IE53272B1 - Process for the manufacture of a multiplicity of webs or plates of thermoplastically workable material having profiles projecting on one or both sides - Google Patents

Description

The invention relates to a process for the manufacture of webs or plates of material having thermoplastic properties whereby from out of the flat material are formed a multuplicity of hollow profile shapes, optionally tapering to a point, which are joined with each other at the base by the material of the flat web.

This forming takes place with the material in the thermally plastified condition, with the help of studshaped tools whose temperature is below that of the plastified material. The stud shaped tools form or shape the plastified material by means of a drawing effect which is maintained until the previously soft material sets as it cools or passes below the range of thermal plasticity.

The invention further relates to a new apparatus for forming a multiplicity of hollow profile shapes, optinally tapering to a point, joined with each other at the base, from a web or plate, of material having thermoplastic properties in continuous or discontinuous operation, in which apparatus the profile shapes, on one or both sides, can be formed from the flat material, remaining, however, joined together in the region of the plane of the material forming the base.

This apparatus according to the invention is particularly suitable for the accomplishment of the previously mentioned process. An important, increasingly - 3 expanding product, particularly within the scope of the synthetic materials processing industry, are the so-called burl webs which have projections or profiles (so-called burls), principally on one side, formed from out of the flat material; these can be formed with widely different spacing with respect to each other.

These profiles can have any desired geometrical shape, but particularly pyramid shape, cone-base shape or also cylindrical shape, tapering to a point. Such profiled webs or -lates (burl webs), which are mostly covered in the plane of the profile tip s by a flat material web and are thereby additionally reinforced, are already employed and proposed in the widest range of application technology. Hence they are found particularly in the technique of packing, for example in the construction of containers, as reinforcing bases for fragile or sensitive goods such as fruit, eggs, ampoules, electrotechnical articles (light bulbs), as reinforcing material for cartons, as acoustic or thermal insulation, in the building industry for insulating walls or roofs, in the aircraft industry, the coachbuilding or floor-making industries, in the field of solar technology and the like.

It has been demonstrated, however, that in the case of webs, plates, foils or other materials having socalled burls whose profiles are developed on one side only, that is, whose profiles are formed only on one side of the web or material plane, there are considerable shortcomings with respect to their mechanical strength - and this applies quite generally, regardless of the material used. The webs or plates are easily bendable, they tend to tear in the area of the base of the profile shape, that is, in the area of the remaining material plane and in order to overcome this shortcoming they mostly have to be used double.

The lack of stability is most disadvantageously noticeable where there is a need to reinforce, but also where supporting bases are needed for fragile goods, so that - 4 additional support and reinforcing elements are necessary in order to achieve the object to some extent.

It has already been proposed (DE-OS 22 58 513) to develop the profiles on both sides from out of the material plane, whereby upward and downward profiles are mainly produced alternately. Indeed, this two-sided burling already leads to a considerable improvement in the physical properties of the profiled end product (burl webs), but however, with the technology applied in the known process, does not permit of the continuous, undisturbed technical production of two-sided profiled webs or plates having any desired kind, size, etc. of profile, and free from rejects.

The known process therefore consciously demands limitation to a quite definite ratio of profile length (height of burl, to profile diameter at the base (material plane).

It further requires the use of quite specifically shaped tools for the actual drawing effect which produces the profile shape. The tools must be available as needles, tapering to a point. Because of the required relationship between profile length and profile diameter at the base, in association with a similarly required and thereby limiting minimum surface of the material which joins the profile with the base, the scope of application of materials profiled in this way is limited to a considerable extent and, for example, owing to the extremely dense sequence of profiles, they are hardly suitable for use as supporting material for larger single-piece fragile goods.

In addition, owing to the required maintenance of a ratio of profile length to base profile diameter of greater than 2 : 1, there exists, in the formation of profiles on two sides, the danger of a considerable reduction in the wall thickness of the profiles with comparatively thick tips, and the mechanical stability of the profiles can be reduced to such an extent that, depending on the material used, the collapse of individual profiles or whole groups of profiles is unavoidable. 53273 - 5 It is evident that the requirement with respect to the maintenance of the relationship of profile length to profile diameter imposes a considerable limitation on the shape of the profiles and prevents completely the manufacture, for example, of relatively wide or largesurface profile ends or short, compact profiles with profile lengths which are shorter than or the same as the profile diameter.

