Patent Publication Number: US-6668698-B1

Title: Continuous platform cutting method

Description:
This application is a continuation-in-part of U.S. Ser. No. 08/899,292, filed Jul. 23, 1997, now U.S. Pat. No. 6,546,836, and U.S. Ser. No. 08/899,398, filed Jul. 23, 1997, now U.S. Pat. No. 6,142,053. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to continuous methods for shaping the surface of a slab of compressible or cellular polymer material, such as polyurethane foam, by cutting portions of the material from the slab with a blade after the slab has been compressed between a compression roller and a patterned surface of a moving platform, preferably at a region where the platform is adjacent to or driven by a drive roller. 
     Several methods and apparatus for cutting slabs of cellular polymer materials have been disclosed in the prior art. For example, U.S. Pat. No. 4,700,447 to Spann discloses convolute-cutting slabs of polyurethane foam by compressing a slab or pad of foam between a pair of rolls with opposed spaced projecting fingers arranged in a pattern and cutting the foam with a saw blade transversely just as it emerges from the rolls. The cut slab is then separated into two pads each with convolute-cut surfaces forming a series of peaks separated by valleys. The valleys formed on one pad are formed by slicing away foam which becomes a mating peak or projection on the other pad. Spann then shaves the peaks to form a more planar top surface. As noted in Spann, convolute cutting alone produces only rounded peaks and rounded valleys, and it is difficult, if not impossible, to produce a cut surface with peaks having substantially flat top surfaces or with recesses having substantially straight side walls. The convolute usually is intended to form the classic symmetrical and repeating “egg crate” pattern of peaks and valleys. To achieve a planar upper surface at other than the recessed portions, the tops of the peaks must be cut or shaped in a second step. 
     Compressible cellular polymer materials may also be cut using a hot wire cutter. A slab of such material is cut by moving the slab relative to one or more hot wires as shown, for example, in U.S. Pat. No. 4,683,791 (Demont). Only straight cuts in regular or symmetrical patterns may be formed using a hot wire cutter. See also U.S. Pat. No. 4,915,000 (MacFarlane) and U.S. Pat. No. 5,573,350 (Stegall). 
     Shapes may be cut into the surface of a slab of cellular polymer material using a punch cutting apparatus, such as disclosed in U.S. Pat. No. 5,299,483 (Ber-Fong). A block of the cellular material is pressed against a template so that a portion of the material is forced through an opening in the template. The exposed material is then cut by a blade and removed, leaving a recess or cavity in the slab. This method cuts one block of material at a time, and only one surface at a time. 
     U.S. Pat. No. 4,351,211 (Azzolini) compresses a block of foam material against a template or die having an aperture therein using a pair of plates with concave and convex portions. The compressed foam is transversely cut along the template as it is held between the plates. More complex cut regions may be obtained than when using a template without the plates with raised and depressed portions, but only one block is cut at a time. Other template or pattern cutting methods are shown in U.S. Pat. No. 3,800,650 (Schroder) and U.S. Pat. No. 3,653,291 (Babcock). 
     The surface of a cellular polymer material may be shaped by molding or embossing, as opposed to cutting. U.S. Pat. No. 4,383,342 (Forster), for example, discloses injecting the foam-forming composition in a mold cavity. After sufficient curing time, the individual foamed article is removed from the mold. Other one-shot molding techniques are known to persons of skill in the art. The molded cellular polymer product generally forms a tough skin at the surfaces that were in contact with the mold. 
     Continuous and semi-continuous molding processes are also known. These processes have the same drawbacks associated with one-shot molding techniques. For example, U.S. Pat. Nos. 4,128,369 and 4,290,248 (Kemerer, et al.) disclose an apparatus and method for impression molding thermoplastic products. The thermoplastic material in a liquid state is injected between compressed traveling belt molds. As the belt molds travel away from the point of introduction of the thermoplastic, they are cooled, which in turns cools the thermoplastic material. The hardened molded thermoplastic material is removed from between the belts to form the finished product. Kemerer does not show a method for cutting or shaping a cellular polymer material, such as polyurethane foam. 
     A method of embossing a foam surface using a patterned metallic embossing belt or band is shown in U.S. Pat. No. 4,740,258 (Breitscheidel). The foam is heated and then pressed against the embossing belt. The belt is removed after the foam surface cools. The embossed surface by design has a hardened skin. No method for cutting or shaping the foam is disclosed. 
