p. 1



# OAR Box 1413 Prepped by Ollie Stewart



## Document

Number: 

# 53 ) 11-1-5 3

Docket Number: 

# A-94-5 2

Printed 7/9/2008 3:11:22 PM

Sheet 53 of 114P. 2 

# United State s Paten

tm Rodger s US005372493 A 

## [li ] Paten tNumber : [45 ] Date o f

Patent : . 5,372,49 3

De c 13,199 4 [54 ] CONTINUOU S CASTIN G APPARATU S USIN G TW

O MOVIN G BELT S [76 ] Inventor : • Gar

y C . Rodgers, 64

7 Laurentia

n Avenue , Nort

h Bay , Ontario , P1 B 7T8 , Canad

a [21 ] AppLNo. : 62^2 4 [22 ] Filed : Ma

y 13,199 3

[51 ] In tCL < •••••••••*»•*_•••••••*••••••«•*••••••••••*.••••• • B29 C 43/2 2 [52 ] VS. O. . 425/188 ; 425/193 ;

425/223 ; 425/224 ; 425/371 ; 425/378.1 ;

425/388 ; 100/151 ; 100/15 2 [58 ] Fiel d o f Searc h425/223,224 , 371 , 372 , 425/378.1,388,85,193,188 , DIG . 60 * 100/151 , 152,154 , 15 3 [56 ] Reference s Cite d U.S . PATEN T DOCUMENT S 4.406,85 0 4,420,35 9 4,541,88 9 4,714,01 5 4,826,56 0 4,839,12 5 5,042,37 2 5,185,11 5 5,244,61 8 9/198 3 12/198 3 9/198 5 12/198 7 5/198 9 6/198 9 8/199 1 2/199 3 5/199 3 Ml

k Goldsworth

y . Held.. - Stabler . Held.. . Id a Bielfddteta

L Thol e ..... . . Kemereretal . -. . 264/17 1

— 100/15 1

„ . 156/583. 5 ,.-. . 100/15 4

— 156/49 8 264/21 6 425/37 1

— 425/37 1

— 425/37 1 Primary Examiner— Khanh Nguye n Attorney, Agent, orFirm-— David P . Gordo n [57 ] ABSTRAC T

2,866,73 0 12/195 8 3,193,88 8 7/196 5 3,376,37 1 4/196 8 3,422,17 8 1/196 9 3,487,14 3 12/196 9 3,620,15 8 11/197 1 3,622,39 3 11/197 1 3,708,56 6 1/197 3 3,745,84 6 7/197 3 3.764.24 7 10/197 3 3,792^5 3 2/197 4 3,904,33 6 9/197 5 4,004,87 0 1/197 7 4,008.02 4 2/197 7 4,311,55 0 1/198 2 4,334.46 8 6/198 2 Potchc n e ta L -_ . Rocheste r Ope l e ta L .....—. . Junke r e ta

L .___ . Bergwal l

________

— Torellieta L — Sherwoo d -~~-.. Junke r eta L —. . Birc_t___e___

i Oanetteta L — Ahrwefle r __._

. Axereta L ..__ . Guttmge r e ta

L — Yokotaeta L — Kerttnl a Guttiage r e ta

L

_ 154/10 0

425/37 1

. 264/21 6

264/21 6 264/21 6 100/15 4 136/14 8 264/17 1 425/22 3 425/37 1

_425/37 1

425/37 1 425/22 4 425/37 1 425/37 1 100/9 3 R P A apparatu

s fo r continuousl

y casting a liquid thermose t resin o r compositio n i n whic h a liquid thermosetresin o r composition i s fed into a spac e define d betwee n a pair o f moving endles s belt

s arrange d such tha

tth e lowe r ru n ofth e uppe

r bel ti s dispose

d abov e th e uppe

r ru n o f th e lowe r belt ; th e adjacen trun s ofth e belt

s ar e move d concurrentl

y wit h each other a

tsubstantiall

y th e same speed an d a firstfluid containe

r i s provided abov e th e uppe r beltwith it s lowe r surfac e i n contac twid i th e lowe r m n ofth e uppe

r bel tA secon d fluid containe r i s provided belo w th e lowe r bel twit h it s uppe r surfac e i n contactwit h th e upper ru

n o f th e lowe r bel tTh e fluid i n th e first fluid container i s maintaine d a ta firstdesired temperatur