It is easily recognized, in the case of doublesided profile developments which are located close together, with thickened tips and the required relationship of profile length to profile base diameter, that a thinning of the material during the drawing process cannot be avoided.

Also the exclusive use of pointed studs as drawing tools for the formation of profiles proves to a large extent to be disadvantageous. Indeed, with this method a point-shaped quenching is achieved, and thereby a point-shaped thickening at the point of contact of the cold tip with the hot material web; but as seen in practice, this can easily lead to a breakthrough of the pointed tool through the material, particularly in the case of materials with a narrow softening range as, for example, glass, so that a considerable number of reject charges occur during continuous operation.

A further disadvantage of the known process lies in the dependence of the profiles on the fixed, unchanging form of the pointed studs as drawing tools manifest in that other geometrical profile forms than long thin, acutely pointed burls cannot be manufactured. The narrow sequence of upper and lower thin pointed profiles does not admit of a smooth seamless transition, ensuring constant spacing, from one profiling tool group to the following one in continuous operation.

As a result of this the webs produced often have different spacing between the individual rows of 53373 profiles, so that the space transitions have bulges or, at least, visible seams.

For this reason also reject charges during operation are often encountered.

It has been shown that for a faultless, operationally undisturbed production of webs and plates of the kind mentioned at the beginning with the profiles (burls) to be developed being geometrically variable in form, and for the elimination of the considerable disadvantages of processes and their products known up till now, quite definite process parameters and their interaction are required, which were first recognized and achieved within the framework of the invention.

The invention provides a process for the development of a multiplicity of hollow profile shapes optionally tapering to a point, joined with each other at the base, from a web of material having thermoplastic softening behaviour wherein the material is exposed to the action of stud-shaped tools guided in a vertical direction with respect to the plane of the material, which tools produce the profiles by tension, characterized in that shortly before reaching the shaping region the temperature of the material is raised to achieve adequate plasticity and subsequently exposed to the action of the tools, which are moved step-wise simultaneously in the vertical and horizontal directions with respect to the plane of the path of the material, and which are at a temperature considerably below that of the material, in such manner that depending on the softening behaviour per unit time of the prestressed material. a) the vertical and horizontal movement of the tools in association with the web speed of the material, has a preferably parabolic progression, so that the tools approach the final height of the profiles asymptotically, from the instant of first contact of the tools with the 33272 - 7 surface of the material up to moment of reaching the planned final height of the profiles, i.e. over the entire shaping distance in which the profile-shaping tension is exerted, b) the vertical velocity of the tools reaches the value zero at the instant the final profile formation is reached, c) the speed and direction of horizontal movement of the tools in the region of the shaping zone coincides with the speed and direction of movement of the material web, d) the entering angle, whose vertex coincides with the point of first contact, defined by the material plane forming the first arm and the chord of the curve described by the tools up to the point of first contact with the web surface forming the second arm, is constant, e) during further horizontal movement and until final hardening of the material the stud-shaped tools retain the position they assumed upon reaching the final height of the profiles, for the creation of a zone for material cooling and stabilization, f) subsequently, the tools are conveyed back, horizontally and vertically at the same time, to the start of the shaping, with a leaving angle which is considerably larger than the entering angle.

Although the new process has been developed primarily for continuous operation, for the two-sided development of profiles formed from out of the flat material, it can also be employed for the one-sided development of profiles.

In this case the material web is led over or carried by, one sided, a supporting, multi-meshed grid or net or a perforated plate having at least a number and distribution of perforations to coincide with and permit passage of the profile-forming, stud-shaped tools, and the grid adopts the movement of the material web. The profile-forming tools thereby work on the. material to be shaped from above downwards or from below upwards.

The size of the shaping distance (referred to as profile development distance or profiling zone) and the speed of penetration in relation to the speed of the web can be varied by means of the entering angle (a).

The size of the shaping distance is a function of the thickness of the material web and the thickness of the obtained or desired profiled end product, of the material viscosity at the instant of profile formation, the mass of the tools (temperature and, as the case may be, the weight of the tool) also the shape (physical appearance) of the individual profiles. The entering angle (a) should be within the range 5-45°, preferably 20-30°.