     U.S. Pat. No. 5,534,208 (Barr) discloses a continuous rotary method for surface shaping synthetic foams in which the foam is compressed between a compression roller and a die roller having raised and recessed portions. The portions of the foam extruded into the recesses in the die roller are cut away. The compressed foam portions return to an uncompressed state after passing through the rollers. As a result, a mirror-image pattern to the pattern on the surface of the die roller is cut on the surface of the foam. The diameter of the die roller limits the length of the shaped foam article that may be formed. 
     The prior art does not disclose a continuous method for shaping a compressible or cellular polymer material by cutting to form recesses of various depths and various symmetrical and non-symmetrical shapes. Nor does the prior art disclose a method for shaping a slab of compressible or cellular polymer material of unlimited length using a movable patterned platform, such as an endless belt, as the template for cutting the surface of the slab. Nor does the prior art disclose a method for forming a profile cut product without the hardened skin or hard spots associated with molded or embossed products. 
     SUMMARY OF THE INVENTION 
     A continuous method for shaping a compressible or cellular polymer material, such as polyurethane foam, by cutting and removing portions of the material is disclosed. A slab of cellular polymer material is compressed between a compression roller and a surface of a moving patterned platform. The moving patterned platform is interposed between the compression roller and a cooperating surface, such as the surface of a drive roller. Because the moving patterned platform may be formed from a flexible material, the compression force preferably is applied at a region where the platform is adjacent to a solid surface of the drive roller. In a less preferred embodiment, the moving patterned platform is interposed between the compression roller and a follower roller and the compression force is applied at a region where the platform is adjacent to a solid surface of the follower roller. A knife blade is positioned downstream from the compression roller and the point at which the compression force is applied, preferably with the blade interposed between the compression roller and the patterned platform. The slab surface is cut transversely by the blade just as the slab emerges from between the compression roller and the moving patterned platform, thus trimming off portions of the cellular material that filled the recesses or voids in the patterned platform. In an alternate embodiment, the blade is positioned so that it shaves a fine scrim layer of foam from the slab surface, and makes deeper cuts into the slab in the regions in which the polymer material has filled the recesses or voids in the patterned platform. If the patterned platform defines upstanding projections, instead of or in addition to recesses, the projections force a portion of the foam material away from the blade and less material is cut from the slab surface in those regions. 
     The patterned platform may be an endless belt or a series of movable panels or plates or any other structure that may travel in a continuous circuit or path. Where the patterned platform is an endless belt, the belt is placed over a series of rollers wherein at least one such roller is driven by a motor. The belt may be engaged to the roller with interconnecting gears or ribs so that the rotation of the drive roller causes the belt to travel. Where the patterned platform is formed by a series of interconnected panels, such as metal plates, the panels preferably are connected movably to a chain and sprocket drive system. Thus when the sprocket is driven, such as by a motor, the sprocket drives the chain and the panels interconnected to the chain. 
     The patterned platform may define at least one recess, which may be a hole or void through the platform, but preferably is a cut-out portion that does not pass through the entire thickness of the platform. The recess may be provided as a simple or complex geometric shape. Where more than one recess is defined in the platform, the recesses may be of the same or different shapes, may be interconnected or separated, may be symmetrical or non-symmetrical, and may be repeating or non-repeating on the patterned surface of the patterned platform. The recesses may be cut to different depths in the platform. Several separate series of different recesses may be provided on one patterned platform. The patterned platform may define at least one upstanding projection. The projection may be provided as a simple or complex geometric shape. Where more than one projection is defined on the platform, the projections may be of the same or different shapes, may be inter-connected or separated, may be symmetrical or non-symmetrical and may be repeating or non-repeating the patterned surface of the patterned platform. The projections may have different heights. The patterned platform may include a combination of recesses and upstanding projections. 
     As the slab travels with the patterned platform and is compressed between the compression roller and patterned platform (with recesses), a portion of the cellular material fills the recesses or voids in the patterned platform. Greater amounts of cellular material are cut from the slab in regions that have been compressed into the recesses or voids in the patterned platform because this material has been forced to one side of the cutting edge of the blade in these regions. The cut portions are removed from the slab after it passes the knife. The resulting profile cut product has on its cut face a series of cut regions that substantially correspond in pattern and shape in mirror image to the recesses provided in the patterned platform. The cut regions in the slab are also cut deeper in those regions that correspond to the deeper recesses in the patterned platform. However, due to the varying compression factors for cellular polymer materials, the depth of cut of the cut regions usually is not identical to the depth of the recesses within the patterned platform. 
