Patent ID: 7651645

Claim:
A method of forming molded materials, comprising the steps of: providing a continuous forming apparatus comprising: at least a first endless mold belt comprising an inner surface and a outer surface; a first endless support belt, the support belt comprising a plurality of rigid cleats, wherein the first plurality of cleats comprises an inner portion and an outer portion relative to a mold cavity, wherein each cleat of the first plurality of cleats comprises a three-dimensional abutment surface located on the inner portion of the cleat that is at least in partial contact with the outer surface of the first endless belt, wherein the abutment surface provides transverse and lateral support to the first endless belt; a second endless support belt comprising a plurality of rigid cleats; a first set of pulleys or sprockets, wherein the first endless belt travels around the first set of pulleys or sprockets; a second set of pulleys or sprockets, wherein at least a portion of the first plurality of cleats is at least partially disposed on the second set of pulleys or sprockets, wherein the first plurality of cleats travels around the second set of pulleys or sprockets; a third set of pulleys or sprockets, wherein the second plurality of cleats is at least partially disposed on the third set of pulleys or sprockets, and wherein the second plurality of cleats travels around the third set of pulleys or sprockets; and a drive mechanism configured to impart motion to at least the first endless belt; introducing a material into the mold cavity defined at least in part by the inner surface of the first endless belt; moving the material in a plane substantially parallel to the inner surface of the first endless belt; and curing the material.