Preferably, the profiles are formed transversely of the material web, in continuous rows and in the case of two-sided profile development, which coincides with the preferred form, these are arranged alternately upwards and downwards. They can also be displaced with respect to each other and have different lenghts, or profiles of greater or less length can be formed alternately, singly or in groups. Finally, deviations are possible, although only to a limited extent, from the vertical arrangement of the profiles with respect to the plane of the material.

Although in the process according to the invention practically all geometrical shapes of profile forming tools can be used, and limiting requirements such as those described in German laid-open Specification No. 22 58 513 are not involved, stud-shaped tools having cylindrical configurations with flat, level ends, but with any desired - 9 peripheral configurationsin cross-section have proved to be particularly suitable. Thereby, the ends of these tools, that is, the end surfaces giving rise to the drawing effect which produces the profile, can have a concave recess rather resembling a hemisphere or a segment of a circle. Finally, also those stud tools which are chamfered at the outermost periphery are particularly effective.

It is understood that individual stages of the process can be subjected to certain changes, operational adaptations or even more effective developments. So, for example, it is possible, in place of a prefabricated material web, a foil, for instance, to employ an extruder, which would not only produce the basic material web, but would also heat it up to the region of adequate plastification.

The locus given by the simultaneous vertical and horizontal movement of the stud-shaped tools, from the beginning of the first contact with the plastified material web until the furthest profile length is reached, that is, in the total region of the so-called shaping zone, corresponds to an inclined plane which, in certain cases, may be modified to a parabolic shape (when the speed of penetration is to be varied in the time cycle) which, with continuously decreasing vertical speed, up to the point where the zero point is reached, passes over into the horizontal plane of the web.

The progress of the simultaneous vertical and horizontal movement of the stud-shaped tools in the shaping zone, whether as an unbent inclined plane or as an approach to the parabolic at the zero point of the vertical movement, is a function of the properties of the material to be shaped, particularly its temperature-related plastifying behaviour, so that for highly viscous material, only plastifiable within a narrow temperature range, as, for example, glasses the parabolic shaping progress appears to be more favourable, while for low-viscosity masses such as polyolefines and the like a smooth, unbent shaping progression, corresponding to the inclined plane is recommended.

Of decisive importance for a faultless, unhindered single-sided or two-sided development of profiles from the web of the thermally plastified material, not subjected to operational disturbances, is an accurate harmonizing of the vertical and horizontal movement (speed) of the tools relative to the material web, to the length of the shaping zone, the length of the cooling and stabilizing zone, the early vertical alignment of the tools perpendicular to the horizontally moved material plane before reaching the first contact also - to be evaluated as a material constant of the end product - in the case of profiles developed on two sides, the spacing of the tools on opposite sides of the shaping zone.

At the commencement of the shaping of the material the tools must have taken up their position, particularly their vertical position, with respect to the plane of the material web and may not alter it during the course of the profile shaping, up to the end of the cooling and stabilizing zone.

The vertical movement of the tools may be slightly variable within the shaping zone, with the highest speed occurring at the first point of contact with the material web and the value zero when the furthermost profile length is reached (parabolic progression). The movement can, however, also decrease at a constant value with the development of the already defined inclined plane whose intersection with the plane of the material web (zero value), again corresponds to the furthermost profile length.

All movement sequences, i.e. the vertical and horizontal movement of the tools, the movement of the material web, the adjustment of the tool spacing in the shaping region, the removal of the studs and thereby the tools from the profiled web, the returning of the tools to 53273 - 11 the starting point of the shaping and the absolute alignment of the tools with respect to the material web at the beginning of the shaping process, must be capable of infinitely variable control and adjustment if all products according to the invention are to be run and different thicknesses and structures not endangered.

If the tools are positioned on endless transport elements care is to be taken in every case - as is the case with the apparatus according to the invention - to ensure that they lie perpendicular to the material web only in the region of tool alignment, they lie next to each other jointlessly in the shaping zone, in the cooling and stabilizing zone and in the region of tool removal, while during transportation back there must be sufficient play between the tools to permit early alignment perpendicular to the web.