     The cut foam product has a series of recesses or projections defined in its surface. If the drive roller drives the patterned platform at one speed and the compression roller is driven at a different speed, the blade cuts the foam material to form angled side walls that are greater than or less than 90° as measured from the base of a cut recess or the top surface of a projection formed on the surface of the cut foam slab. The difference in platform speed as compared to the compression roller speed causes one surface of the slab to enter the predetermined gap prior to the other surface of the slab. 
     Using the method according to the invention, a profile cut cellular product in which portions have been cut from both the upper and lower surface may be formed by feeding the slab through the apparatus twice. First, one surface is cut, then the cut product is inverted and fed through the apparatus a second time to cut its opposite surface. 
    
    
     DESCRIPTION OF THE FIGURES 
     Numerous other objects, features and advantages of the invention shall become apparent upon reading the following detailed description taken in conjunction with the accompanying drawings, in which: 
     FIG. 1 is a schematic perspective view of one embodiment of a continuous platform cutting apparatus that may be used to practice the invention; 
     FIG. 2 is a cross-sectional view taken along line  2 — 2  of FIG. 1; 
     FIG. 3 is a side elevational view of the apparatus shown in FIG. 1; 
     FIG. 4 is a schematic perspective view of an alternate moving platform for a continuous platform cutting apparatus that may be used to practice the invention; 
     FIG. 4A is a schematic perspective view of an alternate configuration for the alternate moving platform of FIG. 4; 
     FIG. 5 is a fragmental side elevational view of a cellular polymer underlayment mat defining patterned recesses that have been cut into the mat using the continuous platform cutting method of the invention; 
     FIG. 5A is a fragmental side elevational view in cross-section taken along line  5 — 5  of FIG. 5; 
     FIG. 6 is a top plan view of the mat of FIG. 5; 
     FIG. 7 is a schematic side elevational view in partial cross-section showing a second embodiment of a continuous platform cutting apparatus that may be used to practice the invention; 
     FIG. 8 is a partial schematic side elevational view in partial cross-section showing a modification to the second embodiment of FIG. 7; and 
     FIG. 9 is a partial schematic side elevational view in partial cross-section showing a third embodiment of a continuous platform cutting apparatus that may be used to practice the invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring first to the apparatus as shown in FIGS. 1-3, a continuous platform profile cutting apparatus for cellular polymer materials  10  is supported on a first frame structure  12  and second frame structure  22 . A shaft  14  is mounted for rotation to the first frame structure  12 , preferably with bearings. A motor  16  drives the shaft  14 . A drive roller  18  is mounted on shaft  14 . The outer surface of the drive roller  18  may be covered or coated with a slip resistant material, such as urethane. Ribs or gear teeth  20  are provided around the outer end or peripheral end surfaces of the first drive roller  18 . Alternatively, separate gears with suitable gear teeth may be provided at each end of the first drive roller  18 . 
     Shaft  24  is mounted for rotation to the second frame structure  22 , preferably using bearings. A first follower roller  28  is mounted on shaft  24 . The outer surface of the first follower roller  28  may be covered or coated with a slip resistant material, such as urethane. 
     A patterned platform, such as endless patterned belt  32 , has a patterned facing surface  34  and an opposite surface  38 . Belt  32  is mounted around the drive roller  18  and first follower roller  28 . The belt facing surface  34  defines recesses  36 , which may be simple or complex shapes, simple geometric patterns, complex patterns, symmetrical or repeating patterns or non-symmetrical and non-repeating patterns. Rectangular  36  and circular  37  recesses are shown by way of example in FIG.  1 . The recesses may be provided at various depths as discussed in more detail below. 
     Mating ribbed sections  39  on the outer edges of the belt opposite surface  38  mate with or engage the ribs or gear teeth  20  provided on the drive roller  18 . When the servo motor  16  drives shaft  14 , which in turn rotates drive roller  18 , the endless belt  32  travels around the drive roller  18  and the first follower roller  28 . The mated ribbed sections  39  and ribs  20  and the frictional engagement between the contacting surfaces of the belt with the rollers keep the belt centered and aligned with the rollers as it travels a path around the rollers. 
     First idler roller  40  is mounted for rotation on shaft  42  which is held by a portion  44  of the frame  12 . First idler roller  40  is positioned at a point between the drive roller  18  and the first follower roller  28  to stabilize the movement of the endless belt  32 . 
