A method for forming a multilayer plastic sheet material (1) for floor and/or wall panels, wherein a first polymer mass comprising a rigid PVC is melted under pressure and is passed through an extruder head at a specified discharge rate in the form of a plastic strand in sheet form that is provided with one or more layers so that a multilayer plastic strand is formed, which is passed to two or more rolls of a finishing stand, which processes the multilayer plastic strand into a sheet of defined thickness, which is then led away via a transport device to a sawing device to be cut to the desired length, wherein, after the plastic strand in sheet form leaves the extruder head, it is first passed between a top roll and a bottom roll of a roughing stand, wherein the speed of the rolls of the finishing stand and the rolls of the roughing stand is synchronized with the discharge rate of the plastic strand in sheet form from the extruder head, so that said plastic strand is processed without stress.

Disclosed are apparatuses and methods for forming films having uniform thicknesses across the entire width of the film. The films are also disclosed. The apparatus for forming the film includes a first nip roller and a second nip roller, each of the first nip roller and the second nip roller being configured to compress the powder as it passes between the first nip roller and the second nip roller and thereby form the film, whereby in the absence of a force counteracting the pressure of the passage of the powder between the first nip roller and the second nip roller the first nip roller is deflected to a greater degree than the second nip roller. Furthermore, the first nip roller and the second nip roller are each associated with one or more eccentric bearings that rotate to apply force vectors to the first nip roller and the second nip roller.

A die assembly for forming a composite gap filler, including a first die having a first portion which extends along a first central axis of the first die and has a first curved surface which has a radius which changes as the first curved surface extends about the first central axis. A second die a second portion which extends along a second central axis of the second die and has a second curved surface which has a radius which changes as the second curved surface extends about the second central axis. A third die defines a third wall member which extends about the third die and which changes in width dimension wherein with the first die abutting the second die and with the third wall member abutting the first and second dies, a closed gap is formed.

A system for forming a thermoplastic may comprise a mandrel configured to receive a thermoplastic charge. The mandrel may rotate about a mandrel axis. A series of rollers may be located circumferentially about the mandrel and configured to apply radially inward pressure. A heating element may be located upstream of the series of rollers.

A method for making a floor or wall panel has a foamed polymer core. A foamable polymer powder is foamed between two conveyor belts in the forming zone of a steel belt press. The sum of the thicknesses of the two conveyor belts and the total thickness of the layers at the entrance of the steel belt press is less than or equal to the opening of the steel belt press at the entrance of the steel belt press. The sum of the thicknesses of the two conveyor belts and the total thickness of the substrate at the outlet of the steel belt press is equal to the opening of the steel belt press at the outlet of the steel belt press and greater than the sum of the thicknesses of the two conveyor belts and the total thickness of the layers at the entrance of the steel belt press.

A method for forming a multilayer plastic sheet material is disclosed, where a first polymer mass is melted under pressure and is passed through an extruder head at a specified discharge rate in the form of a plastic strand in sheet form that is provided with one or more layers so that a multilayer plastic strand is formed. This is passed to two or more rolls of a finishing stand that processes the multilayer plastic strand into a sheet. After the plastic strand in sheet form leaves the extruder head, it is first passed between a top roll and a bottom roll of a roughing stand. The speed of the rolls of the finishing stand and the rolls of the roughing stand is synchronized with the discharge rate of the plastic strand in sheet form from the extruder head, so that the plastic strand is processed without stress.

A method of molding resin on a flexible substrate includes forming discrete regions of resin and forcing resin of at least some of the regions into molding cavities to form a respective array of resin projections extending from a resin base of the regions. Forming the discrete regions of resin includes depositing molten resin directly onto either the substrate or a surface in which the cavities are defined. The resin is deposited as the substrate moves in a processing direction, and the resin is deposited by resin sources spaced from each other along the processing direction.

A method for forming a multilayer plastic sheet material is disclosed, where a first polymer mass is melted under pressure and is passed through an extruder head at a specified discharge rate in the form of a plastic strand in sheet form that is provided with one or more layers so that a multilayer plastic strand is formed. This is passed to two or more rolls of a finishing stand that processes the multilayer plastic strand into a sheet. After the plastic strand in sheet form leaves the extruder head, it is first passed between a top roll and a bottom roll of a roughing stand. The speed of the rolls of the finishing stand and the rolls of the roughing stand is synchronized with the discharge rate of the plastic strand in sheet form from the extruder head, so that the plastic strand is processed without stress.

The invention relates to an apparatus for cross-sectionally shaping a multiplicity of plastics strands guided in parallel alongside one another over at least one rotatable shaping roller (18, 19, 20), in which the shaping roller is provided on its surface with a plurality of encircling shaping recesses which are arranged in parallel and in which the cross section of the plastics strands is shapeable in accordance with the cross-sectional shape of the shaping recesses, wherein preferably three shaping rollers (18, 19, 20) of the same type for sequentially shaping the plastics strands are arranged transversely to the running path of the plastics strands, wherein the plastics strands are guided between a pair of two successive shaping rollers (19, 20) on a first side of the plastics strands and a third shaping roller (18), which is arranged, between the first (19) and second shaping roller (20) of the pair of shaping rollers, on the second side of the plastics strands in the running direction of the plastics strands, and the shaping rollers are mounted in lateral guide plates by means of quick-change apparatuses.

The present application provides a calender, a floor production line and a production method using the calender, wherein the calender comprises a calendering roller rack and a set of calendering rollers arranged on the calendering roller rack. The set of calendering rollers comprises a plurality of calendering rollers arranged in a line and not vertically. The present application changes the arrangement of the calendering rollers. The calendering rollers are arranged in a line, not vertically. This arrangement reduces the overall height of the calender, decreases the requirements of the calender on the height of the factory building and facilitates long-distance transportation by containers. Using the calender to assemble the floor production line, the height space of the factory building occupied by the production line can be saved.