The new process offers the following advantages which enrich the whole art to a considerable extent: Discontinuous operation as well as continuous operation is possible, although the latter is preferred. The studshaped tools - with their carrying elements - are interchangeable at all times, in an infinitely variable manner. Owing to the adjustment of the different movement sequences with respect to each other neither undesirable seams between the boundaries of neighbouring tools occur nor flawed shaping. The drawing pressure for the developemnt of the profiles from the softened material is only effective in the direction of the profiles. Other pressure influences, i.e. which can lead to the widening of the cross-section of the profiles or even to their destruction while the shaping process is still in progress are completely eliminated. The dwell of the stud-shaped tools in the profiles during transit through the entire cooling and stabilizing zone results in the formation of more stable, consolidated profiles having the correct configuration. 53273 - 12 The process can be practically applied to all thermally plastifiable materials. These include the complete class of pertinent synthetic substances, of the homopolymer or copolymer variety, such as vinyl polymers and corresponding interpolymers, polyolefines, polyamides, polynitriles, polycyanates and polymethacrylates, synthetic rubber and related products. In addition, the process can be applied to plastifiable cellulose derivatives.

Certain kinds of glass, some ceramic materials 10 and even thermally workable metals and metal alloys are also suitable.

Foods such as foils or sheets of sugar, chocolate and the like can, under certain conditions, also be profiled by means of the new process. It is understood that with this exemplary enumeration the multiplicity of materials is not exhausted. The length of the profiles, their base diameter or cross section, the degree of possible taper towards the tip, the material thickness of the finished profiles, the size (surface) of the bond to the profile base, the geometrical physical appearance, the sequence of profiles of different configurations, and length, etc. can be varied as desired by the kind of studshaped tools, the depth of draw of the stud-shaped tools, the spacing of the tools arranged to oppose one another in the shaping zone, the length of the shaping zone and the thickness of the plastifiable material fed in.

In this way a multiplicity of possible profile configurations or profiled finished material webs are provided which can find entry into almost all regions of technology.

In the following the process is described in more detail with reference to an apparatus which has proved particularly suitable for the accomplishment of the process.

The illustrations which serve to describe the 35 process and define the mode of operation and the arrangement of the apparatus are: 83272 - 13 FIG. 1 The arrangement of a complete installation; FIG. 2 the same installation in section and plan with the individual parts of the installation or apparatus shown in more detail; FIG. 3 schematic representation of the procedures during the formation of profiles; FIG. 4 the development or the relationship with respect to each other of the entering angle (a) and the leaving angle (b) also the guidance of the tools as unbent inclined plane: FIG. 5 the entry of the tools as a parabolic progress; FIG. 6 the position in section of tools opposing one another, also the finished, formed profiles; FIG. 7 a finished material web, profiled on both sides, according to Fig. 6 shown in plan; FIG. 8 a carrying element (carrying body), shown in section, for holding a set of studshaped tools; FIG. 9 a modified form of carrying element; FIG. 10, 11, 12 and 13 possible end-place arrangements for the carrying elements; - 14 53372 FIG. 14 exemplary possibilities for the development of the profile length (thickness of the finished web, profiled on both sides) and their relationship to the shaping region; FIG. 15 exemplary types of particularly suitable stud-shaped tools.

According to Fig. 1 the complete installation comprises a feed roller (1) for the workable foil or web of thermally plastifiable material, an apparatus (2) for heating-up the material, in or above the plastifying region, the actual shaping device (3) consisting of (not visible) tool aligning zone, shaping zone also cooling and stabilizing zone, the common machine drive with gearing (8), roller stand (4) and product take-off table (5) which can also be arranged as a cutting station for the production of plates.

It is understood that the feed roller (1), the heating apparatus (2), the roller stand (4) or the take-off table (5) can be of any desired type. Thus, for example, the material can be preshaped from the extruder and the fee roller (1) can be omitted. Also for the treatment of glasses and the like, a glass furnace can be installed ahead of the machine (3). The construction possibilities are part of the specialists general technical knowledge and depend upon the kind of material to be treated.

In this way it has proved expedient to insert a further rolling system (optionally headed) between the heating apparatus (2) and the actual profiling (3) for aligning the material web.