     Compression roller  46  is provided at a point between the drive roller  18  and the first follower roller  28 . The compression roller  46  is mounted for rotation on shaft  48 . The shaft  48  is held in a bearing recess within a frame  52 . Tension adjusting means  54 , such as a fluid cylinder or spring or series of springs, may act on frame  52  to adjust the compression force applied. 
     The outer surface  47  of the compression roller  46  contacts the opposite surface  38  of the belt  32  on which the ribbed portions  39  are provided. The outer surface  47  of the compression roller  46  may be covered or coated with a slip resistant material, such as urethane. As shown best in FIG. 2, the surface  47  of the compression roller  46  does not extend to the full outer periphery of the roller, leaving a recess into which the ribbed portions  39  extend so that the surface  47  of the roller  46  contacts the surface  38  of the belt  32 . Greater slip resistance results when the amount of surface engagement between the belt  32  and the roller compression surface  47  is increased. 
     Compression roller  56  with outer compression surface  60  is mounted for rotation on shaft  58 . The shaft  58  is held within frame  62 . A motor  57  drives shaft  58 . The roller  56  is separated from compression roller  46 , leaving a space or gap through which the endless belt  32  travels between the compression surfaces of the rollers. The arrow  64  in FIG. 2 indicates the force applied against the frame  62  to urge roller  56  to toward roller  46 . 
     Referring to FIG. 3, knife blade  76  is held within casing  74 . The blade  76  must have a sharp tip that is sufficiently sharp to cut cellular polymer materials, such as polyurethane foams. Because the blade  76  construction is known and understood by persons of skill in the art of cutting cellular polymer materials, such as polyurethane foams, it will not be described in detail. 
     The blade  76  is positioned adjacent to the compression rollers  46 ,  56  so that the sharp tip of the blade is adjacent to or just beyond the point at which the outer surfaces  47 ,  60  of the compression rollers  46 ,  56  act to their greatest extent to compress material that is placed between the rollers (i.e. the predetermined gap). The blade  76  is also positioned between the compression surface  60  of compression roller  56  and the patterned facing surface  34  of endless belt  32 . The blade  76  should be positioned so that it will not cut the compression surface  60  of the roller  56  or the patterned facing surface  34  of the belt  32 . The blade  76  should not interfere with the rotation of the rollers  46 ,  56  or the movement of the belt  32 . Blade orientation may be adjusted so that the tip of the blade is moved closer or farther from the nip between roller  46  and roller  56 . 
     In one embodiment as shown best in FIGS. 2 and 3, as a slab  80  of cellular material, such as polyurethane foam, is fed between the compression surface  60  of compression roller  56  and the patterned facing surface  34  of the endless belt  32 , the slab  80  is compressed by the rollers  46 ,  56 . When the slab  80  travels into the nip or space or predetermined gap between the rollers  46 ,  56 , portions of the compressed slab material are held within the recesses  36  defined within the facing surface  34  of the belt  32 . 
     Knife blade  76  cuts transversely portions of the slab  80  just as the slab  80  emerges from between the compression rollers  46 ,  56 . As shown in FIG. 3, the cuts into the slab  80  are made in the regions corresponding to those regions in which slab material had been compressed within recesses  36  defined in the facing surface  34  of the belt  32 . A portion of the material that was held within a recess in the belt is cut away from the slab before the compressed cellular material is able to recover to its uncompressed state as it emerges from the compression rollers. Portions of the slab surface not compressed into the recesses or voids in the facing surface  34  of the belt  32  may or may not be cut, depending upon the position of the blade  76 . 
     After the slab is cut as it emerges from the rollers, the cut-away portions  88  are removed as waste, leaving a resulting profiled cellular material  90 . The resulting product  90  has recesses  92  substantially corresponding in shape to the recesses  36  provided in the patterned face surface  34  of the endless belt  32 . Slabs of cellular material may thus be provided with profiled surfaces with an endless array of patterns, whether symmetrical or non-symmetrical, simple or complex, or repeating or non-repeating. For example, alternatively the cut-away portion  88  might be a separate profiled cellular material product  90 . 
     Preferably, only portions of the slab that have been compressed into recesses or voids are cut away, resulting in less waste to remove from the surface of the slab as it emerges from the cutting apparatus. In contrast to prior cutting methods, the waste material does not fall away and contaminate the apparatus, but is carried away by the belt  32 . The waste may then be swept or vacuumed off the belt as it continues to travel along its path defined by the position of the rollers  18 ,  28 . 
