Hot box for hot forming press and method for hot forming workpiece using such hot box

Abstract

The invention provides a hot box of a hot forming press and a method for hot forming a workpiece by using the hot box. The hot box comprises a lower hot box part and an upper hot box part, wherein the lower hot box part comprises a lower shell, a lower heating plate and a lower isolating layer; the upper hot box part comprises an upper shell, an upper heating plate and an upper isolation layer, and the upper isolation layer is located between the upper shell and the upper heating plate; wherein, when the lower hot box portion and the upper hot box portion are in contact with each other, the lower hot box portion and the upper hot box portion provide a thermal barrier around the workpiece accommodated between the lower mold and the upper mold; the lower shell comprises a lower substrate and a lower side wall; the lower substrate, the lower isolating layer and the lower heating plate jointly define a lower bolt channel; the lower hot box part further comprises a lower bolt; and a lower nut assembly operatively coupled to the lower bolt and configured to allow the lower hot box portion to expand and contract without damaging the lower hot box portion.

Description

[0001] This application is a divisional application. The application number of the parent application is 201910990312.4, the application date is October 17, 2019, and the name of the invention is “Hot forming press and method for hot forming workpiece”. Technical Field

[0002] The present disclosure relates to thermoforming presses. Background Art

[0003] Conventional thermoforming presses are expensive. For example, in the aerospace industry, a thermoforming press capable of processing large parts can cost more than $2.5 million, or even as much as $10 million. Moreover, conventional thermoforming presses require expensive maintenance and are subject to unpredictable downtime, which adversely affects manufacturing cycle times. In addition, if a thermoforming press fails in operation, expensive rework of the parts processed by the press at the time of the failure is often required. In the worst case, these parts must be scrapped, resulting in significant additional costs. Summary of the invention

[0004] Therefore, an apparatus and method that aims to solve at least the above-mentioned problems would be of practical use.

[0005] The following is a non-exhaustive list of examples of subject matter that may or may not be claimed in accordance with this invention.

[0006] An example of the subject matter according to the present invention relates to a thermoforming press. The thermoforming press includes a lower press assembly and an upper press assembly. The lower press assembly is movable along a vertical axis and includes a lower mold and a lower hot box portion, and the lower hot box portion is configured to receive the lower mold. The upper press assembly is movable along a vertical axis above the lower press assembly and includes an upper mold and an upper hot box portion. The upper hot box portion is configured to receive the upper mold so that the upper mold is positioned relative to the lower mold. The lower mold and the upper mold are configured to apply a forming pressure to a workpiece contained between the lower mold and the upper mold. The lower hot box portion and the upper hot box portion are configured to heat the workpiece.

[0007] By making both the lower press assembly and the upper press assembly movable along a vertical axis, the components of the thermoforming press that apply the forming force to generate the forming pressure for applying to the workpiece (i.e., the tonnage of the thermoforming press) do not need to have a significant stroke length that takes into account both the operational placement of the workpiece and the removal of the formed part from the thermoforming press, as well as the application of the forming force. Similarly, the components of the thermoforming press that apply the forming force to generate the forming pressure do not need to have a stroke length that also takes into account the removal and replacement of the lower and upper dies. Therefore, the components of the thermoforming press that apply the forming force to generate the forming pressure are subjected to less stress over the same number of cycles as the thermoforming press of the prior art, and therefore require less maintenance and repairs over the life of the thermoforming press.

[0008] Another example of the subject matter according to the present invention relates to a hot box of a thermoforming press. The hot box includes a lower hot box portion and an upper hot box portion. The lower hot box portion includes a lower shell, a lower heating plate, and a lower insulating layer. The lower heating plate is accommodated in the lower shell and is configured to support a lower mold. The lower insulating layer is located between the lower shell and the lower heating plate. The upper hot box portion can be positioned above the lower hot box portion and includes an upper shell, an upper heating plate, and an upper insulating layer. The upper heating plate is accommodated in the upper shell and is configured to support an upper mold. The upper insulating layer is located between the upper shell and the upper heating plate. When the lower hot box portion and the upper hot box portion contact each other, the lower hot box portion and the upper hot box portion provide a thermal barrier around the workpiece accommodated between the lower mold and the upper mold.

[0009] When the thermoforming press is operable to form a portion of a workpiece, the hot box provides a thermal barrier to maintain heat delivered to the lower mold and the upper mold, thereby maintaining heat delivered to the workpiece. The lower housing provides a structure for supporting other components of the lower hot box portion. The lower insulation layer insulates the lower heating plate, which is configured to support the lower mold and conduct heat thereto, thereby promoting efficient heating of the lower mold by limiting conduction away from the lower mold. Similarly, the upper housing provides a structure for supporting other components of the upper hot box portion. The upper insulation layer insulates the upper heating plate, which is configured to support the upper mold and conduct heat thereto, thereby promoting efficient heating of the upper mold by limiting conduction away from the upper mold.

[0010] According to the present invention, another example of the subject matter relates to a method for hot forming a workpiece. The method includes the step of vertically moving both the lower press assembly and the upper press assembly to a loading configuration, in which the lower press assembly and the upper press assembly are spaced apart to receive the workpiece. The method includes the step of positioning the workpiece between the lower die of the lower press assembly and the upper die of the upper press assembly. The method further includes the step of vertically moving both the lower press assembly and the upper press assembly to a closed configuration, in which the lower press assembly and the upper press assembly are positioned to apply forming pressure to the workpiece. The method also includes the step of fixing the upper press assembly. The method further includes the step of moving the lower press assembly toward the upper press assembly to apply forming pressure to the workpiece. The method also includes the step of heating the workpiece.

[0011] By enabling the lower press assembly and the upper press assembly to move vertically between a loaded configuration and a closed configuration, the components of the thermoforming press that apply the forming force to generate the forming pressure for application to the workpiece (i.e., the tonnage of the thermoforming press) do not need to have a significant stroke length that takes into account both the operational placement of the workpiece and the removal of the formed part from the thermoforming press, as well as the application of the forming force. Similarly, the components of the thermoforming press that apply the forming force to generate the forming pressure do not need to have a stroke length that also takes into account the removal and replacement of the lower and upper dies. Therefore, the components of the thermoforming press that apply the forming force to generate the forming pressure are subjected to less stress over the same number of cycles as the thermoforming press of the prior art, and therefore require less maintenance and repair over the life of the thermoforming press.

[0012] By fixing the upper press assembly, the components associated with the vertically moving upper press assembly do not need to be able to apply a forming force sufficient to generate the required forming pressure to operably deform the workpiece. Instead, only the components associated with the vertically moving lower press assembly need to be able to apply a forming force sufficient to generate the required forming pressure to operably deform the workpiece. As a result, the components associated with the vertically moving upper press assembly can be significantly cheaper than the components associated with the vertically moving lower press assembly.

[0013] According to the present invention, another example of the subject matter relates to a method for thermoforming a workpiece, the method comprising the step of delivering actively determined heat to different lower regions of a lower heating plate of a lower heating box part of a heating box of a thermoforming press or to different upper regions of an upper heating plate of an upper heating box part of a heating box of a thermoforming press.

[0014] By enabling the lower press assembly and the upper press assembly to move vertically between a loaded configuration and a closed configuration, the components of the thermoforming press that apply the forming force to generate the forming pressure for application to the workpiece (i.e., the tonnage of the thermoforming press) do not need to have a significant stroke length that takes into account both the operational placement of the workpiece and the removal of the formed part from the thermoforming press, as well as the application of the forming force. Similarly, the components of the thermoforming press that apply the forming force to generate the forming pressure do not need to have a stroke length that also takes into account the removal and replacement of the lower and upper dies. Therefore, the components of the thermoforming press that apply the forming force to generate the forming pressure are subjected to less stress over the same number of cycles as the thermoforming press of the prior art, and therefore require less maintenance and repair over the life of the thermoforming press.

[0015] By fixing the upper press assembly, the components associated with the vertically moving upper press assembly do not need to be able to apply a forming force sufficient to generate the required forming pressure to operably deform the workpiece. Instead, only the components associated with the vertically moving lower press assembly need to be able to apply a forming force sufficient to generate the required forming pressure to operably deform the workpiece. As a result, the components associated with the vertically moving upper press assembly can be significantly cheaper than the components associated with the vertically moving lower press assembly. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Having generally described one or more examples of the present invention, reference will now be made to the drawings, which are not necessarily drawn to scale and in which like reference numerals refer to the same or similar parts throughout the several views, and in which:

[0017] Figure 1A and Figure 1B collectively a block diagram of a thermoforming press according to one or more examples of the present disclosure;

[0018] Figure 2A and Figure 2B collectively, a block diagram of a heat box of a thermoforming press according to one or more examples of the present disclosure;

[0019] Figure 3 According to one or more examples of the present disclosure Figure 1A and Figure 1B A perspective view of a thermoforming press;

[0020] Figure 4 According to one or more examples of the present disclosure Figure 1A and Figure 1B Another perspective view of the thermoforming press;

[0021] Figure 5 According to one or more examples of the present disclosure Figure 1A and Figure 1B a perspective view of a portion of a thermoforming press;

[0022] Figure 6 According to one or more examples of the present disclosure Figure 1A and Figure 1B a cross-sectional perspective view of a portion of a thermoforming press;

