Apparatus for continuously producing foamed material

Claim 1

An apparatus for producing a foamed cellular material from a liquid reaction mixture which is capable of undergoing a creaming action wherein it changes into a foam and its flow characteristics progressively diminish until the point at which full gel strength is reached, at which point the reaction mixture becomes the foamed cellular material of generally fixed shape, said apparatus comprising: an elongated flexible sheet; means in contact with the sheet for moving the elongated sheet in the direction of its longitudinal axis; means for converting the elongated sheet as it moves into a three sided mold having upright sidewalls and a bottom wall located between the sidewalls; means for depositing the liquid reaction mixture in the mold on the bottom wall thereof; and means located beneath the mold for deforming the bottom wall of the mold into a generally V-shaped configuration beyond the location where the liquid reaction mixture is deposited on the mold and before the location where the liquid reaction mixture reaches its full gel strength, the V-shaped configuration having an apex at its one end with the apex of the V creating an elevation in the bottom wall, the apex of the V being generally centered between the sidewalls of the mold and further being directed toward the location at which the liquid reaction mixture is deposited in the mold, the V-shaped configuration becoming progressively wider downstream from the apex and at its opposite end extending substantially the entire width of the bottom wall, whereby some of the liquid reaction mixture will flow toward the sidewalls at the V-shaped configuration in the bottom wall.

Claim 2

An apparatus for producing a foamed cellular material from a liquid reaction mixture which is capable of undergoing a creaming action wherein it changes into a foam and its flow characteristics progressively diminish until the point at which full gel strength is reached, at which point the reaction mixture becomes the foamed cellular material of generally fixed shape, said apparatus comprising: an elongated flexible sheet; means in contact with the sheet for moving the elongated sheet in the direction of its longitudinal axis; means for converting the elongated sheet as it moves into a three sided mold having upright sidewalls and a bottom wall located between the sidewalls; means for depositing the liquid reaction mixture in the mold on the bottom wall thereof; and means located beneath the mold for deforming the bottom wall of the mold into a generally V-shaped configuration beyond the location where the liquid reaction mixture is deposited on the mold and before the location where the liquid reaction mixture reaches its full gel strength, the V-shaped configuration having an apex at its one end with the apex of the V creating an elevation in the bottom wall, the apex of the V being generally centered between the sidewalls of the mold and further being directed toward the location at which the liquid reaction mixture is deposited in the mold, the V-shaped configuration becoming progressively wider downstream from the apex and at its opposite end extending substantially the entire width of the bottom wall, whereby some of the liquid reaction mixture will flow toward the sidewalls at the V-shaped configuration in the bottom wall.

Claim 7

An apparatus for producing a foamed cellular material from a liquid reaction mixture which is capable of undergoing a creaming action wherein it changes into a foam and its flow characteristics progressively diminish until the point at which full gel strength is reached, at which point the reaction mixture becomes the foamed cellular material of generally fixed shape, said apparatus comprising: an elongated flexible sheet; means in contact with the sheet for moving the elongated sheet in the direction of its longitudinal axis; means for converting the elongated sheet as it moves into a three sided mold having upright sidewalls and a bottom wall located between the sidewalls, a portion of the bottom wall being substantially flat; means for depositing the liquid reaction mixture in the mold on the flat portion of the botton wall; and a plurality of rollers located beneath the bottom wall of the mold, the rollers deforming the bottom wall of the mold into a generally V-shaped configuration beyond the location where the liquid reaction mixture is deposited on the mold and before the location where the liquid reaction mixture reaches its full gel strength, the apex of the V creating an elevation in the bottom wall and being directed toward the location at which the liquid reaction mixture is deposited in the mold whereby some of the liquid reaction mixture will flow toward the sidewalls.