e an d th e fluid i n th e secon d fluid containe r i s maintaine

d ata secon d desire

d temperature . Th e lowe r m n ofth e uppe

r bel ti s maintaine

d i n contactwith th e lowe r surfac

e o f th e first fluid container whereb y th e lowe r ru

n o f th e uppe r bel ti s hel d u

p widiou tan

y substantia l sag . 8 Claims , 3 Drawin

g Sheete

_P. 3 

# U.S . Paten

t De c 13,199 4 Shee t1 o f 3 5,372,49 3



# 1 2 2 4



# JP. 4 

# U.S . Paten

t De c 13,199 4 Shee t2 o f 3 

# 5,372,49

3



# SP. 5 

# U.S . Paten

t De c 13,199 4 Shee t3 o f 3 

# 5,372,49

3

12 . 2 8 7 0 7 4



# VP. 6 

## 5,372,493 1 2 example s cite d i n thi s patenti tappears t o produc e th e CONTINUOU S CASTIN G APPARATU S USIN G produc ta ta rat e o f from 0.11 4 t o 0.21 6 meter s pe r TW O MOVIN G BELT S minute . Th e longe r syste m describe d i n U.S . Pa tNo . 4,046.85 0 give s example s o f speed s o f 0.21 7 t o 0.62 4 FIEL D O F TH E INVENTIO N 5 meter s pe r minute . Th e longes tsyste m describe d i n U.S . Thi s inventio n relate s t o a proces s an d apparatus fo r ** • No . 3,376,37 1 give s abd tspee d o f 0.91 4 meter s pe r continuousl y castin g a liqui d diermose tres m o r compo - minute , sition , suc h a s a thermose tplastic , int o a fnish H shape . 1 ° th e above-mentione d prio r system s i twil l b e see n Th e ter m "resin " wil l b e understoo d t o mea n a liqui d tha ta n appropriate length o f tim e i s require d fo r th e polyme r withou tan y filler adde d t o i tTh e term "com - 1 0 

### adequat e transfe r o f

heatfiom th e hea tsourc e t o th e position " wil l b e understoo d t o mea n a blen d o f liqui d produc tbein g forme d o r produce d t o effec tpolymeri polyme r an d som e typ e o f

filler anywher e fiom fibre- zatio n a s desired . Th e method s used t o achiev e thi s hav e glas s t o clay s o r an y organi c o r inorgani c material tha tbee n eithe r runnin g a shortsyste m slowl y o r providin g coul d b e adde d fo r whateve r reason . Th e describe d a longe r mor e complicate d syste m runnin g a ta faster proces s an d apparatu s may b e use d t o produc e eithe r 1 5 

### speed . Thi s increase s th e critica l dimension s o f th e unfille d produc tmad e from resi n o r a produc ttha ti s formin g are a o f th e system . Furthermor e th e produc t mad e fiom a compositio n o f inorgani c o r organi c fil- bein g forme d ha s t o reach sufficien tstrength befor e i t ler(s ) an d resin . ca n tolerat e th e remova l fiom th e surface s whic h defin e Th e unsaturated cross-linkin g monomer s use d i n th e di e produc tshape , du e t o th e nature o f th e belt s re composition s o f

thi s inventio n ar e th e compound s con - 2 ° quire d for thes e system s an d thei r poo r natura

l releas e ventionall y use d for du s purpose , fo r example , styrene ; properties . Thi s als o dictate s th e spee d and/o r lengd i o f alpha-methyl styrene ; 2^-dimethy l styrene ; 2,5 - th e bel tforming section . dimethy l styrene ; 2,4-dimediy l styrene ; alpha-chlor o Th e us e ofth e cavit y forme d betwee n di e meta l belts , styrene ; alpha-ethy l styrene ; methy l propy l styren** ; ^ whateve r means , a s a hea texchange r i s believe d t o p-ethy l styrene ; b*rom<wytrene ; dicbloro-styrene ; iso - » ^ m 

### ^gggj ^ metho d whe o 

### tim e i s a fector. Thi

s propeny l toluene ; viny

l naphthalenes ; tte «>

, m - an d inefficienc

y become s magnifie d th e thicke r th e crossp-chlor^jan

d brom^styrenes

- ester s o f »!?•*-««% - sectio

n o f th e par ttha ti s bein g formed . The cavit

y 1 

### ^ , ( 

### f b 

### Si, a , 

### ^,!^ l l 

### !!^ y l 

### "Sf^jS S formedbythebdtstodefinetheproductbeingfonne d ""f t^ffilS ^ iS^,"" 3 

### * ? **?? « i $ bes tsite d fo r tha tpurpos e alon e anTdrformit

y ^^^^J^^^r^^ . tli^ f shoul d b e avoidST L a

s possible . Effid S methacrylate ; ethy

l methacrylate ; methy

l ethacrylate ; o f



### ^ odwA to 

### " » heate d surfece 

### ' acrylonitrile ; methacrylonitrile ; viny l ester s suc h a s SUMMAR Y O F TH E INVENTIO N viny l acetat e viny l propionate ; viny l butyrate ; viny l 3 5 _..__ . laurat-nv M stearati aidvhiy l chloro-acetate ; viny l Accordin g to on e aspec to f th e presen tinventio n ethers suc h a s viny l methv l ether ; viny l isobuty l ether ; ther e i s provide d a proces s fo r continuousl y castin g a viny l 2-chlor o ethy l ethe r an d viny l stearjr l ether ; viny l &?** thermose tresm o r cjmpoato n whic h comprases ketone s suc h a s a viny l methy l ketone ; viny l hepty i th e step s o f feedin g sai d hqm d thermose tcompositio n keton e an d methy l isopropeny i ketone ; olefin s suc h a s 4 0 iaSo 