[0023] Figure 7 According to one or more examples of the present disclosure Figure 1A and Figure 1B a cross-sectional perspective view of a portion of a thermoforming press;

[0024] Figure 8 According to one or more examples of the present disclosure Figure 2A and Figure 2B The hot box and Figure 1A and Figure 1B A perspective view of a hot box of a thermoforming press;

[0025] Fig. 9 According to one or more examples of the present disclosure Figure 2A and Figure 2B The hot box and Figure 1A and Figure 1B A cross-sectional perspective view of a hot box of a thermoforming press;

[0026] Fig.10 According to one or more examples of the present disclosure Figure 2A and Figure 2B The hot box and Figure 1A and Figure 1B Another perspective cross-sectional view of a hot box of a thermoforming press;

[0027] Fig.11 According to one or more examples of the present disclosure Figure 2A and Figure 2B The upper hot box part of the hot box and Figure 1A and Figure 1B An exploded perspective view of a heat box of a thermoforming press;

[0028] Fig.12 According to one or more examples of the present disclosure Figure 2A and Figure 2B The upper hot box part of the hot box and Figure 1A and Figure 1B Another exploded perspective view of a hot box of a thermoforming press;

[0029] Fig.13 According to one or more examples of the present disclosure Figure 2A and Figure 2B The upper hot box part of the hot box and Figure 1A and Figure 1B a cross-sectional view of a portion of a hot box of a thermoforming press;

[0030] Fig.14 According to one or more examples of the present disclosure Figure 2A and Figure 2B The lower part of the hot box and Figure 1A and Figure 1B An exploded perspective view of a heat box of a thermoforming press;

[0031] Fig.15 According to one or more examples of the present disclosure Figure 2A and Figure 2B The lower part of the hot box and Figure 1A and Figure 1B a cross-sectional view of a portion of a hot box of a thermoforming press;

[0032] Fig.16 According to one or more examples of the present disclosure Figure 1A and Figure 1B A schematic side view of a heating rod of a thermoforming press;

[0033] Fig.17 According to one or more examples of the present disclosure Figure 1A and Figure 1B a front view of a display of a thermoforming press;

[0034] Fig.18 According to one or more examples of the present disclosure Figure 1A and Figure 1B a cross-sectional view of an upper die and a lower die of a thermoforming press and a workpiece;

[0035] Fig.19 According to one or more examples of the present disclosure Figure 1A and Figure 1B a front view of a display of a thermoforming press;

[0036] Fig. 20A and Fig. 20B collectively, a block diagram of a method of thermoforming a workpiece according to one or more examples of the present disclosure;

[0037] Fig.21 is a block diagram of another method of thermoforming a workpiece according to one or more examples of the present disclosure;

[0038] Fig. 22 A block diagram of the production and maintenance methods for the aircraft; and

[0039] Fig.23 A schematic diagram of an aircraft. DETAILED DESCRIPTION

[0040] In the above mentioned Figure 1A , Figure 1B , Figure 2A and Figure 2B , solid lines (if any) connecting various elements and / or components may represent mechanical, electrical, fluid, optical, electromagnetic and other connections and / or combinations thereof. As used herein, "connection" means direct and indirect association. For example, component A may be directly associated with component B, or may be indirectly associated with it, for example, via another component C. It should be understood that not all relationships between various disclosed elements must be represented. Therefore, there may also be connections other than those depicted in the block diagram. Dashed lines (if any), connecting blocks representing various elements and / or components represent connections that are similar in function and purpose to those represented by solid lines; however, the connections represented by dashed lines may be selectively provided or may involve alternative examples of the present disclosure. Similarly, elements and / or components (if any) represented by dashed lines indicate alternative examples of the present disclosure. One or more elements shown in solid and / or dashed lines may be omitted from a particular example without departing from the scope of the present disclosure. Environmental elements (if any) are represented by dashed lines. For clarity, virtual (imaginary) elements may also be shown. Those skilled in the art will understand that, Figure 1A , Figure 1B , Figure 2A and Figure 2B Some of the features shown in can be combined in various ways without necessarily including Figure 1A , Figure 1B , Figure 2A and Figure 2B , other features described in other drawings and / or the attached disclosure, even though this document does not explicitly state such one or more combinations. Similarly, additional features not limited to the examples presented may be combined with some or all of the features shown and described herein.

[0041] In the above mentioned FIG. 20A to FIG. 22 In the embodiment of the present invention, boxes can represent operations and / or parts thereof, and the lines connecting the various boxes do not imply any particular order or dependency of the operations or parts thereof. Boxes represented by dashed lines indicate alternative operations and / or parts thereof. The dashed lines connecting the various boxes (if any) represent alternative dependencies of operations or parts thereof. It should be understood that not all dependencies between the various disclosed operations must be represented. FIG. 20A to FIG. 22 The attached disclosures describing the operations of the methods described herein should not be construed as necessarily determining the sequence of operations to be performed. On the contrary, although an illustrative sequence is indicated, it should be understood that the sequence of operations can be modified when appropriate. Therefore, certain operations can be performed in different orders or simultaneously. In addition, those skilled in the art will appreciate that not all described operations need to be performed.

[0042] In the following description, numerous specific details are set forth to provide a thorough understanding of the disclosed concepts, which concepts may be implemented without some or all of these details. In other cases, details of known devices and / or processes have been omitted to avoid unnecessarily obscuring the present disclosure. Although some concepts will be described in conjunction with specific examples, it should be understood that these examples are not intended to be limiting.

[0043] Unless otherwise indicated, the terms "first", "second", etc. are used herein merely as labels and are not intended to impose order, position, or hierarchy requirements on the items to which these terms refer. In addition, reference to an item such as "second" does not require or exclude the presence of an item such as "first" or lower numbered and / or an item such as "third" or higher numbered.

[0044] Reference herein to "an example" means that one or more features, structures, or characteristics described in connection with the example are included in at least one implementation. The phrase "an example" in various places in the specification may or may not refer to the same example.

[0045] As used herein, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specified function is actually capable of performing the specified function without any changes, rather than merely having the potential to perform the specified function after further modification. In other words, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specified function is specifically selected, created, implemented, utilized, programmed, and / or designed to perform a specified function in order to perform the specified purpose. As used herein, "configured to" means an existing characteristic of a system, device, structure, article, element, component, or hardware that enables the system, device, structure, article, element, component, or hardware to perform the specified function without further modification. For the purposes of this disclosure, a system, device, structure, article, element, component, or hardware that is described as "configured to" perform a particular function may additionally or alternatively be described as "adapted to" and / or "operable to" perform that function.

[0046] The following provides illustrative, non-exhaustive examples of subject matter that may or may not be claimed in accordance with the present disclosure.

[0047] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figures 3 to 7, a thermoforming press 100 is disclosed. The thermoforming press 100 includes a lower press assembly 102 and an upper press assembly 108. The lower press assembly 102 is movable along a vertical axis and includes a lower die 106 and a lower hot box portion 104, the lower hot box portion being configured to receive the lower die 106. The upper press assembly 108 is movable above the lower press assembly 102 along a vertical axis and includes an upper die 112 and an upper hot box portion 110. The upper hot box portion 110 is configured to receive the upper die 112 so that the upper die 112 is positioned relative to the lower die 106. The lower die 106 and the upper die 112 are configured to apply a forming pressure to a workpiece 114 accommodated between the lower die 106 and the upper die 112. The lower hot box portion 104 and the upper hot box portion 110 are configured to heat the workpiece 114. The foregoing subject matter of this paragraph characterizes Example 1 of the present disclosure.

[0048] By making both the lower press assembly 102 and the upper press assembly 108 movable along a vertical axis, the components of the thermoforming press 100 that apply the forming force to generate the forming pressure for applying to the workpiece 114 (i.e., the tonnage of the thermoforming press 100) do not need to have a significant stroke length that takes into account both the operational placement of the workpiece 114 and the removal of the formed part from the thermoforming press 100, as well as the application of the forming force. Similarly, the components of the thermoforming press 100 that apply the forming force to generate the forming pressure do not need to have a stroke length that also takes into account the removal and replacement of the lower die 106 and the upper die 112. Therefore, the components of the thermoforming press 100 that apply the forming force to generate the forming pressure are subjected to less stress over the same number of cycles compared to prior art thermoforming presses, and therefore require less maintenance and repair over the life of the thermoforming press 100.

[0049] The lower heat box section 104 and the upper heat box section 110 are structures that not only support the lower mold 106 and the upper mold 112 , respectively, but also heat the lower mold 106 and the upper mold 112 for operatively forming the workpiece 114 .

[0050] Generally speaking Figure 1A and Figure 1B The lower heat box portion 104 and the upper heat box portion 110 are configured to heat the workpiece 114 to at least 250 degrees Celsius, at least 500 degrees Celsius, ℃ or at least 750 ℃ temperature, or heated to 250 – Temperatures in the range of 1000° C. The foregoing subject matter of this paragraph characterizes Example 2 of the present disclosure, wherein Example 2 also includes subject matter according to Example 1 above.

[0051] Heating the workpiece 114 to a desired temperature enables an operator of the hot forming press 100 to control the yield strength, hardness, and ductility of the workpiece 114, and ultimately the yield strength, hardness, and ductility of a part formed from the workpiece 114. That is, depending on the material selection for the workpiece 114, a temperature or temperature range may be selected, for example, above the recrystallization temperature of the material, to avoid wire hardening of the material during the forming process. Moreover, heating the workpiece 114 allows for forming high strength materials at lower forming pressures than would be required for a cold forming process.

