Fluid film continuous processing method and apparatus

Abstract

Material such as panels, boards, and flexible sheets are produced and processed while passing between two or more surfaces at least one of which has a thin layer of pressurized fluid in direct contact with the product. While in this process zone, the item is shaped, coated, smoothed, textured, heated, cooled, compressed, dried, and/or impregnated. For example, expandable resin is deposited in a continuously formed bag of upper and lower sheet material so that the resin may expand and cure as it is drawn in through a fixed rigid mold having upper and lower (and perhaps side) porous material walls through which pressurized fluid is passed to provide a fluid bearing support and molding surface. The temperature, pressure and flow of the fluid is monitored and controlled separately at spaced locations along the length of the mold to control curing rate, foaming rate, surface characteristics and resistance of material moving through the mold. The surfaces may be planar or curved and may be parallel or variably separated in lateral cross-section. They may also be planar or curved and parallel or variably separated in longitudinal cross-section. The fluid layer is formed by passing a fluid under pressure through a porous wall having the shape of the desired fluid film configuration. This film of fluid moves across the surface of the item being processed, separating the item from the wall to eliminate sliding friction while subjecting the item to pressure, and/or heat, heat loss, absorption, evaporation and impingement.