### a spac e define d betwee n a pai r o f movin g endles s isobutylene ; vinyliden e halide s suc h a s vinyliden e chlo - ^t * arrange d suc h tha tth e lowe r ru n ofth e uppe r bel t rid e an d vinyliden e fluoride; N-viny l compound s suc h i s 

### dispose d abov e th e uppe r ru n o f di e lowe r belt ; caus a s N-vinylpyrrolc ; N-viny l carbazole ; N-viny l indol e i° S th e run s t o mov e concurrentl y wid i eac h othe r a t and N-viny l succinimide ; acrylamide , ethacrylamide , substantiall y th e sam e speed ; providin g a firstfluid con N-methylolacrylamide ; ally l compound s suc h a s dially l 4 5 taine r abov e 

### sai d uppe r bel twit h it s lowe r surfac e i n phthalate ; ally l alcohol ; ally l acetate ; ally l methacrylate ; contac twit h th e lowe r ru n o f sai d uppe r belt ; providin g dially l carbonate ; ally l lactate ; dially l moltmntt- diaDy i a secon d fluid containe r belo w sai d lowe r bd twit h it s g\prm»tfa.AiMy]»f.ipi,tta. ^intlyisebactte;di__Hyt<»ifn_. - upper-snrfi-ce-in-contact - wit h th e uppe r ru n o f sai d conate ; di e dially l este r o f

muconi c acid ; dially l hacon - lowe r bdt ; maintainin g th e fluid i n sai d firstfluid con ate ; dially l chlorophthalate ; trially l citrat e trfaiiyi cyan - 5 0 tame r a ta firstdesire d temperature ; maintainin g th e urate ; trafly l phosphat e trimethally l phosphat e an d SsM i n sai d secon d fluid containe r a ta secon d desire d tetraally l silicate . temperature ; an d mamtainin g th e lowe r ru n o f sai d uppe r bd ti n contac twit h di e lowe r surfac e o f sai d first BACKGROUN D O F THE INVENTIO N fi__container . Previousl y propose d continuou s cas tsystem s use d i n 5 5 Accordin g t o anothe r aspec to f th e inventio n ther e i s resin system s dia tpolymeriz e hav e a sectio n o f th e provide d a n apparatu s fo r continuousl y castin g a liqui d former tha tintroduce s heatt o th e product , an d a se » thermose tresin o r compositio n whic h comprise s a pai r tio n o f th e former th&

tcarrie s ou tth e pos tcur e process . o f movin g endles s belt s definin g a spac e therebetwee n Thi s generaUy makes fo r a lon g syste m tha trequire s a for sai d Uqui d thermose tcompositio n an d arrange d suc h larg e amoun to f

critica l contro l area . I n U.S . Pa tN a 6 0 dia tdi e lowe r ran o f

di e tippe r bd ti s dispose d abov e 3,376^7 1 (issue d Apr . 2,1968-Op d e tal ) th e apparatus th e uppe r ru n o f th e lowe r bdt ; sai d runs , i n use , bein g i s 50. 3 meter s lon g an d i n U.S . Pa tNo . 4,046,85 0 (issue d cause d t o mov e concurrentl y wit h eac h othe r a tsub Sep . 6 , 1977-Kat

o e tal ) th e apparatu s i s 1 5 meter s i n stantiaD y th e sam e speed ; a first fluid containe r abov e length . Othe r system s tha tare shorte r operat e a tsuc h a sai d uppe r bd twit h it s lowe r surfac e i n contac twit h di e slo w spee d dia tdiei r commercial us e i n th e productio n 6 5 lowe r ru n o f

sai d uppe r bdt ; a secon d fluid containe r o f thi s typ e o f

produc ti s questionable . A n exampl e i s bdo w sai d lowe r bd twit h its uppe r surfac e i n contac t U.S . Pa tNo . 3,422,17 8 (issue d Jan . 14 , 1969-Junker e twit h th e uppe r ru n o f sai d lowe r bdt ; mean s fo r main d ) whic h ha s a lengt h o f

3.6 5 meter s an

d referrin g t o th e tainin g th e fluid i n sai d firstfluid containe r a ta desire d 

# SP. 7 

## 5,372,493 3 i 4 temperature ; mean

s fo r maintainin

g th e fluid i n said circulate s heate d wate r througi

h platen contame

r unit s secon d fluid container ata secon d desired temperature ; 1 2 an d 1 8 t o creat

e a temperatur

e whic h i s substantiall

y an d mean s fo r maintainin

g th e lowe r ru

n o f sai d uppe

r equa l t o di e temperatur

e o f th e pre-heated compositio n bd ti n contactwit

h di e lowe r surfac

e o f said first fluid 1 0 a s i tenter s th e space betwee n th e bdts . Thus very container . 5 littl e hea ti s los tint

o th e platen . **«*»* - m r.«TMrr»T»«. , « „ —, m -_ „ . nrn .,_-, « A s shown i n FIG . 1 , th e bdt s 2 an d 4 ar e incline d a

