Method for continuously producing flat mats

Claim 1

A METHOD OF MAKING A SUCCESSION OF FLAT MATS FROM HOT, PLIABLE, SYNTHETIC RESIN PLASTIC OF THE TYPE WHICH SETS UPON BEING COOLED, COMPRISING: THE STEPS OF PROVIDING A ROTATING CYLINDRICAL MOLD HAVING OUTWARDLY PRESENTED THEREON THREE-DIMENSIONAL DESIGN CONFIGURATION OF AT LEAST ONE MAT IN THE NEGATIVE OF THE DESIRED DESIGN CONFIGURATIONS OF THE DESIRED FLAT MATS; EXTRUDING A CONTINUOUS SHEET OF THE HOT, PLIABLE, SYNTHETIC RESIN PLASTIC MATERIAL DIRECTLY FROM AN EXTRUDER AND CONTINUOUSLY FEEDING THE HOT, PLIABLE SHEET INTO THE BIGHT BETWEEN THE CYLINDRICAL MOLD AND AN ELASTIC PRESSURE ROLLER OF SMALLER DIAMETER THAN THE MOLD, PROGRESSIVELY YIELDINGLY TO PRESS THE HOT PLIABLE PLASTIC MATERIAL OF THE SHEET INTO FULL DEPTH AND CONFORMITY WITH SAID NEGATIVE DESIGN CONFIGURATIONS ALONG AN INITIAL POINT OF AXIAL LINE-CONTACT PRESSURE WHILE SIMULTANEOUSLY COOLING THE MOLD WALL AND THEREBY PROGRESSIVELY TO INITIATE COOLING AND SETTING OF THE MOLDED PLASTIC MATERIAL AT SAID POINT OF LINE-CONTACT PRESSURE ALONG WHICH THE ELASTIC OF THE SMALL ROLLER YIELDINGLY ASSURES COMPRESSION OF THE HOTK, PLIABLE, PLASTIC MATERIAL INTO INTERCONNECTED RECESSED PORTIONS OF THE DESIGN CONFIGURATIONS WITHOUT SUBSTANTIAL PERIPHERAL DEFORMATION OF THE ELESTIC ROLLER WHICH COULD OTHERWISE ENTRAP AIR IN SUCH RECESSED PORTIONS TO CAUSE DEFORMITIES IN THE MOLDED MAT DESIGN; SAID AXIAL LINE-CONTACT PRESSURE BEING SO CONTINUOUSLY APPLIED WHILE PROVIDING CONTINUOUS RUN-OUT RELEASE OF ENTRAPPED AIR FROM SAID POINT OF LINE CONTACT THROUGH SAID INTERCONNECTED PORTIONS IN THE MOLD AND RETAINING THE CONTINUOUSLY FORMED SHEET MATERIAL ABOUT A SUBSTANTIAL PERIPHERAL EXTENT OF THE COOLED MOLD FROM SAID POINT OF LINE-CONTACT PRESSURE SUFFICIENT TO ASSURE RETENTION OF RESULTANT FULL-FORMED POSITIVE DESIGN IMPRESSIONS IN THE PROGRESSIVELY MOLDED MATERIAL.

Claim 2

A METHOD OF MAKING A SUCCESSION OF FLAT MATS FROM HOT, PLIABLE, SYNTHETIC RESIN PLASTIC OF THE TYPE WHICH SETS UPON BEING COOLED, COMPRISING: THE STEPS OF PROVIDING A ROTATING CYLINDRICAL MOLD HAVING OUTWARDLY PRESENTED THEREON THREE-DIMENSIONAL DESIGN CONFIGURATION OF AT LEAST ONE MAT IN THE NEGATIVE OF THE DESIRED DESIGN CONFIGURATIONS OF THE DESIRED FLAT MATS; EXTRUDING A CONTINUOUS SHEET OF THE HOT, PLIABLE, SYNTHETIC RESIN PLASTIC MATERIAL DIRECTLY FROM AN EXTRUDER AND CONTINUOUSLY FEEDING THE HOT, PLIABLE SHEET INTO THE BIGHT BETWEEN THE CYLINDRICAL MOLD AND AN ELASTIC PRESSURE ROLLER OF SMALLER DIAMETER THAN THE MOLD, PROGRESSIVELY YIELDINGLY TO PRESS THE HOT PLIABLE PLASTIC MATERIAL OF THE SHEET INTO FULL DEPTH AND CONFORMITY WITH SAID NEGATIVE DESIGN CONFIGURATIONS ALONG AN INITIAL POINT OF AXIAL LINE-CONTACT PRESSURE WHILE SIMULTANEOUSLY COOLING THE MOLD WALL AND THEREBY PROGRESSIVELY TO INITIATE COOLING AND SETTING OF THE MOLDED PLASTIC MATERIAL AT SAID POINT OF LINE-CONTACT PRESSURE ALONG WHICH THE ELASTIC OF THE SMALL ROLLER YIELDINGLY ASSURES COMPRESSION OF THE HOTK, PLIABLE, PLASTIC MATERIAL INTO INTERCONNECTED RECESSED PORTIONS OF THE DESIGN CONFIGURATIONS WITHOUT SUBSTANTIAL PERIPHERAL DEFORMATION OF THE ELESTIC ROLLER WHICH COULD OTHERWISE ENTRAP AIR IN SUCH RECESSED PORTIONS TO CAUSE DEFORMITIES IN THE MOLDED MAT DESIGN; SAID AXIAL LINE-CONTACT PRESSURE BEING SO CONTINUOUSLY APPLIED WHILE PROVIDING CONTINUOUS RUN-OUT RELEASE OF ENTRAPPED AIR FROM SAID POINT OF LINE CONTACT THROUGH SAID INTERCONNECTED PORTIONS IN THE MOLD AND RETAINING THE CONTINUOUSLY FORMED SHEET MATERIAL ABOUT A SUBSTANTIAL PERIPHERAL EXTENT OF THE COOLED MOLD FROM SAID POINT OF LINE-CONTACT PRESSURE SUFFICIENT TO ASSURE RETENTION OF RESULTANT FULL-FORMED POSITIVE DESIGN IMPRESSIONS IN THE PROGRESSIVELY MOLDED MATERIAL.