[0052] Illustrative, non-exclusive examples of materials that may be used for workpiece 114 include, but are not limited to, various aluminum and titanium alloys and steel.

[0053] Generally speaking Figure 1A and Figure 1B , the molding pressure is generated by a molding force of at least 50 metric tons, at least 100 metric tons, at least 300 metric tons, at least 500 metric tons, at least 700 metric tons, at least 1000 metric tons, or at least 2000 metric tons, or by a molding force in the range of 50-2250 metric tons. The foregoing subject matter of this paragraph characterizes Example 3 of the present disclosure, wherein Example 3 also includes the subject matter according to Example 1 or 2 above.

[0054] The molding pressure is selected based on the material properties of the workpiece 114 and the complexity of the part formed from the workpiece 114. In addition, a higher molding pressure may provide a lower temperature requirement to produce the desired material properties of the part formed from the workpiece 114.

[0055] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figures 3 to 7 , the lower press assembly 102 and the upper press assembly 108 are configured to move vertically to a loading configuration, in which the lower press assembly 102 and the upper press assembly 108 are spaced apart to receive a workpiece 114 between the lower die 106 and the upper die 112. The lower press assembly 102 and the upper press assembly 108 are configured to move vertically to a closed configuration, in which the lower press assembly 102 and the upper press assembly 108 are positioned to apply a molding pressure to the workpiece 114 between the lower die 106 and the upper die 112. The foregoing subject matter of this paragraph characterizes Example 4 of the present disclosure, wherein Example 4 also includes subject matter according to any one of Examples 1 to 3 above.

[0056] The loading configuration provides sufficient space for an operator or robotic arm to operably place the workpiece 114 between the lower die 106 and the upper die 112. The closed configuration not only positions the lower press assembly 102 and the upper press assembly 108 for applying forming pressure to the workpiece 114, but also for heating the workpiece 114 to a desired temperature.

[0057] In some examples, the loading configuration also provides sufficient space for an operator or a robotic arm to remove a part formed from the workpiece 114 after the thermoforming press 100 has formed the part. Thus, in some examples, the loading configuration may also be referred to as an unloading configuration. However, in some examples, the loading configuration may not provide sufficient space for removing and replacing the lower die 106 and the upper die 112 from the lower press assembly 102 and the upper press assembly 108.

[0058] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figure 4 , the upper press assembly 108 is configured to be selectively locked in the closed configuration. The foregoing subject matter of this paragraph characterizes Example 5 of the present disclosure, wherein Example 5 also includes subject matter according to Example 4 above.

[0059] By locking the upper press assembly 108 in the closed configuration, the forming force required to generate the forming pressure on the workpiece 114 need only be applied by the lower press assembly 102. Thus, the components of the thermoforming press 100 that vertically move the upper press assembly 108 do not need to be able to apply as much force as needed to generate the desired forming pressure, but rather only need to be able to move the upper press assembly at least between the loading configuration and the closed configuration.

[0060] Generally speaking Figure 1A and Figure 1B , especially reference Figures 3 to 6 , the thermoforming press 100 further includes an upper press head 134, at least one locking rod 138, and at least one rod clamp 140. The upper press assembly 108 is vertically movable relative to the upper press head 134. The at least one locking rod 138 is fixed to the upper press assembly 108. The at least one rod clamp 140 is fixed to the upper press head 134 and is configured to selectively clamp the at least one locking rod 138 to fix the upper press assembly 108 relative to the upper press head 134. The foregoing subject matter of this paragraph characterizes Example 6 of the present disclosure, wherein Example 6 also includes the subject matter according to Example 5 above.

[0061] The upper press assembly 108 is fixed relative to the upper ram 134 when the at least one locking bar 138 is clamped by the at least one bar clamp 140. Therefore, when the lower press assembly 102 applies a forming force to generate a forming pressure, the upper press assembly 108 inherently applies an equal and opposite forming force for generating a forming pressure applied to the workpiece 114 to deform it.

[0062] like Figures 3 to 6The illustrated thermoforming press 100 includes four locking bars and corresponding four bar clamps; however, any suitable number of locking bars and bar clamps may be used, for example depending on the size of the thermoforming press 100, the tonnage of the thermoforming press 100, and the strength and capacity of the locking bars and bar clamps. The locking bars and bar clamps may take any suitable configuration, such that at least one bar clamp 140 is configured to receive and selectively lock the relative movement of the locking bars 138. The bar clamps may additionally or alternatively be referred to as locking units, and an illustrative, non-exclusive example of at least one bar clamp 140 is a locking unit KB sold by SITEMA GmbH of Germany.

[0063] The upper ram 134 may be of any suitable configuration so that when the lower press assembly 102 applies a forming force to generate a forming pressure for deforming the workpiece 114, the upper ram 134 provides sufficient rigidity to secure the upper press assembly 108. Figures 3 to 6 As shown, in one or more examples, the upper ram 134 is constructed of two spaced-apart steel plates with a steel rib for structural reinforcement between the two plates, a rod clamp is coupled to the top of the upper ram 134, and a locking rod extends through the upper ram 134. The upper ram 134 and the subsequently discussed lower ram 126 and vertical support 116 can be described as defining a frame of the thermoforming press 100.

[0064] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figures 3 to 7 , the thermoforming press 100 further includes a vertical support 116. The lower press assembly 102 is movable along the vertical support 116. The upper press assembly 108 is movable along the vertical support 116. The foregoing subject matter of this paragraph characterizes Example 7 of the present disclosure, wherein Example 7 also includes subject matter according to any one of Examples 1 to 6 above.

[0065] The vertical supports 116 limit movement of the lower press assembly 102 and the upper press assembly 108 along a vertical axis of the thermoforming press 100 .

[0066] like Figures 3 to 7 As shown, in one or more examples, four vertical supports 116 are included and are generally located at the four corners of the thermoforming press 100. Although the illustrated example has vertical supports 116 that are generally cylindrical, any suitable configuration of vertical supports 116 can be incorporated into the thermoforming press 100 so that the vertical supports 116 serve as tracks or guides for the lower press assembly 102 and the upper press assembly 108 to move along when switching between the loading configuration and the closed configuration (and optionally also the setting configuration discussed later). In some examples, the vertical supports 116 are chrome-plated steel columns.

[0067] Generally speaking Figure 1A and Figure 1B , especially with reference to Figure 3 , Figure 4 , Figure 6 and Figure 7 , the lower press assembly 102 further includes a lower pad 128. The lower pad 128 is located below the lower hot box portion 104 and vertically supports the lower hot box portion. The vertical support member 116 extends through the lower pad 128. The foregoing subject matter of this paragraph characterizes Example 8 of the present disclosure, wherein Example 8 also includes the subject matter according to Example 7 above.

[0068] The lower backing plate 128 supports the lower hot box section 104 and provides a structure for the lower press assembly 102 to translate along the vertical supports 116 without affecting the isolation function of the lower hot box section 104 .

[0069] like Figure 3 , Figure 4 , Figure 6 and Figure 7 As shown, in one or more examples, the lower backing plate 128 is formed of two spaced-apart steel plates with steel ribs between the two steel plates for structural reinforcement, the lower hot box portion 104 is coupled to the top side of the lower backing plate 128, and the vertical support member 116 extends through the lower backing plate 128. Additionally or alternatively, the lower backing plate 128 can be referred to as a lower ram or a lower support frame of the lower press assembly 102.

[0070] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figures 3 to 6 , the upper press assembly 108 further includes an upper pad 130. The upper pad 130 is located above the upper hot box portion 110 and vertically supports the upper hot box portion. The vertical support 116 extends through the upper pad 130. The foregoing subject matter of this paragraph characterizes Example 9 of the present disclosure, wherein Example 9 also includes the subject matter according to Example 7 or 8 above.

[0071] The upper backing plate 130 supports the upper hot box section 110 and provides a structure for the upper press assembly 108 to translate along the vertical supports 116 without affecting the isolation function of the upper hot box section 110 .

[0072] like Figures 3 to 6 As shown, in one or more examples, the upper backing plate 130 is formed of two spaced-apart steel plates with steel ribs between the two steel plates for structural reinforcement, the upper hot box portion 110 is coupled to the underside of the upper backing plate 130, and the vertical support member 116 extends through the upper backing plate 130. Additionally or alternatively, the upper backing plate 130 can be referred to as an upper stamping portion or an upper support frame of the upper press assembly 108.

[0073] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figures 3 to 6 , the thermoforming press 100 further includes a lower translation mechanism 118. The lower translation mechanism 118 is operably coupled to the lower press assembly 102 and is configured to move the lower press assembly 102 along a vertical axis. The thermoforming press 100 also includes an upper translation mechanism 120. The upper translation mechanism 120 is configured to vertically move the upper press assembly 108 along a vertical axis. The foregoing subject matter of this paragraph characterizes Example 10 of the present disclosure, wherein Example 10 also includes subject matter according to any one of Examples 1 to 9 above.