t BRIE F DESCRIPTIO N O F TH E DRAWING S anangleo f abou t1 5 degree s t o th e horizont d an d th e Embodiment

s o f th e presen

tinventio n wil l no w b e resin composition i s hd d i n a batc h mixing holdin g tan

k described , b y wa y o f

example , wit

h reference t o th e unit4 0 an d i s fed t o th e dispense r uni t8 b y a metering accompanying drawings , i n which : 1 0 pum p uni t4 2 which measures th e resin composition an d FIG . 1 i s a diagrammati

c representation o f

apparatu s th e catalys tfor adding later , accordin g t o on e embodimen tofth e presen

tinvention , Afte r emergin g fro m betwee n th e uppe

r an d lowe r FIG . 2 show s par

to f th e apparatu

s o f FIG . 1 i n bdt s 2 an d 4 a tdi e poin to f

egres s 44 , di e produc

t1 0 greate r detail , an

d travel s alon g a horizonta

l movin g endles s conveye r bd t FIG . 3 i s a cross-sectiona

l vie w o f par tofth e appara

- 1 5 4 6 havin g been transforme d int o a formed sheet48 . tu s accordin g t o a secon d embodimen to f di e invention . A sa w uni t5 0 i s provide d abov e th e bd t4 6 t o cu tth e Th e sam e reference numeral

s ar e applied t o lik e part

s formed shee

t4 8 into desire d lengths , i n all th e figures. Th e powe r for drivin g th e uppe r an d lowe r bdt s 2 nBcronmn u /-_

» TOT S _,_.__,

! imm . an( * * i s obtaine d firom a synchronou s drive uni t52 . A DESCRIPTIO N O F THEFREFERRE D M foithe[ synchronou s drfye uni t5 4 i s als o provided for EMBODIMENT S ^ 1<Jwe r^44^, 1 for^ horizonta l conveyo r bd t46 . Referrin g t o th e figures, a pai

r o f movin g endles s I n FIG . 2 , a hea d pulle y 5 6 an

d a tail pulley 5 8 fo r th e bdt s 2 an d 4 define s a spac e 6 betwee n them . Th e bdt s uppe r bd t2 ar e show n i n greate r detai

L A bdttensione r may , fo r example , b e fabric bdts . A dispenser unit8 unh 6 0 i s provide d in associatio n with th e tai l pulle y 58 . (FIG . 2 ) feed s a quantit

y o f liquid thermose

tresi n o r 2

5 A correspondin

g hea d pulle y 6 2 and tail pulley 6 4 with compositio n 1 0 ata controlle d rat e o n t o th e upper ru

n a tenaone r uni

t6 6 ar e provide d fo r th e lowe r bd t4 . th e lowe r bd t4 ahea

d o f th e spac e 6 betwee n di e tw o Th e sa w un h 5 0 indude s a highl y polished chrome bdt s 2 an d 4 . ste d rod o r tube o n whic h on e sid e o f a sa w bridg e i s A plate n un h 1 2 i s provide d above th e lowe r ru n o f supporte

d an d along whic h i tca n trave l Th e sa w i s th e upper bd t2 an

d i s constructed as a hollo w vess d 3 0 mounte d o n a travers e threaded scre w mechanis m an d a havin g a flatexterna

l surfac e toward s th e bd t2 and hydrauli c drive moto r i s provide d fo r th e saw . I n its res t fluid inle tan

d oude tport

s 1 4 an d 16 . A correspondin g positio n di e sa w i s raise d u p an d adjustabl

e fee tar e platen un h 1 8 i s provide d belo w th e upper ru n o f th e provide d t o penni tsdectio n o f a n appropriat

e cuttin g lowe r bd t4 an

d i s constructe d a

s a hollo w vess d hav - dept h dependen

to n di e thicknes s o f

th e forme

d shee t in g a flatexterna

l surfac e toward s th e bd t4 an d fluid 3 5 48 . Th e sa

w o r slitte r i s subjectt o friction advancemen t inletan d oude tport

s 2 0 and 22 . alon g wit h shee t4 8 as th e slitte r move s transversd y o f A s can b e seen more dearl y i n FIGS . 2 an d 3 a vac - th e shee t uu m plenu m un h 2 4 i s locate d abov e th e platen uni t1 2 A cantilever arrangemen ti s provided ' for th e uppe r an d i s connecte d t o groove s 2 6 i n said flatexterna l platen uni

t1 2 and, referrin

g t o FIG . 3 i twil l b e see n t o surfac e o f plate n unit1 2 b y wa y o f

pipe s o r tube s 2 8 4

0 indud e a lowe r suppor

tmembe r 68 , a n uppe r suppor t passing throug

h th e platen uni

t12 . Th e groove s 2 6 ma

y membe

r 7 0 wit h a n intermediat

e lif tcylinde r 72 . Gaug

e b e herringbon

e o r chevron-shaped an

d hole s drille d clamp s 7 4 an d 7 6 ar e als o show n i n FIG . 3 a s wd l a s throug h th e plate

