Patent ID: 6709616
Filing Date: 2004-03-23
Classification: B29C

Abstract:
A method for forming an extended strip having a thickness of greater than approximately one-eighth of an inch and a non-constant cross-section, the method comprising:providing a molten molding material to a single rotating shaping wheel that includes a molding template having features thereon suitable for forming desired features in the molding material, wherein at least a portion of said molding template comprises a die that is distinct and separate from the single rotating shaping wheel, and wherein at least a portion of the molding template is oriented about the single rotating shaping wheel such that each molding template feature comprises a substantially constant cross-section along an axis extending from the center of the rotating shaping wheel through the feature, and wherein a substantial portion of the molding template features comprise at least one side profile that is exposed, thereby forming an extended strip having a thickness of greater than approximately one-eighth of an inch and a non-constant cross section comprising discrete shapes connected to a web via interconnects having widths smaller than the widths of their respective discrete shapes; flattening the molten material within the shaping wheel as the shaping wheel rotates; and removing the flattened extended strip having a thickness of greater than approximately one-eighth of an inch and a non-constant cross section from the shaping wheel.