[0074] As described above, the lower translation mechanism 118 and the upper translation mechanism 120 move the lower press assembly 102 and the upper press assembly 108, respectively, along a vertical axis. Thus, in one or more examples, the lower press assembly 102 and the upper press assembly 108 are selectively positioned in various vertical positions relative to each other to allow loading of the workpiece 114 and unloading of parts formed from the workpiece 114, to allow insertion and removal of the lower die 106 and the upper die 112, and to allow maintenance of the various component parts of the lower press assembly 102 and the upper press assembly 108.

[0075] In one or more examples, lower translation mechanism 118 and upper translation mechanism 120 take various forms, including, but not limited to, the specific examples disclosed and shown herein. In an illustrative, non-exclusive example, each of lower translation mechanism 118 and upper translation mechanism 120 includes one or more of a hydraulic cylinder, a drive screw assembly, a ratchet assembly, a pneumatic assembly, a gear assembly, and / or a pulley assembly.

[0076] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figure 4 and Figure 6 The lower translation mechanism 118 is configured to apply a molding force to generate a molding pressure. The foregoing subject matter of this paragraph characterizes Example 11 of the present disclosure, wherein Example 11 also includes subject matter according to Example 10 above.

[0077] The molding pressure operatively deforms the workpiece 114 between the lower die 106 and the upper die 112 .

[0078] Generally speaking Figure 1A and Figure 1B , the upper translation mechanism 120 is not configured to apply a forming force to generate a forming pressure. The foregoing subject matter of this paragraph characterizes Example 12 of the present disclosure, wherein Example 12 also includes subject matter according to Example 10 or 11 above.

[0079] By not applying a forming force to the upper translation mechanism 120, the upper translation mechanism 120 does not need to be able to apply a forming force sufficient to generate the required forming pressure to operably deform the workpiece 114 into a formed part. Therefore, in one or more examples, the upper translation mechanism 120 is less expensive and easier to maintain than the lower translation mechanism 118, which is configured to apply and is capable of applying the forming force required to generate the forming pressure to operably deform the workpiece 114. In addition, in one or more examples, by not applying a forming force to the upper translation mechanism 120, the upper translation mechanism 120 is configured to have a much longer stroke than the lower translation mechanism 118, such as for reconfiguring the thermoforming press 100 to a loading configuration. As a result, in one or more examples, the lower translation mechanism 118 is significantly less expensive than a corresponding mechanism of a thermoforming press of the prior art.

[0080] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figure 4 and Figure 6 , the lower translation mechanism 118 includes at least one hydraulic cylinder 124. The foregoing subject matter of this paragraph characterizes Example 13 of the present disclosure, wherein Example 13 also includes subject matter according to any one of Examples 10 to 12 above.

[0081] The hydraulic cylinders are capable of applying the necessary forming force to generate the desired forming pressure for operable deformation of the workpiece 114 .

[0082] Depending on the circumstances, for example, based on the tonnage of the thermoforming press 100, the specifications of the hydraulic cylinders, etc., any number of hydraulic cylinders may be suitable for use. Figure 4 In the illustrated example of the thermoforming press 100, four hydraulic cylinders are located between the lower ram 126 and the lower pad 128. By having more than one hydraulic cylinder 124, a less expensive, off-the-shelf hydraulic cylinder is used in one or more examples to achieve the desired tonnage of the thermoforming press 100.

[0083] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figure 4 and Figure 6 , the thermoforming press 100 further includes a lower ram 126 and at least one hydraulic cylinder 124. The lower press assembly 102 is vertically movable relative to the lower ram 126. The at least one hydraulic cylinder 124 is operably coupled between the lower press assembly 102 and the lower ram 126 to vertically move the lower press assembly 102 relative to the lower ram 126 and apply a forming pressure to the workpiece 114. The foregoing subject matter of this paragraph characterizes Example 14 of the present disclosure, wherein Example 14 also includes subject matter according to Example 13 above.

[0084] The lower ram 126 provides a fixed structure against which the at least one hydraulic cylinder 124 pushes to vertically move the lower press assembly 102 and is operable to apply forming pressure to the workpiece 114 .

[0085] exist Figure 4 and Figure 6 In the illustrated example of the thermoforming press 100, the lower press head 126 is located below the floor surface 101 of the production environment in which the thermoforming press 100 is installed. Thus, in one or more examples, the lower press assembly 102 is positioned relative to the floor surface 101 so that an operator of the thermoforming press 100 can easily access the lower press assembly 102 and its component parts, such as for maintenance, insertion and removal of the lower mold 106, etc.

[0086] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figures 3 to 6 , the upper translation mechanism 120 includes a single drive screw assembly 132. The foregoing subject matter of this paragraph characterizes Example 15 of the present disclosure, wherein Example 15 also includes subject matter according to any one of Examples 10 to 14 above.

[0087] By including only a single drive screw assembly 132, the cost of the upper translation mechanism 120 is significantly reduced compared to prior art thermoforming presses. In addition, in one or more examples, by including only a single drive screw assembly 132, the drive screw is positioned in the center of the upper press assembly 108 and the upper ram 134, thereby shielding the single drive screw assembly 132 from radiant heat emitted from the hot box 300, including radiant heat emitted from the lower mold 106, the upper mold 112, and the workpiece 114 during molding, such as when the lower press assembly 102 and the upper press assembly 108 are in a loading configuration for removing molded parts and loading the workpiece 114.

[0088] exist Figures 3 to 6 In the illustrated exemplary thermoforming press 100 , a single drive screw assembly 132 includes a direct drive motor 121 mounted above an upper ram 134 and includes a drive screw 123 extending through the upper ram 134 and operably coupled between the direct drive motor 121 and the upper backing plate 130 .

[0089] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figures 3 to 6, the thermoforming press 100 further includes an upper press head 134. The upper press assembly 108 is vertically movable relative to the upper press head 134. A single drive screw assembly 132 is operably coupled between the upper press assembly 108 and the upper press head 134 to vertically move the upper press assembly 108 relative to the upper press head 134. The foregoing subject matter of this paragraph characterizes Example 16 of the present disclosure, wherein Example 16 also includes subject matter according to Example 15 above.

[0090] In one or more examples, the upper press head 134 provides a fixed structure relative to which the single drive screw assembly 132 vertically translates the upper press assembly 108 .

[0091] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figure 6 and Figure 7 , the lower press assembly 102 is configured to move vertically to a die setting configuration in which the lower die 106 is spaced apart from the lower hot box portion 104 to selectively remove and replace the lower die 106. The foregoing subject matter of this paragraph characterizes Example 17 of the present disclosure, wherein Example 17 also includes subject matter according to any one of Examples 1 to 16 above.

[0092] As noted, in one or more examples, in the mold setup configuration, the lower mold 106 is removed and replaced from the lower hot box portion 104. Thus, in one or more examples, the thermoforming press 100 is selectively configured for forming various parts.

[0093] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figure 6 and Figure 7 , the thermoforming press 100 further includes at least one lower mold lift pin 136. The at least one lower mold lift pin 136 extends into the lower hot box portion 104 and is positioned to operably engage the lower mold 106. The lower press assembly 102 is vertically movable relative to the at least one lower mold lift pin 136. When the lower press assembly 102 is vertically moved to the mold setting configuration, the at least one lower mold lift pin 136 positions the lower mold 106 above the lower hot box portion 104 for selective removal and replacement of the lower mold 106. The foregoing subject matter of this paragraph characterizes Example 18 of the present disclosure, wherein Example 18 also includes the subject matter according to Example 17 above.

[0094] In one or more examples, the lower mold 106 can be removed and replaced by operably positioning the lower mold 106 above the lower hot box portion 104. Thus, the thermoforming press 100 can be selectively configured for forming a variety of parts.

[0095] Any suitable number and configuration of lower mold lift pins may be incorporated into the thermoforming press 100. Typically, the lower mold lift pins 136 are elongated structures that extend through the lower hot box portion 104 for engagement with the lower mold 106. More specifically, Figure 6 and Figure 7 In the thermoforming press 100 of the present invention, four lower mold lift pins are supported by corresponding bases 137, which are fixed to the upper surface of the lower press head 126, wherein the bases 137 partially extend through the lower backing plate 128, and the lower mold lift pins extend from the bases 137, through the lower backing plate 128 and through the lower hot box portion 104 to engage the lower mold 106. Therefore, when the lower translation mechanism 118 vertically lowers the lower press assembly 102 to the mold setting configuration, the lower mold lift pins remain engaged with the lower mold 106, so that the remainder of the lower hot box portion 104 is lowered relative to the lower mold 106. As a result, the lower mold 106 is spaced apart from and located above the remainder of the lower hot box portion 104, so that it can be selectively removed from the lower press assembly 102. For example, in one or more examples, a forklift is used to lift and remove the lower mold 106 from the lower press assembly 102. Similarly, in one or more examples, a forklift is used to position a new lower mold on top of the lower mold lift pins 136 .

[0096] Generally speaking Figure 1A , Figure 1B , Figure 2A and Figure 2B , especially with reference to e.g. Figures 6 to 10 and Fig.14 , the lower hot box portion 104 includes a lower shell 142, a lower heating plate 144 and a lower insulation layer 148. The lower heating plate 144 is housed within the lower shell 142 and is configured to contact the lower mold 106 and include different lower areas 146. The lower insulation layer 148 is located between the lower shell 142 and the lower heating plate 144. The lower press assembly 102 further includes a lower heat source 150, which is configured to deliver actively determined heat to different lower areas 146 of the lower heating plate 144. The foregoing subject matter of this paragraph characterizes Example 19 of the present disclosure, wherein Example 19 also includes subject matter according to any one of Examples 1 to 18 above.