n 1 2 interconnectdi e tubes an d th e gaug e blocks 78 an d 80 . Th e cantileve r arrangemen t respectiv e groov e o r groove s ma y b e oriente d i n such a facilitates remova l and/o r replacemento f

th e bdt s an

d way a s t o pul l wrinkles ou tt o th e edg e o f di e bd t4

5 i n th e raise

d positio n th e upper platen unit1 2 i s hd d in Th e embodimen

tshow n i n FIG . 3 i s simila r t o tha ti n positio n b y mean

s o f a hoo k arrangement

. T o change a FIGS . 1 an

d 2 excep tdi e platen unit

s 1 2 an d 1 8 ar e no tbd tassociate

d cylinders ar

e retracted , di e bd tthen constructed as large tank s o r container

s fo r water , o r become s loos e an d ca n b e sli d off

. A differen

tsiz e ca n othe r heatin g fluid , bu tar e constructed from tw o layer s b e puto n i f one want s t o chang e th e dimensions—fo r o f aluminu m plat e fo r th e plate

n wit h channel s 3 0 50 example , t o produc e a wide r o r a thinne

r produc t withi n th e meta

l t o for m a cavit y for di e wate r t o circu - In operation, th e proces s i s started b y th e loadin g o f lat e therein . Th e channel s 3 0 ar e forme d b y groovin g th e batc h mixin g tan k un h 4 0 wit h u p t o 112

5 kg s o f ou ton e ofth e plates , th e plate s bein g wdde d alon g thei r resin , an d addin g tinter s a s pe r batchin g instructions , edges . However , distortion ma y b e difficultt o avoi d so , Tmte r an d resi n ar e blende d togethe r whfle a vacuu m i s alternatively , a

n O-rin g sea l coul d b e used al l aroun d 5 5 draw n o n th e mixin

g tan k 40 . AT H filler i s metere d int o th e perimete

r wit h dampin g bolts fo r th e plates . th e tan k throug h a flush bal l valv e mounte d o n th e Th e lowe r bd t4 i s constructed with integrel sid e botto m o f the tan k directe d int o th e mixin g hea d o r dam s 32 . Thes e ma

y b e polyurethan

e preforme

d rectan- blades . 100

0 kg bag s o f filler ar e hun g from a frame gula r strip s bonde

d t o par to f di e bd t4 an

d the y ac ta s mounte

d o n digita l read-ou tscale s t o monitor flow rat e guid e strip s whid i hel p t o defin e di e widt h an d heigh t6

0 an d shut-of f poin tVacuum shoul d b e minimni n o f 20 " ofth e produc

twhic h i s nonnall y a forme d shee tThe y an

d preferre d t o b e 25" . Fee d rat

e ofth e filler shoul d b e trav d aroun

d with bd t4 . Alternativdy , th e strip s coul d 20-2 5 kgs/minute . Afte r al l filler i s loaded , vacuu m b e fed i n sepaxatd

y instea d o f bein g bonded t o th e bd tshoul d clim b t o 27 " an

d mixin g continue fo r 20-3 0 I n FIG . 1 a parti d vacuum/exhauste r unit3 4 i s pro - minutes . Temperatur e shoul d b e monitored a

tthi s stage , vide d t o maintai

n th e vacuu

m o r suctio n pressur

e o n th e 6 5 120 t o 12

5 degree s F . i s expected , lowe r ru n o f th e uppe r bd t2 to hol d i ti n contac twith Th e mi x a tthi s pointwil l hav e a viscosit y o f th e plate n uni t1 2 an d preventsag ofth e bd tA ho t14-1600 0 cps . A metering pum p i n th e tan

k uni t4 0 wil l wate r tan k 3 6 wit h a n associated circulatio n pum p 3 8 dra

w th e matri

x from di e botto m o f

th e tan k an d pum p

(,. 

# nP. 8 

## 5,372,493 5 6 i tthroug h a ho twate r hea

texchanger whic h wil l fur - Catalyzatio

n produce s a

n exothermic hea tgain . En ther rais e th e temperatur

e to 150-160 degrees F . Probes dosin g th e production an d curing section s wfll utiliz e wil l b e installed a

tsevera l point s o n th e materia

l sectio n di e hea

tto mnintam a controlle d temperatur e environ o f th e exchange r t o monito r th e correcthea tgradien tmen tHeatin di e curin g sectio n shoul d b e hd d aroun d gain . A controlle r wil l var y th e flow rat

e o f th e wate r as 5 180 degree s F . Th e ai r i n thi s are a wil l stratify , allowin g require d to mee tpredetermine

d values . Th e matri

x wi U th e produc

tto coo l as h reaches th e lowe r curing sec b e drculate d bad e int o di e batc h tan k 4 0 until th e dis - tion levds . Supplementar y hea twil l b e require

d t o charg e temperatur

e i s see n to b e stable a

trequire d vd - bring di e environmen ttemperatur

e up o n productio n ues . A tthi s point , di e discharg e from th e exchanger wil l lin e star tup . Exother

