Roller manifold for forming a continuous sheet of viscous material

Abstract

The present invention is directed to a method and apparatus for forming a continuous sheet of a molten material with particularly viscous, sticky properties. This molten material may be moldable, plasticized or a food product such as cheese. More specifically, the invention includes a manifold that discharges the molten material in a continuous layer upon the surface of a casting belt. This manifold comprises a roller, a chamber with a hollow interior, at least one inlet and a drive mechanism.

1 - 16 . (canceled)  
   
   
       17 . A method of using an apparatus to dispense a continuous sheet of molten, viscous material, comprising the steps of: 
 a. providing an apparatus comprising: 
 i. a discharge manifold configured to discharge molten, viscous material having a hollow interior chamber with at least one open side;  
 ii. at least one manifold inlet opening into said chamber for receiving the molten, viscous material, each at least one manifold inlet opening configured for attachment to piping;  
 iii. a discharge opening on at least one side configured to discharge said molten viscous material from said chamber; and  
 iv. a roller rotatably mounted adjacent to the chamber wherein a gap is defined between an outer surface of the roller and the casting surface,  
 wherein the roller is configured to discharge a continuous sheet of molten, viscous material and to cooperate with the casting surface to extrude the material received in said gap from said discharge opening;  
   b. driving a casting belt of a casting line in a constant direction, said casting belt having a width;    c. introducing molten, viscous starting material through at least one pipe connected to at least one manifold inlet;    d. driving the roller in the same direction as the casting belt, said roller being attached to the manifold such that the starting material passes between the roller and casting belt;    e. drawing the starting material from the chamber through a tandem movement of the roller and the casting belt in the same direction; and    f. dispensing a continuous sheet of molten, viscous material upon the casting belt as the belt is revolvingly driven.    
   
   
       18 . The method of  claim 17 , wherein the starting material is introduced into the manifold under pressure from a pump.  
   
   
       19 . The method of  claim 18 , wherein the starting material is introduced under a pressure of at least 1 psi.  
   
   
       20 . The method of  claim 17 , wherein a continuous sheet of material is dispensed upon the casting belt under pressure from a pump.  
   
   
       21 . The method of  claim 20 , wherein the continuous sheet of material is introduced under a pressure of at least 1 psi.  
   
   
       22 . A method for forming a continuous sheet of material from a molten, viscous starting material comprising the steps of: 
 a. driving a casting belt of a casting line in a constant direction, said casting belt having a width;    b. introducing molten, viscous starting material through at least one pipe feeding into a manifold chamber mounted in an area adjacent to the casting belt, said material exiting the manifold through an outlet;    c. driving a roller in the same direction as the casting belt, said roller being attached to the manifold such that the starting material passes between the roller and casting belt;    d. drawing the starting material from the chamber through tandem movement of the roller and the casting belt in the same direction; and    e. dispensing a continuous sheet of material upon the casting belt as the belt is revolvingly driven.    
   
   
       23 . The method of  claim 22 , wherein the starting material is introduced into the manifold under pressure from a pump.  
   
   
       24 . The method of  claim 23 , wherein the starting material is introduced under a pressure of at least 1 psi.  
   
   
       25 . The method of  claim 22 , wherein a continuous sheet of material is dispensed upon the casting belt under pressure from a pump.  
   
   
       26 . The method of  claim 25 , wherein the continuous sheet of material is introduced under a pressure of at least 1 psi.