[0097] The lower housing 142 provides a structure for supporting the other components of the lower hot box portion 104. The lower insulation layer 148 insulates the lower heating plate 144 from contact with the lower mold 106, thereby promoting efficient heating of the lower mold 106 by limiting conduction away from the lower mold 106. By having the lower heat source 150 deliver actively determined heat to different lower regions 146 of the lower heating plate 144, the heat delivered to the different lower regions 146, and thus the temperature of the different lower regions, can be controlled to provide desired heating of the lower mold 106 and corresponding regions of the workpiece 114. For example, it may be desirable to heat portions of the lower mold 106 corresponding to a tighter bend to be formed in the workpiece 114. Additionally or alternatively, it may be desirable to deliver greater heat to outer regions of the lower mold 106 than to inner regions of the lower mold 106 due to conductive heat losses through the lower insulation layer 148.

[0098] In one or more examples, the lower housing 142 is constructed of any suitable material and any suitable configuration such that it supports the other components of the lower hot box portion 104. Figure 6-Figure 10 and Fig.14 In the lower hot box portion 104, the lower housing 142 includes a lower base plate 302 and a lower side wall 304 formed of an alloy (such as Inconel).

[0099] In one or more examples, the lower heated platen 144 (which may additionally or alternatively be described as a lower heated platen) takes any suitable form such that it is configured to receive heat from the lower heat source 150 and deliver heat to the lower mold 106. Figure 6-Figure 10 and Fig.14 As shown, and as discussed herein, the lower heating plate 144 defines a portion of a lower heating rod channel 152 in which a corresponding lower heating rod of the lower heat source 150 extends.

[0100] Generally speaking Figure 1A , Figure 1B , Figure 2A and Figure 2B , especially with reference to e.g. Figure 6-Figure 8 , Fig.10 and Fig.14 , the lower heating plate 144 defines a lower heating plate volume 320 within which the lower mold 106 is located. The foregoing subject matter of this paragraph characterizes Example 20 of the present disclosure, wherein Example 20 also includes subject matter according to Example 19 above.

[0101] By defining a lower heating plate volume 320 within which the lower mold 106 is located, the lower heating plate 144 is able to deliver heat to the lower mold 106 not only from below the lower mold 106 but also from the sides of the lower mold 106. As a result, heating of the lower mold 106 is efficient.

[0102] Generally speaking Figure 1A and Figure 1B , especially for example Figure 6 , Figure 7 , Fig. 9 , Fig.10 , Fig.14 and Fig.15 , the lower heating plate 144 and the lower shell 142 together define a lower heating rod channel 152. The lower heat source 150 includes a lower heating rod 154, which extends into the lower heating rod channel 152. The foregoing subject matter of this paragraph characterizes Example 21 of the present disclosure, wherein Example 21 also includes subject matter according to Example 19 or 20 above.

[0103] The lower heating rods 154 of the lower heat source 150 can control the heating of the lower heating plate 144, and thus the heating of the lower mold 106 over the entire span of the lower heating plate 144. As a result, the temperature of various portions of the lower heating plate 144 can be effectively and efficiently controlled.

[0104] In one or more examples, the lower heating rods 154 take various forms such that they are configured to deliver heat to the lower heating plate 144. As an illustrative, non-exclusive example, the lower heating rods 154 include an elongated heating element constructed of nickel steel, encapsulated by a ceramic layer, and embedded in a stainless steel sheath. The ceramic layer absorbs oxygen to limit oxidation of the heating element.

[0105] Any suitable number of lower heating rods 154 and corresponding lower heating rod channels may be provided, for example based on the size of the lower heating plate 144, the degree of temperature control desired for the thermoforming press 100, etc. Figure 6 , Figure 7 , Fig. 9 , Fig.10 and Fig.14 In the illustrated example of , forty lower heater rod channels 152 are defined by the lower heater plate 144 and the lower housing 142 .

[0106] In the example of the lower heat box portion 104 where the lower insulation layer 148 extends over the sides of the lower heating plate 144 , the lower insulation layer 148 together with the lower heating plate 144 and the lower housing 142 define a lower heating rod channel 152 .

[0107] Generally speaking Figure 1A and Figure 1B, especially with reference to e.g. Fig.16 , the lower heating rod 154 is straight along the entire length of the lower heating rod 154. The foregoing subject matter of this paragraph characterizes Example 22 of the present disclosure, wherein Example 22 also includes subject matter according to Example 21 above.

[0108] Because the lower heating rod 154 is straight along its entire length, the integrity of the lower heating rod 154 remains intact for a considerable period of time, thereby eliminating the need for expensive replacement.

[0109] For example, the ceramic layer of the lower heating rod 154 will not crack like the bent heating rod of the prior art, thereby avoiding the intrusion of air into the lower heating rod 154 and avoiding unwanted oxidation and degradation of the heating element of the lower heating rod 154 .

[0110] Generally speaking Figure 1A and Figure 1B , especially reference Figure 3 , Figure 4 , Figure 6 and Figure 7 , the lower heat source 150 further includes a lower connection box 158 and a lower connection cable 160, and the lower connection cable 160 interconnects the lower heating rod 154 with the lower connection box 158. The lower press assembly 102 further includes a lower pad 128, which is located below the lower heat box portion 104 and vertically supports the lower heat box portion 104. The lower connection box 158 is mounted on the lower pad 128. The foregoing subject matter of this paragraph characterizes Example 23 of the present disclosure, wherein Example 23 also includes the subject matter according to Example 21 or 22 above.

[0111] In one or more examples, by mounting the lower connection box 158 to the lower pad 128, for example, at its periphery or on its underside, and by interconnecting the lower heating rod 154 to the lower connection box 158 via a lower connection cable 160, the lower connection box 158 is protected from, or at least isolated from, radiant heat emanating from the lower mold 106 and the upper mold 112 when the thermoforming press 100 is in a loading configuration.

[0112] In contrast, in prior art thermoforming presses, connecting cables and boxes are typically coupled to and in direct contact with hot surfaces of the thermoforming press, resulting in a short life of these components and requiring frequent maintenance or replacement.

[0113] Generally speaking Figure 1A and Figure 1B , when heat is radiated from the lower heat box portion 104, the lower pad 128 shields the lower connection box 158 from the heat. The foregoing subject matter of this paragraph characterizes Example 24 of the present disclosure, wherein Example 24 also includes the subject matter according to Example 23 above.

[0114] By shielding the lower connection box 158 from heat radiated from the lower hot box portion 104, the lower connection box 158 is protected and has a longer life than connection boxes of prior art thermoforming presses.

[0115] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Fig.16 , the lower heating rods 154 each include a lower heating region 162. The temperature of the lower heating region 162 is independently controlled. The lower heating region 162 coincides with a different lower region 146 of the lower heating plate 144. The foregoing subject matter of this paragraph characterizes Example 25 of the present disclosure, wherein Example 25 also includes subject matter according to any one of Examples 21 to 24 above.

[0116] By dividing into different lower heating zones 162, the lower heating rods 154 may be used to independently control the amount of heat delivered to different lower regions 146 of the lower heating plate 144, and therefore different regions of the lower mold 106. As discussed, the amount of heat delivered to the different lower regions 146, and therefore the temperatures of the different lower regions 146, may be controlled to provide desired heating of the lower mold 106 and corresponding regions of the workpiece 114. For example, in some cases, it may be desirable to heat portions of the lower mold 106 that correspond to tighter bends to be formed in the workpiece 114. Additionally or alternatively, in some cases, it may be desirable to deliver greater heat to outer regions of the lower mold 106 than to inner regions of the lower mold 106 due to conductive heat losses through the lower insulation layer 148. Furthermore, in examples of the lower heat box portion 104 where the lower insulation layer 148 has different thicknesses on opposite sides of the lower heating plate 144, greater heat can be transported to areas of the lower heating plate 144 proximate such thinner areas of the lower insulation layer 148 due to greater heat losses in the thinner areas.

[0117] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Fig.16 , the lower heating region 162 includes an outer lower region 168 and at least one inner lower region 170, which is located between the outer lower regions 168. The outer lower region 168 has a higher heating capacity than the at least one inner lower region 170. The foregoing subject matter of this paragraph characterizes Example 26 of the present disclosure, wherein Example 26 also includes the subject matter according to Example 25 above.

[0118] In some cases, it may be desirable or necessary to deliver a greater amount of heat to the outer lower region 168 than to the at least one inner lower region 170 because areas of the lower heating plate 144 proximate the outer lower region 168 lose heat at a greater rate than areas of the lower heating plate 144 proximate the at least one inner lower region 170. Thus, in one or more examples, a lower heating rod 154 having at least one inner lower region 170 with less heating capacity than the outer lower region 168 is less expensive than a heating rod having uniform heating capacity along its length.

[0119] like Fig.16 As shown, in one or more examples, the lower heating rod 154 further includes a lower rod region 155 proximate to the corresponding lower connecting cable, wherein the lower rod region 155 is configured to not conduct heat therefrom, for example, the heating element of the lower heating rod 154 extends only through the outer lower region 168 and at least one inner lower region 170. In addition, in one or more examples, the lower rod region 155 extends out from the lower hot box portion 104, in which case it is desired that the lower rod region 155 is not heated.