Further, Fig. 1 shows the arrangement of the vertically disposed movement elements (9), rotated in a cycle about a vertical axis, the commonly driven spindle - 15 ends, adjustable upwards and downwards (10), the box-shaped or plate-shaped carrying elements (6,61) for holding the stud-shaped tools, driving faces (11) and also, extending beyond the material web on both sides, arranged fourfold, parallel-sided studs or cams (7), in which the preferably bar-shaped movement elements (9) engage. By way of the interacting, infinitely variable gear (8) the speed of the driving faces (11) and of the movement elements (9) also the height adjustment of the spindles (10) can be varied as desired and adapted to the material web, or its advancing speed, and it is advantageous to run the driving faces (11), which engage the tool carriers in the driving region, with slightly increased power in order to achieve a seamless compression of the tools.

As is further evident from Fig. 1, the tools in the region of shaping and cooling or stabilizing are packed tightly together so that a transition-free profile development takes place. At the instant of lifting, i.e. of withdrawal from the set profiles, the spacing of the tools or tool-carriers (6,6') increases, they are engaged by the driving faces (11) and returned with the fastest return movement to the material entry. Before reaching the driving faces (71), of course, the tool carrying elements (6,6') leave the region of influence of the vertical movement elements (9).

The installation shown in Fig. 2 corresponds to the one according to Fig. 1. A detailed side elevation and a plan are illustrated and here, too, an apparatus for the formation of profiles from both sides of the material web is involved. As shown, the carrying elements (6,6') are guided in a cycle over upper and lower rails (7.7') and under the influence of the opposing stud-shaped tools, held by carrying elements (6,6') the material web moves in the horizontal plane (from right to left in the system illustrated). In Fig. 2 are seen the region of the tool aligning zone (D) - alignment into the vertical and formation - 16 of a solid, gap-free correlation - the actual shaping zone (A), the cooling and stabilzing zone (B) and (not shown) the tool removal zone at the left end of the machine (3).

Bar-shaped movement elements (9) on each side of the machine (3) determine the accurate (vertical) positioning of the tool carrying elements (6,6’) in combination with the clutch-operated driving faces (11), which run with increased power and engage these as soon as they are advanced by the driving faces, which engage at the guide piece 30 according to Fig. 8.

As already stated, the tool spacing in the shaping region (A) can be adjusted by means of spindles (10). With this, the depth of the profile formation can also be varied independently of the length of the studshaped tools. This means that with a tool having a certain length, shorter-length profiles can also be formed (i.e. shorter than the tool).

Thereby, it is even possible during the shaping process, by means of the spindles (10), to alter the tool spacing in such a way that rows of profiles having alternately greater and smaller lengths can be produced with unaltered tool length.

Finally, Fig. 2 shows that with the aid of the spindles (10) the length of the shaping zone (A) itself, as well as the entering angle between the upper and lower tool path can also be altered. This step is always necessary if the material to be shaped requires an extremely long shaping zone (A), for example, owing to its temperature-related viscosity or plastifying behaviour or the tools in (D), aligned vertically with respect to the material web, are required to act cautiously, i.e. with reduced tension on the material.

Fig. 3 shows in more diagrammatic representation the procedures within a machine with profile formation on both sides out of the thermally softened material web (16). 53273 - 17 After the rapid return of the tool carrying elements (6,6') from the (left) end of the machine for renewed action on the material web they are first positioned, with the aid of the bar-shaped movement elements (9), see Fig. 1 and 2, perpendicular to the material web (zone D,, with simultaneous horizontal and vertical movement, and subsequently enter the shaping zone (A) at (A'). Here the drawing effect, for the formation of the profiles (22) , proceeds asymptotically until, at the point of transition to (B) the vertical movement has reached the value zero. After final solidification in the cooling and stabilizating zone (B), the lifting of the tools takes place (studs 12,12') and the leaving angle (b) described here is considerably larger than the entering angle (a) (Fig. 4).

Within the shaping zone (A) the locus of progression of the tools can resemble an unbent, inclined plane, but it can also be parabolic in character (Fig. 5).

Fig. 6 shows a sectional view of the position of opposed tool carrying elements (6) and the stud-shaped tools (12) during or at the end of the shaping procedure.

The material plane (16) is practically no longer present.