     Long slabs of cellular material may be continuously fed into and shaped by the continuous platform cutting apparatus. The method may be used to cut multiple products continuously from a single slab of material. The recesses and/or projections formed in a single patterned platform may be arranged in separate configurations for different products. Alternately, repeating recess patterns may be formed in the patterned platform. In addition, patterned platforms of different lengths may be used to form finished cut products of different lengths. 
     An example of a profile-cut product  300  made according to the invention is shown in FIGS. 5 and 6. The profile cut product  300  represents a cellular polymer insulating barrier or underlayment that will be installed in the interior of a motor vehicle between the floor surface and the carpeting. The upper surface  310  of the underlayment has been cut to provide complex patterns of recesses or voids. As shown in FIG. 6, generally rectangular-shaped recesses  312  have been cut into the surface of the product  300 . In addition, more complex shaped recesses, such as interconnecting generally oval shaped recesses  314  and interconnecting straight-edged and curved-edged recesses  316 , may be cut into the cellular material. For the underlayment for a motor vehicle, preferably one surface, here what has been referred to as the upper surface  310 , is cut and the opposite surface remains uncut. The cut surface of the underlayment is placed adjacent to the motor vehicle surface so that the voids and recesses in the underlayment mate with shaped portions projecting from the vehicle surface. In this manner, the underlayment may be provided so as to match the contour of the vehicle interior surface. Once the underlayment is installed in the vehicle, carpet or other covering may be installed adjacent to the uncut and generally smooth surface of the underlayment. 
     The depth of the recesses  36 ,  37  of the belt  32  are typically a small fraction of the depth of the corresponding cuts to be made in the surface of the foam material  80 . Because of the compression factor of the foam against the pattern belt  32 , a shallow depression  36 ,  37  in the pattern belt  32  yields a much deeper depression in the foam. For example, a ⅝ inch thick sheet of foam material compressed against a depression  36  of 20 thousands of an inch in the patterned belt, in the apparatus  10  described above, yielded approximately a ½ inch deep depression in the foam sheet  80 . The spacing between the belt surface  34  and the roller surface  56 , if all other factors are equal, determines the compression factor of the foam and consequently, the ratio of patterned belt depth to foam cut depth. The depth of cut in the foam can be reduced for a given pattern belt recess depth or projection height by increasing the spacing between the roller surface  56  and the belt surface  34 , thus reducing the compression factor. 
     Where the belt  32  is driven at the same speed as the roller  56 , the cut product has recesses (or projections) formed with sidewalls substantially perpendicular (90°) to the top surface of the product. The angle of the cut sidewalls may be varied by driving the belt  32  at a different speed than the speed roller  56  is driven. When different drive speeds are used, one surface of the slab  80  will enter the predetermined gap before the other surface. The drive speed may be adjusted continually as the foam material slab  80  is introduced into the gap. In this way, side wall angles may be the same or different in different regions of the cut product. Referring to FIG. 5A, the recess is cut with substantially perpendicular (90°) sidewalls  340 , but there is shown in phantom outline a recess cut with angled sidewalls  342 . When the compression roller is driven at 25 feet per minute surface speed and the patterned platform runs at 35 feet per minute surface speed, the cut product has recesses with side walls cut at an angle of about 110° to 115°. However, the cut angle is about 90° when both surfaces are driven at the same speed. 
     For certain applications, it may be desired to cut both the upper and lower surfaces of a slab of cellular material. If the apparatus shown in FIGS. 1-3 is used for this purpose, once the slab has been fed between the compression rollers and cut on one side, the slab may then be inverted and fed between the compression rollers so that it may be profile-cut on the opposite surface. 
     The endless belt  32  preferably is formed from a flexible material such as rubber or silicone rubber or urethane. The belt  32  is thick enough to withstand the compressive forces, preferably about 0.375 inches or more, and has a durometer of about 35 or higher, preferably 75 or higher, most preferably at least 90. Alternatively, the belt may be formed of fiberglass reinforced polyurethane or other composite materials suitable for endless belts with such thickness and durometer. 
     As shown in FIG. 4, rather than using an endless belt, the patterned platform  200  may be constructed as a continuous or endless series of inter-linked panels driven by chain and sprocket. The series of plates  208 , preferably formed from metal or other sturdy substrate, are mounted on shafts  210 . The shafts  210  are held for rotation within bearing sleeves  212 . Y-shaped follower bars  214  are connected at one end to the shafts  210  and at the other two ends to pin members  204 . The recesses  216 ,  216   a  may be cut in non-uniform, non-symmetrical and not repeating shapes. The recesses need not be contained wholly within a single plate. Rather, a recess defined by one plate may complement the recess defined by an adjacent plate. 