Claim 8

An apparatus for producing a foamed cellular material from a liquid reaction mixture which is capable of undergoing a creaming action wherein it changes into a foam and its flow characteristics progressively diminish until the point at which full gel strength is reached, at which point the reaction mixture becomes the foamed cellular material of generally fixed shape, said apparatus comprising: an elongated flexible sheet; means in contact with the sheet for moving the elongated sheet in the direction of its longitudinal axis; means for converting the elongated sheet as it moves into a three sided mold having upright sidewalls and a bottom wall located between the sidewalls, a portion of the bottom wall being substantially flat; means for depositing the liquid reaction mixture in the mold on the flat portion of the botton wall; and a plurality of rollers located beneath the bottom wall of the mold, the rollers deforming the bottom wall of the mold into a generally V-shaped configuration beyond the location where the liquid reaction mixture is deposited on the mold and before the location where the liquid reaction mixture reaches its full gel strength, the apex of the V creating an elevation in the bottom wall and being directed toward the location at which the liquid reaction mixture is deposited in the mold whereby some of the liquid reaction mixture will flow toward the sidewalls.

Claim 13

An apparatus for producing a foamed cellular material from a liquid reaction mixture which is capable of undergoing a creaming action wherein it changes into a foam and its flow characteristics progressively diminish until the point at which full gel strength is reached, at which point the reaction mixture becomes the foamed cellular material of generally fixed shape, said apparatus comprising: an elongated flexible sheet; conveying means in contact with the sheet for moving the elongated sheet downstream in the direction of its longitudinal axis, the conveying means further supporting the flexible sheet as it is conveyed with the support so provided being such that the sheet forms a bottom wall which is inclined very slightly downwardly from the horizontal; means for depositing the liquid reaction mixture on the bottom wall near the elevated upstream end thereof; distorting means located beneath the bottom wall for deforming the bottom wall to a generally V-shaped configuration beyond the location at which the reaction mixture is deposited on the bottom wall and before the location at which the reaction mixture reaches its full gel strength, the V-shaped configuration being raised with respect to the portion of the bottom wall which precedes it and having an apex at its upstream end with the apex being directed toward the location at which the reaction mixture is deposited on the bottom wall, the V-shaped configuration becoming progressively wider downstream from the apex and merging without abrupt change in elevation into the portion of the bottom wall which follows it, whereby some of the liquid reaction mixture will flow toward the sides of the bottom wall at the V-shaped configuration in the bottom wall.

Claim 14

An apparatus for producing a foamed cellular material from a liquid reaction mixture which is capable of undergoing a creaming action wherein it changes into a foam and its flow characteristics progressively diminish until the point at which full gel strength is reached, at which point the reaction mixture becomes the foamed cellular material of generally fixed shape, said apparatus comprising: an elongated flexible sheet; conveying means in contact with the sheet for moving the elongated sheet downstream in the direction of its longitudinal axis, the conveying means further supporting the flexible sheet as it is conveyed with the support so provided being such that the sheet forms a bottom wall which is inclined very slightly downwardly from the horizontal; means for depositing the liquid reaction mixture on the bottom wall near the elevated upstream end thereof; distorting means located beneath the bottom wall for deforming the bottom wall to a generally V-shaped configuration beyond the location at which the reaction mixture is deposited on the bottom wall and before the location at which the reaction mixture reaches its full gel strength, the V-shaped configuration being raised with respect to the portion of the bottom wall which precedes it and having an apex at its upstream end with the apex being directed toward the location at which the reaction mixture is deposited on the bottom wall, the V-shaped configuration becoming progressively wider downstream from the apex and merging without abrupt change in elevation into the portion of the bottom wall which follows it, whereby some of the liquid reaction mixture will flow toward the sides of the bottom wall at the V-shaped configuration in the bottom wall.

Claim 17

An apparatus for casting a foamed material from a liquid reaction mixture having the capability of creaming into a foam and thereafter setting up in a cellular condition and further being capable of flowing as it creams into the foam, said apparatus comprising: dispersing means for discharging the liquid reaction mixture; a flexible mold-forming material capable of supporting and containing the liquid reaction mixture after it is dispersed; propelling means for conveying the flexible mold-forming material beneath the dispersing means such that the mold-forming material has an upwardly presented surface and will support the liquid reaction mixture and the foam resulting therefrom, the propelling means including an endless belt and end rollers around which the belt passes, the end rollers having their axes of rotation horizontal so that the belt has upper and lower passes with the upper pass of the endless belt supporting the flexible mold-forming material; and distorting means for elevating the upper pass of the belt between the sides thereof to thereby cause the upwardly presented surface of the flexible mold-forming material to undergo a similar change in configuration at the location where liquid reaction mixture creams and before the mixture sets up, the distorting means including at least one elevating roller positioned between the two passes of the belt and bearing against the underside of the upper pass between the sides thereof to distort the center of the upper pass upwardly.