m can raise th e temperatur e ofth e b e connecte d to a stati c mixer. Catdys tlin e wil l b e 1 0 produc tto 25 0 degree s F . an

d wil l probabl

y b e abl e to connected an

d productio n lin e ca

n star tsupply mos to r al l ofth e hea tafte r star tup . I f required , Graph s and flow chart

s wil l hav e bee n produced coolin g ma y b e adde d t o lowe r level s o f

th e curing givin g th e resin and catdys tstar tse tpoint s a s expecte d section . t o b e require

d dependin g o n siz e o f

sheetbein g pro - A s describe d above , pre-heatin

g take s plac e in a sepa du<*« d Th e pum

p ha s infoitd y an

d independend

y vari - 1 5 ratd y designed hea

texchanger t o heatth e product able strok e length s as wd l as a

n infinitd y variable driv e prio r to introduction int o th e formin

g cavity . Th e ad speed . Stroke length s wil l b e adjuste d manually . Driv e vantages o f thi s appea

r to b e tha tth e heated productha

s spee d o f th e piston s ar

e inter-connected wit

h control s lowe r viscosit y an d wil l flow an

d fill di e cavity better , regulatin g th e variabl e driv e speed o f di e fonning sec - Sinc e heating o f th e produc

tha s alread y been carrie

d tion. A slowin g up o r a

n increas e i n speed ofth e form - 2 0 ou th i s read

y t o polymeriz e a

s soo n a s i ti s shape

d i n in g bdt s wi

U automatically adjus

tth e flow o f

matri x b y th e cavit

y thu s permittin

g a shorte r overal l lengt

h o f di e makin g th e required spee d changes to th e pump . system ; introduction o f th e catdys ta

tth e pointo f

dis Viscosit y o f th e matri x i s no w abou

t7-800 0 cp s an

d charge into th e formin g cavh y wil l produc e a substan flows quit e fredy. Thi s ensure

s a goo d fill o f

th e in - tiall y stres s free produc ti n cross-sectio n sinc e th e tem clined cavity bein g filled. Du e t o di e raise d temperatur

e 2 5 peratur e o f di e produc

ti s unifor m throughoutth e resinan d resi n design , gelatio n begin s i n 50-5 5 second s afte r ou s mixture . I n th e above-mentione d prio r ar tsystems , catalyzation . A t60-6 5 seconds , th e shap e o f th e matri x th e resinous mixtur

e i s pre-catdyze d an

d heate d i n th e i s permanen

tTh e discharg e o f

th e stati c mixe

r mus tb e fonnin g section . Th e produc ti n contactwit h th e heate d within a fe w fee to f

th e former opening . Producing J " surface s wil l begi n polymerization firstth e proces s an d productio n wif l mea n 3.5- 4 second s ofproductio n i n di e 3 0 th e related shrinkag

e no tbein g consistentan d eve n static mixer. Anothe r 3 second s wi B b e used up i n di e throug h th e cross-section . Th e greate r th e cross-sectio n lin e fiom th e en d oftii e stati c mixe r to th e actua

l desire d dimension , th e greater th e proble m whic h ma

y arise , discharg e poin ta tth e fee d end o f

th e former

. Bot h A furthe

r advantag

e ofth e instan

tdescribed syste

m fonning platen s ar

e temperatar

e controUe

d t o ensur

e appear

s to b e tha

tdi e design o f

di e heatin g for di e tba tther e wfll no tb e any hea

tlos s fiom th e heated 3

5 formin g sectio n are

a ca n b e simplifie

d to maintai

n a matrix . Th e ensures a mor

e unifor m cur e throug h th e proces s temperatur e rathe r tha n provid e th e proces s cros s sectio n o f

th e matri x an d a mor e predictabl e g d temperature, tim e throug h th e duration o f

di e production run . I n some prio r system s the lengt h o f tim e fo r th e prod A tth e desig n speed o f

6'pe r minute , th e matri

x wi U uc tto attain a desire d temperatur

e ca n resulti n fiUers o f b e dimenaon d formed an d stable i n m e first5 ' o f

di e 4 0 greater specifi c gravit y settlin g ou to f

th e resin . Th e formin g section . B y th e tw o minut e mark , an d poin to f instan

tdescribe d syste m reduces thi s proble

m du e t o th e discharge , th e materi d i s quit e flexible bn

tdimension - continu d movemento f th e produc

tthroug h th e hea t all y stabl e an d permanen tItals o releases very readil y exchanger an

d equipmen

tblending th e catdys tinto th e fro m th e Teflo n covere d formin g bdt s o r other self