The drawing effect of the studs has led to uniform profiling (20).

In plan the web is presented as a sequence of profiles directed upward (17) and downward (18) (Fig. 7).

A preferred embodiment of a tool-carrying element (6) with a set of comb-like, stud-shaped tools (12) is illustrated in Fig. 8. The ends of the carrying elements are shaped as pins or bearings (30) with driving cams (31) which are held by the rails (7,7'), see Fig. 2 and, clamped in constraining guideways in the forwarding zone ensure upward and downward tool guidance with absolute certainty according to the process. Tool securing elements (33) in the region of the lower frame (32) of the carrying elements (6) are constructed so as to allow the stud-shaped tools (12) to be changed easily. 53372 - 18 Fig. 9 shows a somewhat modified form of carrying elements (6). Here, a set of stud-shaped tools is secured contrally at (34) in the region of frame (32).

According to Fig. 10 and 11 the end plates (24) of the tool-carrying elements (6) support cam-shaped or stud-shaped elements (25, 26, 27, 28) arranged rectangularly with respect to each other, between which the bar-shaped movement elements (9), see Fig. 2, engage and effect the transport horizontally and the alignment vertically of the stud-shaped tools.

In another embodiment of the end plates (24) the carrying elements (6) as shown in Fig. 12 and 13 are completely covered, and the illustrated set of comb-like stud-shaped tools (12) is likewise partly covered by the end plates (24).

The tools engage by means of constrictions (29) in the carrying elements (6), which act like bayonet catches, and the tools cannot be pushed out laterally. An enlarged vertical space between the upper (25,26) and lower (27,28) stud-shaped elements conduces simultaneously to improved stability between the carrying-element endplate (6) and the bar-shaped movement element (9) engaged therewith at a given time, see Fig. 2. Also, with this type of endplate the length of the bar-shaped movement elements (9) can be reduced.

From Fig. 14 emerge exemplary possibilities for the development of a predetermined and defined profile length (= thickness (e) of the finished material web obtained, profiled on both sides) related to the length of the shaping zone, with a given material and a given length of stud-shaped tools.

Thus, according to Fig. 14, for example, for a product thickness of (e) = 100 mm the product requires a shaping distance of (f) = about 800 mm. With decreasing product thickness, to (e) = 50 mm (Fig. 14 b), for example, the length of the shaping distance is reduced to (f) =400 mm. - 19 i.e. it is consequently 50% shorter. From this there already emerges a mathematical relationship between the thickness of the product (e) and the length of the shaping distance (f) whereby, however, the properties of the material (viscosity, temperature range of plastification, thermal stability of the material and the like) appear as variables.

The further progress of the decrease in the thickness of the product (e) to 25 mm (Fig. 14 c) reduces the shaping distance (f) to 200 mm and finally, according to Fig. 14 d, for a product thickness of approximately 4 mm, a shaping distance (f) of only 100 mm is required.

This exemplary procedure quoted here was determined with a given set of tools, with profile formation on both sides of polyurethane copolymers, and a continuous process for the manufacture of a web 1000 mm wide was taken as a basis.

The change in or the adaptation of the shaping distance (f in Fig. 4) can be achieved by adjusting the opposing tools by means of the machine spindles, whereby the spacing of the stud-shaped tools was varied while their length remained unchanged. However, it is also possible to interchange the guide members.

Finally, reference is made to a particularly favourable type of stud-shaped tools, as shown schematically in Fig. 15.

While smooth stud-shaped drawing tools approximately in accordance with Fig. 6, depending on the material used, can definitely produce usable results, it can occasionally be advantageous to form the ends hemispherically or in the shape of a dish, concave, (Fig. 15 a). In this way less mass is brought in contact at the first touch with the hot material to be plastified, so that the drawing effect promotes the stability of the profiles during the shaping procedure, and a hardening bulge is avoided. 53273 - 20 Fig. 15 b shows another form of tool ends wherein the bevelling enables an occasional, possible tearing of the plastic material film at the tip of the stud-shaped tool to be avoided.

Optimum properties are possessed by those studshaped tools whose ends, according to Fig. 15 c, have not only bevelling according to Fig. 15 b, but also a concave end surface according to Fig. 15 a. By means of these configurations defects in the material caused during the formation of profiles and during shaping and subsequent hardening procedures are practically completely avoided.