[0120] Generally speaking Figure 1A , Figure 1B , Figure 2A and Figure 2B , especially with reference to e.g. Figure 3 and Figure 4 , the lower hot box portion 104 has a lower front side 172 and a lower rear side 174. The lower hot box portion 104 is configured to receive the lower mold 106 at a position closer to the lower front side 172 than the lower rear side 174. The outer lower region 168 near the lower front side 172 has a higher heating capacity than the outer lower region 168 near the lower rear side 174. The foregoing subject matter of this paragraph characterizes Example 27 of the present disclosure, wherein Example 27 also includes subject matter according to Example 26 above.

[0121] By being positioned closer to the lower front side 172 , the lower die 106 , along with the upper die 112 and the workpiece 114 , are more easily accessible from the lower front side 172 by an operator of the thermoforming press 100 to facilitate insertion and removal of the workpiece 114 .

[0122] However, by positioning the lower mold 106 closer to the lower front side 172, and therefore by making the lower insulation layer 148 thinner on the lower front side 172 than on the lower back side 174, in some cases, due to the greater heat loss in the thinner area, it is necessary to deliver greater heat to the area of ​​the lower heating plate 144 proximate such thinner area of ​​the lower insulation layer 148. In such an example, the outer lower area of ​​the lower heating rod proximate the lower front side 172 has a higher heating capacity than the outer lower area of ​​the lower heating rod proximate the lower back side 174.

[0123] Generally speaking Figure 1A and Figure 1B , the thermoforming press 100 further includes a lower temperature sensor 164 and a controller 156. The lower temperature sensor 164 is configured to sense the temperature of the different lower regions 146 of the lower heating plate 144. The controller 156 is operably coupled to the lower connection box 158 and is configured to control the actively determined amount of heat delivered to the different lower regions 146 of the lower heating plate 144 based at least in part on the temperature of the different lower regions 146 of the lower heating plate 144. The foregoing subject matter of this paragraph characterizes Example 28 of the present disclosure, wherein Example 28 also includes subject matter according to any one of Examples 19 to 27 above.

[0124] By sensing the temperatures of different lower regions 146 of the lower heating plate 144, the controller 156 is able to direct heat delivered to the different lower regions 146 based on the sensed temperatures to ensure that the different lower regions 146 of the lower heating plate 144 and, therefore, corresponding regions of the lower mold 106 are heated to the desired temperature for a particular operation of the thermoforming press 100.

[0125] The lower temperature sensors 164 may take any suitable form such that they are configured to sense the temperature of the different lower regions 146 of the lower heating plate 144. For example, in one or more examples, the lower temperature sensors 164 are thermocouples embedded within the lower heating plate 144.

[0126] Generally speaking Figure 1A and Figure 1B , the thermoforming press 100 further includes a lower mold temperature sensor 166 and a controller 156. The lower mold temperature sensor 166 is configured to sense the temperature of the lower mold 106. The controller 156 is configured to record or display the temperature of the lower mold 106. The controller 156 is configured to control the actively determined amount of heat delivered to the different lower regions 146 of the lower heating plate 144 not based on the temperature of the lower mold 106. The foregoing subject matter of this paragraph characterizes Example 29 of the present disclosure, wherein Example 29 also includes subject matter according to Example 28 above.

[0127] The temperature of the lower mold 106 may be recorded or displayed for quality control purposes, including, for example, generating a report showing temperature compliance within or deviation from an expected temperature range for the lower mold 106. Additionally or alternatively, an alarm may be generated during the molding process for an operator to take corrective action or otherwise record one or more issues that may need to be addressed.

[0128] Generally speaking Figure 1A and Figure 1B , especially reference Figure 3 , Figure 4 and Fig.17 , the thermoforming press 100 further includes a display 176. The display 176 is operably coupled to the controller 156 and is configured to display the temperature of different lower regions 146 of the lower heating plate 144. The foregoing subject matter of this paragraph characterizes Example 30 of the present disclosure, wherein Example 30 also includes subject matter according to Example 28 or 29 above.

[0129] By displaying the temperatures of different lower regions 146 of the lower heating plate 144, such temperatures may be monitored in real time by an operator of the thermoforming press for quality control purposes.

[0130] like Fig.17 As shown, the display 176 provides thermal information, such as thermal information associated with different lower zones 146 of the lower heating plate 144. In the example of the display 176 shown, twelve zones of the lower heating plate 144 are monitored. Each zone has a different controller or amplifier stack associated with it for controlling the amount of current delivered to each circuit associated with the lower heating zone 162 of the corresponding lower heating rod. These different controllers also monitor if there is a problem with the lower heating rod and communicate with the controller 156 to determine if the lower heating rod 154 is properly maintaining its temperature or if more energy is needed. Each of these different controllers can feed more or less power to the corresponding lower heating rod based on the temperature sensed by the lower temperature sensor 164.

[0131] exist Fig.17In the illustrated example of the display 176 in FIG. 1 , the temperature sensed by the lower temperature sensor 164 is indicated by a digital "needle" or line superimposed on a representation of an analog gauge representing a temperature range, the analog gauge having an acceptable temperature range represented in the middle and an undesirable temperature range represented on the left and right sides of the analog gauge. Thus, when the needle is in the middle range, the corresponding lower area of ​​the lower heating plate 144 is at the desired temperature. However, if the needle is in the left range, the corresponding area of ​​the lower heating plate 144 is too cold, and the corresponding area of ​​the associated one of the lower heating rods 154 may be defective or not functioning properly. If the needle is in the right range, the corresponding area of ​​the lower heating plate 144 is too hot, and the corresponding area of ​​the associated one of the lower heating rods 154 may be defective or not functioning properly. In one or more examples, when the needle is in the middle range, the middle range is displayed in green or another color, thereby reminding the operator that the corresponding area is functioning properly. In one or more examples, when the needle is in the left or right range, the middle range is displayed in yellow or another color, thereby reminding the operator that the corresponding area may not function properly.

[0132] like Fig.17 As shown, the operator of the thermoforming press 100 can customize the temperature tolerance. In the example shown, the tolerance is set to 50 degrees.

[0133] Generally speaking Figure 1A , Figure 1B , Figure 2A and Figure 2B , especially with reference to e.g. Figure 6-Figure 10 , Fig.14 and Fig.15 , the lower hot box portion 104 further includes a lower cold plate 178. The lower cold plate 178 is at least partially positioned between the lower insulation layer 148 and the lower shell 142, and is configured to draw heat away from the lower hot box portion 104. The foregoing subject matter of this paragraph characterizes Example 31 of the present disclosure, wherein Example 31 also includes subject matter according to any one of Examples 19 to 30 above.

[0134] The lower cold plate 178 draws heat away from the lower hot box portion 104, which is conducted from the lower heated plate 144 through the lower insulation layer 148. Thus, the lower cold plate 178 prevents the lower housing 142 and the lower backing plate 128 from becoming too hot for an operator of the thermoforming press 100.

[0135] The lower cold plate 178 is a heat transfer device and is implemented so that it effectively draws heat away from the lower hot box portion 104. For example, in one or more examples, the lower cold plate 178 is made of stainless steel, wherein one or more cooling channels extend through the lower cold plate 178 and a coolant (e.g., ethylene glycol) circulates through the one or more cooling channels. In some examples, the lower cold plate 178 is made of two separate parts welded together. This two-piece structure facilitates the processing of a single circuitous cooling channel in each component. Alternatively, in one or more examples, the lower cold plate 178 is made of a single piece, which avoids coolant leakage and the need for a gasket between the two components of the two-piece structure. In such a single-piece structure, in one or more examples, the cooling channel is gun-drilled through the lower cold plate 178, thereby requiring external pipes to connect the cooling channels together. In one or more examples, the coolant is transported and removed from the lower cold plate 178 via a factory-based coolant system.

[0136] Generally speaking Figure 1A , Figure 1B , Figure 2A and Figure 2B , especially with reference to e.g. Figure 7 , Fig.10 , Fig.14 and Fig.15 , the lower hot box portion 104 further includes a lower hot box fastener 180, which operably interconnects the lower housing 142, the lower heating plate 144, and the lower insulation layer 148. The lower hot box fastener 180 includes a lower bolt 182 and a spring-loaded lower nut assembly 184. The spring-loaded lower nut assembly 184 is operably coupled to the lower bolt 182 and is configured to allow the lower hot box portion 104 to expand and contract without damaging the lower hot box portion 104. The foregoing subject matter of this paragraph characterizes Example 32 of the present disclosure, wherein Example 32 also includes subject matter according to any one of Examples 19 to 31 above.

[0137] The lower hot box fasteners 180 enable the components of the lower hot box portion 104 to expand and contract due to the significant temperature range experienced by the lower hot box portion 104 when the thermoforming press 100 is in use and when the thermoforming press 100 is not in use.