- resinous syste

m whic h keep s th e partide s i n suspension , lubricatin g surfaces . Althoug h di e bdt s in th e formin g 4 5 Also , th e heate

d produc ti s ready t o polymeriz e as soo n sectio n ar e moving , the y ar

e motiodes s relative to eac h a s th e catdys ti s introduced providin g a gdatin g o f th e other an d di e productbein g cas twithi n di e cavit y de - resinous mixtur

e i n les s tha

n 1 mete r int o th e fonnin g fined b y th e bdts . BasicaUy , w e hav e on e continuousl

y seaio n an

d thu s aHowin g 1 ^ time fo r an

y s^aratin g o f moving mol d tha

tcome s togethe r aton e en d t o defin e th e particles from th e min . I twfl l b e appreciated tha

t th e shap e an d open s a

tdi e odie r end to release th e 5 0 di e heate

d les s viscou s mixtur

e ca n provid e th e advan producttag e o f highe r fiUer loading an

d bette r wettin g outo f A s th e productexit

s th e fonnin g section , a I S degre e th e partide s i n di e produc tprovidin g a bette r bond flexing i s required fo r th e produc tto b e take

n o n th e betwee n di e partide s an d resm. horizonta l conveyo r 4 6 (FIG . 1) . Thi s sectio n indude s I n th e syste m described with referenc e t o FIGS . 1, 2 th e cut-of f sa w o r slitte r 50 . Th e consistenc y o f fh e 5 5 an d 3 a formin

g lengt h o f 3 meter s ha s bee n demon produc tatthi s pointi s somewha tlik e chedda

r chees e strated atbel tspeed s from 1 t o 2. 4 meter s pe r minute , wit h a litd e more flexural an d body strength . Depend - I n th e abov e descriptio n th e liqui d thermose tresin in g o n th e actu d physic d propertie s o f th e produc

tcompositio n 1 0 i s fed direcdy o n t o th e lowe r bd t4 t o bein g produced , a circular slittin g blade wfl l cu tdead y provid e th e forme d shee t48 . Th e describe

d apparatu

s i s withou tan y "sa w dust" . I f

required, a very thin , fine 6 0 equaU y applicable fo r us e i n applying a resin coatin g o r toothe d o r abrasiv

e blad e coul d b e instaUed. Th e prod - a resi n compositio n t o a pre-forme d rigid o r semi-rigid ucti s quit e free from an

y stickines s a

tthi s poin tboard . Thi s woul d b e place d o n th e lowe r bd t4 befor e A s th e productmove s dong , i tactivates a sensor th e applicatio n o f th e liquid compositio n 1 0 (FIG . 2 ) located a ta pointtha

twfl l star tth e slitter uni

t50 , cut - an

d woul d the

n trav d betwee n th e tw o bdt s 2 an d 4 tin g th e produc

tto specified length . Afte r th e sUtte r ha s 6 5 where th e liqui

d wfll bond t o th e boar

d an d a mor e mad e it s cu ta roller rotating above wfl l lowe r an

d unifor

m thicknes s ca

n normall y b e obtaine

d whe n corn accelerat e th e productgivin g itsuffiden tvdodt y to pare

d t o on e previou s system wher e sanding machines , loa d i tont o th e loadin g til ttabl

e ofth e curing section . hav e t o b e use d t o produce a unifor

m thicknes s afte

r 

# 7P. 9 

## 5,372,49 3 

## 8

1 0 forming a secon d compositio n shee tseparatd y an d bondin g i tt o th e board . Th e bdt s 2 an d 4 i n FIG . 1 would , o f course , b e mor e horizonta l an d in-lin e wit h di e bd t46 . Th e produc twi n b e produce d continuousl y and ta chometer s ar e use d throughou tt o sens e th e driv e spee d an d will , fo r example , suppl y th e compositio n to di e forme r sectio n whereb y whe n on e get s th e required flow spee d thati s workin g wd l attha tspeed , i twfl l b e "locke d in" . I f

th e produc ti s a litd e to o sof tan adjust mentca n b e mad e t o slo w tha tsectio n dow n an d allo w a littl e mor e curin g time . Th e dispensin g wiU automati caU y adjus tAlso , to spee d u p productio n an adjustment ca n b e made . Th e plate s giv e shap e definitio n fo r di e i s produc tan d no tth e bdts . Previously , saggin g o f th e lowe r ru n o f

th e uppe r bd tdiminishe d o r distorte d th e siz e o f di e cavit y betwee n th e bdts . I n FIG . 1 di e wate r i n plate n units 1 2 an d 1 8 i s main taine d a tapproximatd y th e sam e temperatur e b y a com mo n ho twate r tan

k 36 . However , i f

differen ttempera tures are require d the n th e plate n unit s 1 2 an d 1 8 ca n b e connecte d t o separat

e ho twate r tank s an d no tinter connected . I twfl l als o b e understoo d tha ta coolin g fluid could , dternativdy , b e use d i f desired . Th e continuou s cas tsyste m accordin g to on e con structe d embodimentwa s designe d for continuou s productproductio n from pre-mixe d liqui d state t o indi vidu d sheet s induding : 1 . infinitd y adjustable productio n rate wit h sd f regu latin g produc tdispensin g rate ; 2 . automati c shee tcuttin g t o lengt h o n di e fly; 3 . automati c sel f

regulating materi d handlin g from shee tcutting , diroug h curin g station , an d ont o skid s a t35 curin g statio n discharg e point ; 4 . shee twidt h and shee tthicknes s change d wit h ex pecte d dow n tim e o f