Claims (35)

1. CLAIMS;1. Process for the development of a multiplicity of hollow profile shapes optionally tapering to a point, joined with each other at the base, from a web of material having thermoplastic softening behaviour wherein the material is exposed to the action of stud-shaped tools guided in a vertical direction with respect to the plane of the material, which tools produce the profiles by tension, characterized in that shortly before reaching the shaping region the temperature of the material is raised to achieve adequate plasticity and subsequently exposed to the action of the tools, which are moved step-wise simultaneously in the vertical and horizontal directions with respect to the plane of the path of the material, and which are at a temperature considerably below that of the material, in such manner that depending on the softening behaviour per unit time of the prestressed material a) the vertical and horizontal movement of the tools in association with the web speed of the material describes an inclined plane optionally with a slightly parabolic progression, so that the tools approach the final height of the profiles asymptotically, from the instant of first contact of the tools with the surface of the material up to moment of reaching the planned final height of the profiles, i.e. over the entire shaping distance in which the profile-shaping tension is exerted, b) the vertical velocity of the tools reaches the value zero at the instant the final profile formation is reached, c) the speed and direction of horizontal movement of the tools in the region of the shaping zone coincides with the speed and direction of movement of the material web. 53373 - 22 d) the entering angle, whose vertex coincides with the point of first contact, defined by the material plane forming the first arm and the chord of the curve described by the tools up to the point of first 5 contact with the web surface forming the second arm, is constant, e) during further horizontal movement and until final hardening of the material the stud-shaped tools retain the position they assumed upon reaching the final 10 height of the profiles, for the creation of a zone for material cooling and stabilization. f) subsequently, the tools are conveyed back, horizontally and vertically at the same time, to the start of the shaping, with a leaving angle which is considerably 15 larger than the entering angle.

2. Process according to claim 1, characterized in that the material cooling and stabilizing zone is shortened up to a distance approaching zero.

3. Process according to claim 1 or 2, characterized 20 in that the vertical movement of the tools is concluded before the material web hardens, i.e. is no longer workable.

4. Process according to claim 1 or 2, characterized in that the vertical web movement of the tools is not yet concluded at the instant of hardening. 25 5. Process according to claim 1 for the development of a multiplicity of profiles formed from out of both sides of the material web, characterized in that the stud-shaped tools act simultaneously and on both sides of the intermediately guided prestressed material. - 23 6. Process according to claim 1 for the development of a multiplicity of profiles formed from out of one side of the material web, characterized in that the material web is led over or carried by, one sided, a supporting

5. Multi-meshed grid or net or a perforated plate having at least the number of grid vacancies or perforations to coincide with the number of stud-shaped tools and the tools work on the material from above downwards or from below upwards. 10 7. Process according to any of claims 1 to 3, characterized in that the magnitude of the shaping distance is a function of the entering angle.

6. 8. Process according to any of claims 1-3, characterized in that the magnitude of the shaping distance 15 is a function of the material web thickness, the viscosity of the material, the mass of the tools and the final height of the profiles.

7. 9. Process according to any of claims 1-5, characterized in that the magnitude of the entering angle 20 is 5-45°, preferably 20 - 30°.

8. 10. Process according to any of claims 1-6, characterized in that the profiles are formed transversely of the material web, in successive rows.

9. 11. Process according to any of claims 1-7, 25 characterized in that the rows are positioned alternately upwards and downwards with respect to the plane of the material.

10. 12. Process according to any of claims 1-8, characterized in that the profiles are staggered with 30 respect to each other. - 24

11. 13. Process according to any of claims 1-9, characterized in that the profiles are formed with different final heights.

12. 14. Process according to any of claims 1 - 10, 5 characterized in that long and less long profiles are formed alternately, individually or in groups.

13. 15. Process according to any of claims 1 - 11, characterized in that the profile elements have a direction which deviates from their normal 90° orientation to the 10 plane of the material.

14. 16. Process according to any of claims 1 - 12, characterized in that the stud-shaped tools employed have parallel-sided configurations with flat or even end surfaces and any desired geometrical cross section. 15

15. 17. Process according to claim 13, characterized in that the end surfaces of the stud-shaped tools are formed in a concave manner.