[0138] The lower hot box fasteners 180 are implemented so that they allow for expansion and contraction of the lower hot box portion 104 without causing damage thereto. Fig.15, the lower bolt 182 is composed of two parts, namely, a first lower bolt part 183 including a bolt head and composed of a high temperature alloy (such as Supersam) and a second lower bolt part 185 welded to the first lower bolt part 183, the first lower bolt part 183 including a bolt head and composed of a high temperature alloy (such as Supersam), and the second lower bolt part 185 composed of a lower temperature and cheaper alloy (such as Inconel). As an example, the spring-loaded lower nut assembly 184 includes a stack of Belleville washers.

[0139] Generally speaking Figure 1A , Figure 1B , Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 , Figure 7 and Figure 9-12 , the upper hot box portion 110 includes an upper shell 186, an upper heating plate 188 and an upper insulation layer 192. The upper heating plate 188 is housed within the upper shell 186 and is configured to contact the upper mold 112 and include different upper regions 190. The upper insulation layer 192 is located between the upper shell 186 and the upper heating plate 188. The upper press assembly 108 further includes an upper heat source 122. The upper heat source 122 is configured to deliver actively determined heat to different upper regions 190 of the upper heating plate 188. The foregoing subject matter of this paragraph characterizes Example 33 of the present disclosure, wherein Example 33 also includes subject matter according to any one of Examples 1 to 32 above.

[0140] The upper housing 186 provides a structure for supporting the other components of the upper hot box portion 110. The upper insulating layer 192 insulates the upper heating plate 188 from contacting the upper mold 112, thereby promoting efficient heating of the upper mold 112 by limiting conduction away from the upper mold 112. By having the upper heat source 122 deliver actively determined amounts of heat to different upper regions 190 of the upper heating plate 188, the amount of heat delivered to the different upper regions 190, and thus the temperatures of the different upper regions 190, can be controlled to provide desired heating of the upper mold 112 and corresponding regions of the workpiece 114. For example, in some cases, it may be desirable to heat portions of the upper mold 112 that correspond to tighter bends to be formed in the workpiece 114. Additionally or alternatively, in some cases, it may be desirable to deliver greater heat to outer regions of the upper mold 112 than to inner regions of the upper mold 112 due to conductive heat losses through the upper insulating layer 192.

[0141] In one or more examples, the upper housing 186 is constructed of any suitable material and any suitable configuration such that it supports the other components of the upper hot box portion 110. Figure 6 , Figure 7 and Figure 9-12As shown, in one or more examples, the upper housing 186 includes an upper sidewall 332 and an upper top plate 330 constructed of an alloy, such as Inconel.

[0142] The upper heated platen 188, which may additionally or alternatively be described as an upper heated platen, is implemented in any suitable form such that it is configured to receive heat from the upper heat source 122 and deliver heat to the upper mold 112. Figure 6 , Figure 7 and Figure 9-12 As shown, and as discussed herein, in one or more examples, the upper heating plate 188 defines a portion of an upper heating rod channel 194 within which a corresponding upper heating rod of the upper heat source 122 extends.

[0143] Generally speaking Figure 1A , Figure 1B , Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 , Figure 7 , Fig. 9 , Fig.10 and Fig.12 , the upper heating plate 188 defines an upper heating plate volume 346, and the upper mold 112 is located within the upper heating plate volume 346. The foregoing subject matter of this paragraph characterizes Example 34 of the present disclosure, wherein Example 34 also includes subject matter according to Example 33 above.

[0144] By defining an upper heating plate volume 346 within which the upper mold 112 is located, the upper heating plate 188 can deliver heat to the upper mold 112 not only from above the upper mold 112 but also from the sides of the upper mold 112. As a result, heating of the upper mold 112 is effective.

[0145] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figure 6 , Figure 7 and Figure 9-12 , the upper heating plate 188 and the upper shell 186 together define an upper heating rod channel 194. The upper heat source 122 includes an upper heating rod 196, which extends into the upper heating rod channel 194. The foregoing subject matter of this paragraph characterizes Example 35 of the present disclosure, wherein Example 35 also includes subject matter according to Example 33 or 34 above.

[0146] The upper heating rods 196 of the upper heat source 122 can control the heating of the upper heating plate 188, and therefore the heating of the upper mold 112 over the entire span of the upper heating plate 188. As a result, the temperature of various portions of the upper heating plate 188 can be effectively and efficiently controlled.

[0147] The upper heating rods 196 are implemented such that they are configured to deliver heat to the upper heating plate 188. As an illustrative, non-exclusive example, the upper heating rods 196 include an elongated heating element constructed of nickel steel, encapsulated by a ceramic layer, and embedded in a stainless steel sheath. The ceramic layer absorbs oxygen to limit oxidation of the heating element. In one or more examples, the upper heating rods 196 are the same or similar to the lower heating rods 154.

[0148] Any suitable number of upper heating rods 196 and corresponding upper heating rod channels 194 may be provided, for example based on the size of the upper heating plate 188, the degree of temperature control desired for the thermoforming press 100, etc. Figure 6 , Figure 7 and Figure 9-12 In the illustrated example, twenty-eight upper heater rod channels 194 are defined by the upper heater plate 188 and the upper housing 186 .

[0149] In the example of the upper heat box portion 110 where the upper insulation layer 192 extends over the sides of the upper heating plate 188 , the upper insulation layer 192 together with the upper heating plate 188 and the upper shell 186 define an upper heating rod channel 194 .

[0150] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Fig.16 , the upper heating rod 196 is straight along the entire length of the upper heating rod 196. The foregoing subject matter of this paragraph characterizes Example 36 of the present disclosure, wherein Example 36 also includes subject matter according to Example 35 above.

[0151] Because the upper heating rod 196 is straight along its entire length, the integrity of the upper heating rod 196 can be maintained for a considerable period of time without damage and thus does not require expensive replacement.

[0152] For example, the ceramic layer of the upper heating rod 196 will not crack like the bent heating rod of the prior art, thereby avoiding air intrusion into the upper heating rod 196 and avoiding unwanted oxidation and degradation of the heating element of the upper heating rod 196 .

[0153] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figures 3 to 6 and Fig.16, the upper heat source 122 further includes an upper connection box 198 and an upper connection cable 200, and the upper connection cable 200 interconnects the upper heating rod 196 with the upper connection box 198. The upper press assembly 108 further includes an upper pad 130. The upper pad 130 is located above the upper heat box portion 110 and vertically supports the upper heat box portion 110. The upper connection box 198 is mounted on the upper pad 130. The foregoing subject matter of this paragraph characterizes Example 37 of the present disclosure, wherein Example 37 also includes the subject matter according to Example 35 or 36 above.

[0154] By mounting the upper connection box 198 on the upper pad 130, for example, on its periphery or on its upper side, and by interconnecting the upper heating rod 196 to the upper connection box 198 by an upper connection cable 200, the upper connection box 198 can be shielded from, or at least isolated from, radiant heat emitted from the lower mold 106 and the upper mold 112 when the thermoforming press 100 is in the loading configuration.

[0155] In contrast, in prior art thermoforming presses, connecting cables and boxes are typically coupled to and in direct contact with hot surfaces of the thermoforming press, resulting in a short life of these components and requiring frequent maintenance or replacement.

[0156] Generally speaking Figure 1A and Figure 1B , when heat is radiated from the upper heat box portion 110, the upper pad 130 shields the upper connection box 198 from the heat. The foregoing subject matter of this paragraph characterizes Example 38 of the present disclosure, wherein Example 38 also includes the subject matter according to Example 37 above.

[0157] By shielding the upper connection box 198 from heat radiated from the upper hot box portion 110, the upper connection box 198 is protected and has a longer life than connection boxes of prior art thermoforming presses.

[0158] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Fig.16 , the upper heating rods 196 each include an upper heating zone 202. The temperature of the upper heating zone 202 is independently controlled. The upper heating zone 202 coincides with a different upper zone 190 of the upper heating plate 188. The foregoing subject matter of this paragraph characterizes Example 39 of the present disclosure, wherein Example 39 also includes subject matter according to any one of Examples 35 to 38 above.

[0159] By dividing into upper heating zones 202, the upper heating rods 196 may be used to independently control the amount of heat delivered to different upper zones 190 of the upper heating plate 188, and therefore different zones of the upper mold 112. As discussed, the amount of heat delivered to the different upper zones 190, and therefore the temperatures of the different upper zones 190, may be controlled to provide desired heating of corresponding zones of the upper mold 112 and the workpiece 114. For example, in some cases, it may be desirable to heat portions of the upper mold 112 that correspond to tighter bends to be formed in the workpiece 114. Additionally or alternatively, in some cases, it may be desirable to deliver greater heat to outer zones of the upper mold 112 than to inner zones of the upper mold 112 due to conductive heat losses through the upper insulation layer 192. Furthermore, in the example of the upper heat box portion 110 where the upper insulation layer 192 has different thicknesses on opposite sides of the upper heating plate 188, greater heat can be transferred to areas of the upper heating plate 188 proximate such thinner areas of the upper insulation layer 192 due to greater heat losses in the thinner areas.

[0160] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Fig.16 , upper heating zone 202 includes outer upper zones 204 and at least one inner upper zone 206, which is located between outer upper zones 204. Outer upper zone 204 has a higher heating capacity than at least one inner upper zone 206. The foregoing subject matter of this paragraph characterizes Example 40 of the present disclosure, wherein Example 40 also includes subject matter according to Example 39 above.