1 5 t o 2 0 minutes ; 5 . shee tlengt h adjustabl e t o 12,10 , an d 8 foo tlength s from mai n contro l consol e sdecto r switch ; 4 0 6 . productio n rat

e o f 12. 5 to 1 8 sq . f tpe r minute , dependin g o n productwidth ; 7 . thre e standar

d thicknesses ; 2 0



### 2 5

3 0 

### L Apparatu s fo r continuousl y castin g a Uqui d ther mose tresi n o r compositio n t o produc e a forme d shee t whic h comprises : 0 ) a n uppe r movin g endles s bd tan d a lowe r movin g endles s bd tdefinin g a spac e therebetwee n fo r sd d Uqui d thermose tresi n o r compositio n an d eac h bd t havin g an d a lowe r ru n arranged suc h tha tth e lowe r ru n o f th e uppe r bd ti s dispose d abov e th e uppe r run o f

th e lowe r belt ; 0 0 sai d runs , i n use , bein g cause d to mov e concur rentl y wit h eac h othe r a tsubstantiaU y th e sam e speed ; (ui ) a first fluid containe r havin g a lowe r surfac e abov e sai d lowe r ru n o f

sd d uppe r bd twit h it s lowe r surfac e constitutin g a plate n i n contac twit h di e lowe r n m o f

sai d uppe r bd tsai d first fluid containe r havin g a n inle tan d an oude tport ; Qv ) a secon d fluid containe r havin g an uppe r surfac e belo w sd d uppe r run o f

sd d lowe r bd twit h it s uppe r surfac e constitutin g a plate n i n contac twit h th e uppe r ru

n o f sd d lowe r bd tsai d secon d fluid containe r havin g a n inle tand a n oude tport ; (v ) a ho tliqui d tank to suppl y pre-heate d Uquid to th e inle tpor to f

on e o f sai d fluid contamer s an d receive return Uqui

d from th e oude tpor to f

th e odie r o f sai d fluid containers , th e oude tpor to f sai d on e fluid containe r bein g connecte d t o th e inle tpor to f sd d othe r fluid container ; (vi ) groove s forme d i n th e extern d surfac e o f th e plate n o f sai d first fluid containe r towards sai d lowe r ru n o f

sd d uppe r bdt ; an d (vii ) a vacuu m plenu m uni tconnecte d to eac h o f sai d groove s to maintain a parti d vacuu m o r suctio n pressur e i n sd d groove s to hol d u p sai d lowe r ru n o f sd d uppe r bd twidiou tan y substanti d sag . 2 . Apparatu s accordin g to clai m 1 wherei n sd d vac uu m plenu m um ti s locate d abov e sd d first fluid con taine r an d i s connecte d t o sd d groove s b y tubular mem ber s passin g throug h sd d first fluid container . 3 . Apparatu s accordin g to clai m 1 wherei n sai d first and secon d container s eac h compris e tw p layer s o f meta l plat e connecte d togethe r wit h fluid channel s therewithin . 4 . Apparatu s accordin g t o clai m 1 wherei n integra l 8 . produc e soh d colours , "granite " look , an d easil y adaptabl e t o "marble " loo k product ; 4 5 sid e daaa 

### " * provide d o n sd d lowe r bd tt o defin e th e 9 . machin e easil y modifie d t o produc e custo m lengdi s widt h an d hdgh to f Mid forme d shee t othe r tha n industr

y standards ; 5 . Apparatu s accordin g t o clannlmdudm g a cantile 

## i^iiufft^-ts~emm^i^m--mmm v « ar^emra t for ^^ ^ lLp^uctio n lin e operate d b y on e operato r and on e 5 0 

### %g£££,?* ^ ^ "" ^ uA/a rCplaCe 

### " 6 . Apparatu s accordin g to clai m 1 wherei n sai d pai r o f endles s bdt s i s a ta

n acut e angl e to th e horizonta l an d materi d handling ; 1 1 PL C control ; 13 . clos e dimension d tolerances ; an d 14 . manufactured to "hazardou s locations " standards . I twfl l b e readil y apparen tt o a perso n skille d i n th e 5 5 ar ttha ta numbe r o f

variation s an d modification s ca n b e mad e withou tdeparting from th e tru e spiri to f di e in ventio n whic h wfll no w b e pointe d ou ti n th e appended claims . I claim : 6 0 indudin g a furthe r movin g endles s bd tfo r recdvin g th e shee texitin g from sd d spac e o n h s uppe r run . 7 . Apparatu s accordin g t o clai m 6 wherei n sd d acut e angl e i s approximatd y 1 5 degrees . 8 . Apparatu s accordin g t o clai m 6 indudin g a sa w unitabov e th e uppe r ru n o f

sd d farthe r endles s bd tto cu tsd d forme d shee t

• * * • •

6 5



# 9.