Claim 18

An apparatus for casting a foamed material from a liquid reaction mixture having the capability of creaming into a foam and thereafter setting up in a cellular condition and further being capable of flowing as it creams into the foam, said apparatus comprising: dispersing means for discharging the liquid reaction mixture; a flexible mold-forming material capable of supporting and containing the liquid reaction mixture after it is dispersed; propelling means for conveying the flexible mold-forming material beneath the dispersing means such that the mold-forming material has an upwardly presented surface and will support the liquid reaction mixture and the foam resulting therefrom, the propelling means including an endless belt and end rollers around which the belt passes, the end rollers having their axes of rotation horizontal so that the belt has upper and lower passes with the upper pass of the endless belt supporting the flexible mold-forming material; and distorting means for elevating the upper pass of the belt between the sides thereof to thereby cause the upwardly presented surface of the flexible mold-forming material to undergo a similar change in configuration at the location where liquid reaction mixture creams and before the mixture sets up, the distorting means including at least one elevating roller positioned between the two passes of the belt and bearing against the underside of the upper pass between the sides thereof to distort the center of the upper pass upwardly.

Claim 20

An apparatus for casting a foamed material from a liquid reaction mixture having the capability of creaming into a foam and thereafter setting up in a cellular condition and further being capable of flowing as it creams into the foam, said apparatus comprising: dispersing means for discharging the liquid reaction mixture; a flexible mold-forming material capable of supporting and containing the liquid reaction mixture after it is dispersed; propelling means for conveying the flexible mold-forming material beneath the dispersing means such that the mold-forming material has an upwardly presented surface and will support the liquid reaction mixture and the foam resulting therefrom, the propelling means including an endless conveyor belt and end rollers around which the conveyor belt passes, the end rollers having their axes of rotation horizontal so that the conveyor belt has upper and lower passes with the upper pass of the conveyor belt supporting the flexible mold-forming material; and distorting means for elevating the upper pass of the conveyor belt between the sides thereof and imparting a V-shaped upward distortion to the conveyor belt with the apex of the V being directed toward the dispersing means, the distorting means causing the upwardly presented surface of the flexible mold-forming material to undergo a similar change in configuration at the location where liquid reaction mixture creams and before the mixture sets up, the distorting means including elevating rollers mounted for rotation about axes spaced longitudinally along the conveyor belt and secondary belts trained over the rollers and extending between them to support the conveyor belt.

Claim 21

An apparatus for casting a foamed material from a liquid reaction mixture having the capability of creaming into a foam and thereafter setting up in a cellular condition and further being capable of flowing as it creams into the foam, said apparatus comprising: dispersing means for discharging the liquid reaction mixture; a flexible mold-forming material capable of supporting and containing the liquid reaction mixture after it is dispersed; propelling means for conveying the flexible mold-forming material beneath the dispersing means such that the mold-forming material has an upwardly presented surface and will support the liquid reaction mixture and the foam resulting therefrom, the propelling means including an endless conveyor belt and end rollers around which the conveyor belt passes, the end rollers having their axes of rotation horizontal so that the conveyor belt has upper and lower passes with the upper pass of the conveyor belt supporting the flexible mold-forming material; and distorting means for elevating the upper pass of the conveyor belt between the sides thereof and imparting a V-shaped upward distortion to the conveyor belt with the apex of the V being directed toward the dispersing means, the distorting means causing the upwardly presented surface of the flexible mold-forming material to undergo a similar change in configuration at the location where liquid reaction mixture creams and before the mixture sets up, the distorting means including elevating rollers mounted for rotation about axes spaced longitudinally along the conveyor belt and secondary belts trained over the rollers and extending between them to support the conveyor belt.