Patent ID: 7150614

Claim:
An apparatus for the production of a continuous foam product comprising: a vacuum chamber, the vacuum chamber including an extruder for forming an extrudate; an internal liquid reservoir having a first liquid level; a bulkhead partially submerged within the internal liquid reservoir; an external liquid reservoir having a second liquid level; an orifice formed in the bulkhead, the orifice located completely below both the first liquid level and the second liquid level, the orifice providing a connection between the internal liquid reservoir and the external liquid reservoir; conveying means for guiding the extrudate from the extruder into the internal liquid reservoir, through the orifice and into the external liquid reservoir, the extrudate passing through the orifice with an orientation substantially perpendicular to a plane defined by the bulkhead; a pair of side gate assemblies, the side gate assemblies arranged adjacent and external to the orifice, the side gate assemblies being operable for controlling the effective width and horizontal position of the orifice, wherein each side gate assembly includes a side gate, the side gate being moveable along a first axis inclined relative to a major surface of the foam product; and the vertical gate assembly includes a vertical gate, the vertical gate being moveable along a second axis substantially perpendicular to the major surface of the foam product, wherein each side gate assembly includes a track assembly, the track assembly being arranged on a external surface of the bulkhead, parallel to the first axis and at least partially containing the side gate; a reversible motor, the reversible motor being mechanically linked to the side gate for extending and retracting the side gate along the track assembly; and a first motor controller, the first motor controller determining the direction, speed and duration of movement of the reversible motor in response to measurements of the extrudate; a roller assembly arranged adjacent and external to the side gate assemblies for defining a effective lower surface of the orifice; a vertical gate assembly arranged adjacent and external to the side gate assemblies, the vertical gate assembly being operable for controlling, in cooperation with the roller assembly, the effective height of the orifice.