A method for making objects by forming a thermoformable sheet material includes forming the objects by interaction of a die assembly and a forming assembly. The method further includes, compressing and crushing a first portion of the sheet material by a crushing punch device before forming the objects and maintaining the first portion crushed during the forming operation to reduce the thickness thereof and to orientate chains of molecules that compose a structure of the sheet material at the first portion, in order to weaken the structure and the first portion. The first portion is thus easily perforable, tearable and breakable.

In an example method, a NWM molding blank, including a non-woven material held in compression by a binder, is placed in a separable mold, and heated to a melting temperature of the binder. The molding blank expands, forming as an intermediate NWM object a NWM molded object with a 3D geometric form. The intermediate NWM object is cooled through a temperature band with an upper boundary and a lower boundary, and further cooled to a solidifying temperature of the binder. The upper boundary is above the solidifying temperature and the upper boundary is lower than the binder melting temperature. While in the temperature band, the mold is separated, rendering accessible an exposed surface of the intermediate NWM object. The object is then transported to a contoured forming surface of a forming base, by an actuatable arm having an end effector gripping the exposed surface via vacuum suction, lifting the object from the mold and placing the object on the contoured forming surface. Optionally, the end effector contact surface includes a final forming feature. The actuatable arm compresses the intermediate NWM object against the contoured forming surface, and the optional end effector final forming feature and continues compressing until cooling to the solidifying temperature.

The present invention provides a method of forming a thermoplastic work piece having a deformation temperature. The method comprises locally heating a desired portion, such as a crease line, of the work piece with a stream of a heated fluid, such as a gas, having a temperature at least as high as the plastic deformation temperature of the work piece, and forming the work piece at the heated portion. An apparatus for forming a thermoplastic work piece having a deformation temperature is also provided. The apparatus comprises a heated fluid nozzle operable to deliver a stream of a heated fluid, such as a gas, to a desired portion, such as a crease line, on the work piece to heat the portion to a deformation temperature, and a forming tool for forming the work piece at the heated portion. The method and apparatus involve a conveyor, which rapidly passes the work piece through a sheet of heated fluid to form a line of weakness, which can subsequently be bent and cooled.

An armor production tool including a housing having at least two housing portions that form a substantially air-tight chamber when closed. The tool can include a lower thermal diaphragm forming at least a portion of a mold, and an upper thermal diaphragm forming at least a portion of the mold and capable of engaging the lower flexible membrane. The thermal diaphragms may comprise a thermal transfer membrane, a pressure bearing membrane and a fluid dispersion layer between the thermal transfer membrane and the pressure bearing member. A heating or cooling fluid can be circulated through the fluid dispersion layer to apply heat or to cool the armor part during the molding process. The tool can include a pressure port for pressurizing the chamber and to move the thermal diaphragm towards each other to apply compression on the molded armor part, and a locking mechanism for locking the two housing portions.

A forming device has a machine frame and a forming apparatus disposed on the machine frame. At least one heating chamber is disposed on the machine frame. A heatable support is received in the at least one heating chamber in a position of use for preheating semi-finished products and can be moved in a movement direction out of the at least one heating chamber into a removal position for removal of preheated semi-finished products from the support. In the removal position, the support is at least partially located adjacent to the machine frame and enables access to preheated semi-finished products. At least one heating device is associated with the at least one heating chamber and has one or more convection heating devices that discharge at least one directable heating air flow.

A multi-cavity mold (1) for a thermoforming machine used in high-volume, continuous thermoforming of thin-gauge plastic products (2) from a preheated thin-gauge thermoplastic sheet (3) comprising an upper tool (11) and a lower tool (12) arranged in a cooperating manner; the lower tool (12) comprising cavities (8) in which cavity molds (8) are placed and base plates (91) from which supporting blocks (92) extend perpendicularly over a predetermined total height (a), situated between adjacent cavities (8), each supporting block (92) comprising two zones, a first substantially rectangular shaped zone (92a) and a second substantially isosceles trapezoid shaped zone (92b) in a vertical cross section through a y-z plane and two vertical channels (81) to alter, during forming of the products (2), a thickness of a peripheral flange (B), to decrease from a medium thickness (t) to a lesser thickness (t1).

Steam heating and molding of single or multilayer nonwoven materials, particularly suitable for the formation of three-dimensionally shaped automotive sound insulators.

A thermoforming device heats a plastic film to a substantially uniform temperature, in order to impart a curved shape to said film. The device includes a chamber, the internal pressure of which is variable and which is closed by the film, a system for measuring a sag in the film arranged outside the chamber and opposite said film, and a system for heating the film. The heating system includes a hot air blowing unit which is suitable for producing a hot airflow flowing parallel to the film between two opposite edges of said film.

A forming device has a machine frame and a forming apparatus disposed on the machine frame. At least one heating chamber is disposed on the machine frame. A heatable support is received in the at least one heating chamber in a position of use for preheating semi-finished products and can be moved in a movement direction out of the at least one heating chamber into a removal position for removal of preheated semi-finished products from the support. In the removal position, the support is at least partially located adjacent to the machine frame and enables access to preheated semi-finished products. At least one heating device is associated with the at least one heating chamber and has one or more convection heating devices that discharge at least one directable heating air flow.

This thermoforming machine includes a thermoforming chamber having at least one heated air inlet through which heated air flows into the thermoforming chamber at a controlled pressure. The air inlet cooperates with a heated air flow distribution regulator located in the thermoforming chamber and through which the heated air flows out of the thermoforming chamber at a predetermined temperature. The regulator includes a heated air flow regulating mask receiving heated air flow, having a plurality of flow restricting elements providing different air flow restrictions.