mold includes a flexible silicone rubber mold adhered to a multi-ply woven fabric belt. A surface of desired shape on one revolving rubber mold mates with the desired shape of an opposed revolving rubber mold forming a continuously moving mold channel between the mold belts into which is fed hot thermoplastic material at moldable temperature. After discharging molded plastic product from the exit of the moving mold channel, localized surface heat in the rubber molds resulting form contact with hot plastic is removed by air blown directly onto the rubber mold surfaces. Each carriage frame includes a back-up plate coated with low friction coefficient material over which slides a continuously moving belt mold.

Abstract: Continuous process and apparatus form products from thermoplastic materials between top and bottom mold carriages. A flexible silicone rubber mold on a fiber belt continuously moves around each carriage frame. A surface of desired shape on one rubber mold mates with the desired shape of an opposed rubber mold forming a continuously moving mold channel into which is fed hot thermoplastic material at moldable temperature. After discharging the molded plastic product from the moving mold channel, localized surface heat in the molds resulting from contact with hot plastic is removed from the belt molds by air blown onto mold surfaces. Each carriage frame includes a back-up plate coated with low friction coefficient material over which slides a continuously moving belt mold. These slippery plates have numerous air-bearing holes feeding high pressure air between them and the respective moving fiber belt for reducing friction and wear.

Abstract: Continuous process and apparatus form products from thermoplastic materials between top and bottom mold carriages. A flexible silicone rubber mold adhered to a fiber belt continuously moves around each carriage frame. A surface of desired shape on one rubber mold mates with the desired shape of an opposed rubber mold surface forming a continuously moving mold channel into which is fed hot thermoplastic material at moldable temperature. After discharging the molded plastic product from the moving mold channel, localized surface heat in the molds resulting from contact with hot plastic is removed from the belt molds by blowing cold air onto mold surfaces. Each carriage frame includes a back-up plate coated with low friction coefficient material over which slides a continuously moving belt mold. These slippery plates have numerous air-bearing holes feeding high pressure air between them and the respective moving fiber belt for reducing friction and wear.

Abstract: A continuous process and apparatus are disclosed for forming products from thermoplastic polymeric material having three-dimentional patterns and surface textures on one or both faces that may be similar or dissimilar with or without a continuously changing profile and with or without shaped edges, such as shake shingle panels, board and batten panels, rough barn board panels, wainscoting panels, brick panels, stone panels, patterned door panels, similar structural wall panels, roofing or siding panels, ribbed soffits, fascia board, flooring reinforced with egg crate ribs, forms for pouring contoured concrete structures, and other three-dimensional pattern and surface textured plastic products which may extend in widths up to 4 feet or more and in lengths up to 20 feet or more.

Abstract: An improved method is described for varying the profile as seen in cross section of an elongated extrudate article. The method provides for varying the profile of an extrusion orifice while an extrudate stock material is being forced through the orifice. An elongated extruded article is formed having a varying profile conforming to the variations in the profile of the extrusion orifice.

Abstract: An improved method and apparatus is described for varying the profile as seen in cross section of an elongated extrudate article. The method and apparatus provides for varying the profile of an extrusion orifice while an extrudate stock material is being forced through the orifice. An elongated extruded article is formed having a varying profile conforming to the variations in the profile of the extrusion orifice.

Abstract: Continuous apparatus for impression molding products containing thermoplastic material and having three-dimensional patterns on one or both surfaces, similar or dissimilar, with or without continuously changing profile or shaped edges. The thermoplastic material to be formed may or not contain foamants, fillers, strata or plys of differing composition to reinforce, decorate or protect, and is heated above its glass transition temperature before introduction between revolving flexible belt molds, which revolve in opposed relationship, being cooled, forming a travelling mold channel, at least one having a flexible three-dimensional pattern form on its front face. Opposed nip rolls press the revolving belt molds against the entering thermoplastic material. At least one belt mold travels partially around the nip roll impressing its three-dimensional pattern form in the heated material in a progressive localized rolling squeezing action in the nip region.