A continuous forming apparatus for molding foam material into foam products that includes a first endless belt and a second endless belt that cooperates with the first endless belt to mold the foam material. The continuous forming apparatus may also include a first plurality of cleats and a second plurality of cleats opposed to the first plurality of cleats that support the first endless belt and the second endless belt respectively. The first plurality of cleats may include a three-dimensional abutment surface that provides transverse and lateral support to the first endless belt. Additionally, the continuous forming apparatus may include a first frame disposed to support the first plurality of cleats, a second frame disposed to support the second plurality of cleats, and a drive mechanism for imparting motion to the first endless belt, the second endless belt, the first plurality of cleats, and the second plurality of cleats.

Multilayer riblet applique and methods of producing the same are described herein. One disclosed example method includes applying a first high elongation polymer material to a web tool, where the web tool is to be provided from a first roll, and heating, via a first heating process, the first high elongation polymer material. The disclosed example method also includes applying a second high elongation polymer material to the first high elongation polymer material, and heating, via a second heating process, the second high elongation polymer material. The disclosed example method also includes applying, via a laminating roller, a support layer to the second high elongation polymer material.

Multilayer riblet applique and methods of producing the same are described herein. One disclosed example method includes applying a first high elongation polymer material to a web tool, where the web tool is to be provided from a first roll, and heating, via a first heating process, the first high elongation polymer material. The disclosed example method also includes applying a second high elongation polymer material to the first high elongation polymer material, and heating, via a second heating process, the second high elongation polymer material. The disclosed example method also includes applying, via a laminating roller, a support layer to the second high elongation polymer material.

Multilayer riblet applique and methods of producing the same are described herein. One disclosed example method includes applying a first high elongation polymer material to a web tool, where the web tool is to be provided from a first roll, and heating, via a first heating process, the first high elongation polymer material. The disclosed example method also includes applying a second high elongation polymer material to the first high elongation polymer material, and heating, via a second heating process, the second high elongation polymer material. The disclosed example method also includes applying, via a laminating roller, a support layer to the second high elongation polymer material.

Multilayer riblet applique and methods of producing the same are described herein. One disclosed example method includes applying a first high elongation polymer material to a web tool, where the web tool is to be provided from a first roll, and heating, via a first heating process, the first high elongation polymer material. The disclosed example method also includes applying a second high elongation polymer material to the first high elongation polymer material, and heating, via a second heating process, the second high elongation polymer material. The disclosed example method also includes applying, via a laminating roller, a support layer to the second high elongation polymer material.

A method of forming a substrate in a thermal compression bonding process that permit substantially greater amounts of fillers than previously accomplished. The method employs a dispersion of a thermoplastic binder and a filler. The dispersion is then thermally compression bonded to form a substrate. Lightweight fillers are one example of fillers that are ideally suited for the thermal compression bonding through the use of a dispersion. Such lightweight fillers enable the formation of a substrate with a very low and desirable specific gravity.

A method of forming a substrate in a thermal compression bonding process that permit substantially greater amounts of fillers than previously accomplished. The method employs a dispersion of a thermoplastic binder and a filler. The dispersion is then thermally compression bonded to form a substrate. Lightweight fillers are one example of fillers that are ideally suited for the thermal compression bonding through the use of a dispersion. Such lightweight fillers enable the formation of a substrate with a very low and desirable specific gravity.

A continuous forming apparatus for molding foam material into foam products that includes a first endless belt and a second endless belt that cooperates with the first endless belt to mold the foam material. The continuous forming apparatus may also include a first plurality of cleats and a second plurality of cleats opposed to the first plurality of cleats that support the first endless belt and the second endless belt respectively. The first plurality of cleats may include a three-dimensional abutment surface that provides transverse and lateral support to the first endless belt. Additionally, the continuous forming apparatus may include a first frame disposed to support the first plurality of cleats, a second frame disposed to support the second plurality of cleats, and a drive mechanism for imparting motion to the first endless belt, the second endless belt, the first plurality of cleats, and the second plurality of cleats.

A method of making products with a functional relief surface (2) with high resolution up to 10 nm, which is copied from a template (1) or carrier of the negative relief of the surface, the so-called master. The template (1) of the relief surface (2) is provided with at least one layer of geopolymer composite, applied in a precursor state (3), in form of a liquid dispersion or grout in plastic or thixotropic condition, whose thickness is the same or greater than the depth of the template relief (1), at temperatures in the interval from the temperature corresponding to properties of the precursor (3) to the temperature corresponding to thermal decomposition of the precursor (3), and after hardening of geopolymer composite the layer or layers is/are separated from the template (1).

A method of making products with a functional relief surface (2) with high resolution up to 10 nm, which is copied from a template (1) or carrier of the negative relief of the surface, the so-called master. The template (1) of the relief surface (2) is provided with at least one layer of geopolymer composite, applied in a precursor state (3), in form of a liquid dispersion or grout in plastic or thixotropic condition, whose thickness is the same or greater than the depth of the template relief (1), at temperatures in the interval from the temperature corresponding to properties of the precursor (3) to the temperature corresponding to thermal decomposition of the precursor (3), and after hardening of geopolymer composite the layer or layers is/are separated from the template (1).