16. 18. Process according to claim 13 or 14, characterized in that the end regions of the stud-shaped tools are 20 bevelled around their outer periphery.

17. 19. Process according to any of claims 1 - 15, characterized in that the heating of the material to the temperature of adequate plasticity and the formation of the undeveloped material web is carried out with the aid 25 of an extruder.

18. 20. Application of the process according to any of claims 1 - 16 to thermoplastioally workable organic substances, particularly those with polymer character. - 25

19. 21. Application of the process according to any of claims 1 - 16 to thermoplastically workable inorganic substances, particularly glass, ceramics, metals, alloys and the like.

20. 22. Apparatus for performing the process according to any of claims 1 - 16, characterized by an apparatus for heating the material to be formed to a temperature which provides adequate plasticity, a further apparatus, directly connected over a short distance with this heating unit for prestressing and evenly aligning the plastified web, one upper and/or one lower engaging device, driven in a circuit at variable speed by suitable driving elements, for a multiplicity of interchangeable box-shaped or plate-shaped carrying elements to carry a multiplicity of stud-shaped tools, said carrying elements being adapted to the width of the web, engageable and moved from both ends by the engaging devices by way of supporting and roller elements mounted on the sides and below, and the carrying elements have preferably parallelsided bearings, cams or studs projecting on both sides in which, to achieve parallel alignment of the upper and lower carrying elements operating under pressure opposed to each other or vertically and horizontally approaching each other, bar-shaped movement elements, moved about pivotal axes, engage, these elements effect the further movement of the carrying elements up to engagement with lower and/or upper, front and rear driving faces mounted in pairs on a common shaft and driven with increased power, by means of which driving faces the carrying elements are located, with change of direction, in the working position, at the material entrance, several spindles, adjustable up and down, particularly in the region of the material web entry and exit zones, whereby the speeds of the elements driving the carrying devices, the bar-shaped movement elements and the driving faces as well as the positions of the steplessly - 26 variable spindles can be co-ordinated and controlled with respect to each other.

21. 23. Apparatus according to claim 19, characterized by supporting and roller elements which are joined 5 together from carrying element to carrying element and can be expanded so that the carrying elements can be returned at elevated speed.

22. 24. Apparatus according to claim 19 or 20, characterized in that the bar-shaped movement elements 10 are guided on both sides of the material web in two parallel ranks, in circuit.

23. 25. Apparatus according to any of claim 19-21, characterized in that the speed of the installation is controlled solely via the speed of the driving device. 15

24. 26. Apparatus according to any of claims 19 - 22, characterized in that at the material removal end the lower driving device travels a greater distance than the upper driving device.

25. 27. Apparatus according to any of claims 19 - 23, 20 characterized in that at the material removal end the driving faces have different rotational speeds in pairs.

26. 28. Apparatus according to any of claims 19 -24, characterized in that the spacing of the opposed tools in the shaping region is variable and their convergence at 25 the material entrance can be controlled by the variable entering angle.

27. 29. Apparatus according to any of claims 19 - 28, characterized in that the speed of the tools in the region of the fastest-possible return movement is considerably in

28. 30 excess of that of the tools in the region of the material entrance, the shaping zone and the cooling and stabilizing zone. - 27 30. Apparatus according to any of claims 19 - 29, characterized in that the tools are cooled or warmed during the return movement.

29. 31. Apparatus according to any of claims 19 - 30, 5 characterized in that the control of the elevating guidance is by means of constraining paths which engage in the guide pieces.

30. 32. Apparatus according to any of claims 19 - 31, characterized in that the entry angle is optionally 10 defined by non-rectilinear shanks and that the variation in the vertical speed of penetration takes place by means of the guide pieces according to claim 31.

31. 33. Apparatus according to claim 32, characterized in that these guide pieces are interchangeable for 15 varying the shaping distance and the penetrating speed,

32. 34. Sets of tools, characterized in that they correspond to the sturctures of the claims 7 - 15.

33. 35. Process as claimed in claim 1, substantially as herein described. 20

34. 36. Apparatus as claimed in claim 22, substantially as herein described.

35. 37. Sets of tools as claimed in claim 34, substantially as herein described.