     When a series of plates are used as the patterned platform, the slab of cellular material will be pressed against the plates by a compression roller (not shown in FIG. 4) so that a portion of the material is compressed into the recesses in the plates and is cut away from the slab by a knife blade just as the cellular material emerges from the compression roller. A support platform  222  is provided below the plates  208  to support the plates when compression forces are exerted on them by the compression roller. 
     FIG. 7 shows a preferred embodiment of the invention. Like reference numerals in FIG. 7 refer to like elements as shown in FIGS. 1-3 because the apparatus  100  in FIG. 7 is similar to the apparatus  10  shown in FIGS. 1-3. There is provided a drive roller  18  that travels in the direction indicated by the arrow  302 . The outer surface of the drive roller  18  is provided with teeth  20 . The apparatus also includes follower roller  28 . 
     A belt  32  has a patterned surface  34  with one or more recesses  36  and has an opposite surface  38 . Mating ribs or teeth  39  are proved on the opposite surface  38  of the belt. The teeth  39  engage the teeth  20  provided on the drive roller  18 . As the belt travels along a path around the drive roller  18  and follower roller  28 , it also contacts the outer surfaces of first and second idler rollers  40 ,  40 ′. 
     A compression roller  56  mounted on a shaft  58  is provided with an outer surface  60 . In the apparatus  100 , the compression roller  56  is positioned close to the outer surface of the drive roller  18  to define a predetermined gap between the outer surface  60  and the roller  18 . The roller  56  position is adjustable, such that the outer surface  60  of the roller may be closer to or farther from the outer surface of the drive roller  18  to change the gap. The belt  32  travels between the outer surface  60  of the compression roller  56  and the outer surface of the drive roller  18 . 
     A slab of compressible material  80  is fed into the gap between the patterned surface  34  of the belt  32  and the outer surface  60  of the compression roller  56 . The gap is set to a distance that causes the compressible material to be compressed between the outer surface  60  of the compression roller  56  and the patterned surface  34  of the belt  32 . Portions of the compressible material are forced into the recesses  36  formed into the patterned surface  34  of the belt  32 . 
     A knife blade  76  held within knife casing  74  is positioned just downstream from the gap. Just as the compressible material  80  passes through the gap, portions of the slab  80  held within the recess  36  are cut by the blade  76 . The cut slab emerges with a profile-cut surface with recesses. The cut-away portions  88  are separated from the slab  80  and are carried away by the belt  32  to be removed, either by falling away, by manual removal or by vacuum. 
     The apparatus in FIG. 8 shows a modification  100 ′ to the apparatus of FIG.  7 . To more smoothly compress the slab  80  of compressible material between the compression roller  56  and the moving patterned belt  32 , idler rollers  304  and  306 , and a follower roller  308  are provided. A belt  301  travels in a circuit defined by the compression roller  56  and the follower roller  308  and idler rollers  304 ,  306 . A narrowing gap is defined between the belt  301  and the belt  32 . As the slab  80  passes between the belt  32  and the belt  301  and through the progressively narrowing gap, the compressible material is compressed to a greater degree, until the greatest compression in the predetermined gap between the compression roller  56  and the belt  32 . 
     FIG. 9 shows another modification  100 ″ of the apparatus of FIG. 7, wherein a belt  32 ′ is modified to include raised projections  320  projecting from the patterned surface  34 ′. Some cut products are formed by cutting away a scrim or thin layer from the surface along the entire length of the slab  80 . With projections  320  provided on the belt  32 ′, cut products can be formed without cutting away material where portions of the slab passing through the predetermined gap are held to one side of the blade  76  by the projections  320 . Idler roller  40 ′ contacts the surface of the belt  32 ′ and a further idler roller  40 ″ is placed in contact with the slab  80  on the slab surface which is not in contact with the belt  32 ′. 
     The methods according to this invention might be used to make profile cut products for a variety of end uses. In addition to motor vehicle carpet systems, profile cut products might be made for other vehicle interior applications, such as head liners, side panels and dash panels. Profile cut products might also be used for mattresses, mattress pads, pillows, furniture cushions, filters, sports equipment, footwear components and packaging. The above list is intended to be representative and not exhaustive as to all the possible applications for the invention. 
     While preferred embodiments of the invention have been described and illustrated here, various changes, substitutions and modifications to the described embodiments will become apparent to those of ordinary skill in the art without thereby departing from the scope and spirit of the invention.