[0161] In some cases, it may be desirable or necessary to deliver a greater amount of heat to the outer upper region 204 than to the at least one inner upper region 206 because areas of the upper heating plate 188 proximate the outer upper region 204 lose heat at a greater rate than areas of the upper heating plate 188 proximate the at least one inner upper region 206. Thus, in one or more examples, an upper heating rod 196 having at least one inner upper region 206 with a lower heating capacity than the outer upper region 204 is less expensive than a heating rod having uniform heating capacity along its length.

[0162] like Fig.16As shown, in one or more examples, the upper heating rod 196 further includes an upper shaft region 197 proximate to the corresponding upper connecting cable, wherein the upper shaft region 197 is configured to not conduct heat therefrom, for example, the heating element of the upper heating rod 196 only extends through the outer upper region 204 and at least one inner upper region 206. In addition, in one or more examples, the upper shaft region 197 extends out from the upper hot box portion 110, in which case it is desired that the upper shaft region 197 is not heated.

[0163] Generally speaking Figure 1A , Figure 1B , Figure 2A and Figure 2B , especially with reference to e.g. Figure 3 and Figure 4 , the upper hot box portion 110 has an upper front side 208 and an upper rear side 210. The upper hot box portion 110 is configured to receive the upper mold 112 at a position closer to the upper front side 208 than to the upper rear side 210. The outer upper region 204 near the upper front side 208 has a higher heating capacity than the outer upper region 204 near the upper rear side 210. The foregoing subject matter of this paragraph characterizes Example 41 of the present disclosure, wherein Example 41 also includes subject matter according to Example 40 above.

[0164] By being positioned closer to the upper front side 208 , the upper die 112 , along with the lower die 106 and the workpiece 114 , are more easily accessible by an operator of the thermoforming press 100 from the upper front side 208 to facilitate insertion and removal of the workpiece 114 .

[0165] However, by positioning the upper mold 112 closer to the upper front side 208, and therefore by making the upper insulation layer 192 thinner on the upper front side 208 than the upper back side 210, in some cases, due to greater heat losses in the thinner areas, it is necessary to deliver greater heat to areas of the upper heating plate 188 proximate such thinner areas of the upper insulation layer 192. In such an example, the outer upper area of ​​the upper heating rod proximate the upper front side 208 has a higher heating capacity than the outer upper area of ​​the upper heating rod proximate the upper back side 210.

[0166] Generally speaking Figure 1A and Figure 1B, the thermoforming press 100 further includes an upper temperature sensor 212 and a controller 156. The upper temperature sensor 212 is configured to sense the temperature of the different upper regions 190 of the upper heating plate 188. The controller 156 is operably coupled to the upper connection box 198 and is configured to control the actively determined amount of heat delivered to the different upper regions 190 of the upper heating plate 188 based at least in part on the temperature of the different upper regions 190 of the upper heating plate 188. The foregoing subject matter of this paragraph characterizes Example 42 of the present disclosure, wherein Example 42 also includes subject matter according to any one of Examples 33 to 41 above.

[0167] By sensing the temperature of different upper regions 190 of the upper heating plate 188, the controller 156 is able to deliver heat to the different upper regions 190 based on the sensed temperature to ensure that the different upper regions 190 of the upper heating plate 188 and therefore the corresponding regions of the upper mold 112 are heated to the desired temperature for the particular operation of the thermoforming press 100.

[0168] In one or more examples, the upper temperature sensors 212 are implemented such that they are configured to sense the temperature of different upper regions 190 of the upper heating plate 188. For example, in one or more examples, the upper temperature sensors 212 are thermocouples embedded within the upper heating plate 188.

[0169] Generally speaking Figure 1A and Figure 1B , the thermoforming press 100 further includes an upper mold temperature sensor 214 configured to sense the temperature of the upper mold 112. The controller 156 is configured to record or display the temperature of the upper mold 112. The controller 156 is configured not to control the actively determined amount of heat delivered to the different upper regions 190 of the upper heating plate 188 based on the temperature of the upper mold 112. The foregoing subject matter of this paragraph characterizes Example 43 of the present disclosure, wherein Example 43 also includes subject matter according to Example 42 above.

[0170] In one or more examples, recording or displaying the temperature of the upper mold 112 is performed for quality control purposes, including, for example, generating a report showing temperature compliance within or deviation from an expected temperature range for the upper mold 112. Additionally or alternatively, in one or more examples, an alarm is generated during the molding process for an operator to take corrective action or otherwise record one or more issues that may need to be addressed.

[0171] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Figure 3 , Figure 4 and Fig.17, the thermoforming press 100 further includes a display 176 operably coupled to the controller 156 and configured to display the temperature of different upper regions 190 of the upper heating plate 188. The foregoing subject matter of this paragraph characterizes Example 44 of the present disclosure, wherein Example 44 also includes subject matter according to Example 42 or 43 above.

[0172] In one or more examples, by displaying the temperature of different lower regions 146 of the lower heating plate 144 , such temperature is monitored in real time by an operator of the thermoforming press for quality control purposes.

[0173] like Fig.17 As shown, the display 176 provides thermal information, such as thermal information associated with different upper zones 190 of the upper heating plate 188. In the example of the display 176 shown, twelve zones of the upper heating plate 188 are monitored. Each zone has a different controller or amplifier stack associated with it for controlling the amount of current delivered to each circuit associated with the upper heating zone 202 of the corresponding upper heating rod of the upper heating rod 196. These different controllers also monitor whether there is a problem with the upper heating rod and communicate with the controller 156 to determine whether the upper heating rod 196 is properly maintaining its temperature or whether more energy is needed. Each of these different controllers can feed more or less power to the corresponding upper heating rod based on the temperature sensed by the upper temperature sensor 212.

[0174] exist Fig.17 In the illustrated example of the display 176 in FIG. 1 , the temperature sensed by the upper temperature sensor 212 is indicated by a digital "needle" or line superimposed on a representation of an analog gauge representing a temperature range, the analog gauge having an acceptable temperature range represented in the middle and an undesirable temperature range represented on the left and right sides of the analog gauge. Thus, when the needle is in the middle range, the corresponding upper area of ​​the upper heating plate 188 is at the desired temperature. However, if the needle is in the left range, the corresponding area of ​​the upper heating plate 188 is too cold, and the corresponding area of ​​the associated one of the upper heating rods 196 may be defective or not functioning properly. If the needle is in the right range, the corresponding area of ​​the upper heating plate 188 is too hot, and the corresponding area of ​​the associated one of the upper heating rods 196 may be defective or not functioning properly. In one or more examples, when the needle is in the middle range, the middle range is displayed in green or another color, thereby alerting the operator that the corresponding area is functioning properly. In one or more examples, when the needle is in the left or right range, the middle range is displayed in yellow or another color, thereby alerting the operator that the corresponding area may not function properly.

[0175] like Fig.17As shown, the operator of the thermoforming press 100 can customize the permissible deviation of the temperature. In the example shown, the deviation is set to 50 degrees.

[0176] Generally speaking Figure 1A , Figure 1B , Figure 2A and Figure 2B , especially with reference to e.g. Figure 6-Figure 13 , the upper hot box portion 110 further includes an upper cold plate 216. The upper cold plate 216 is at least partially positioned between the upper insulation layer 192 and the upper shell 186, and is configured to draw heat away from the upper hot box portion 110. The foregoing subject matter of this paragraph characterizes Example 45 of the present disclosure, wherein Example 45 also includes subject matter according to any one of Examples 33 to 44 above.

[0177] The upper cold plate 216 draws heat away from the upper hot box section 110, which is conducted from the upper heated plate 188 through the upper insulation layer 192. Thus, the upper cold plate 216 prevents the upper housing 186 and the upper backing plate 130 from becoming too hot for an operator of the thermoforming press 100.

[0178] The upper cold plate 216 is a heat transfer device, and in one or more examples, is implemented so that it effectively draws heat away from the upper hot box portion 110. For example, in one or more examples, the upper cold plate 216 is made of stainless steel, wherein one or more cooling channels extend through the upper cold plate 216 and a coolant (e.g., ethylene glycol) circulates through the one or more cooling channels. In some examples, the upper cold plate 216 is made of two separate parts welded together. This two-piece structure facilitates the processing of a single circuitous cooling channel in each component. Alternatively, in one or more examples, the upper cold plate 216 is made of a single piece, which avoids coolant leakage and the need for a gasket between the two parts of the two-piece structure. In some examples, in this single-piece structure, the cooling channel is gun-drilled through the upper cold plate 216 all the way, thereby requiring external pipes to connect the cooling channels together. In one or more examples, the coolant is transported and removed from the upper cold plate 216 via a factory-based coolant system.

[0179] Generally speaking Figure 1A , Figure 1B , Figure 2A and Figure 2B , especially with reference to e.g. Figure 7 and Figure 10-13, the upper hot box portion 110 further includes an upper hot box fastener 218 that operably interconnects the upper housing 186, the upper heating plate 188, and the upper insulation layer 192. The upper hot box fastener 218 includes an upper bolt 220 and a spring-loaded upper nut assembly 222, the upper nut assembly 222 being operably coupled to the upper bolt 220 and configured to enable the upper hot box portion 110 to expand and contract without damaging the upper hot box portion 110. The foregoing subject matter of this paragraph characterizes Example 46 of the present disclosure, wherein Example 46 also includes subject matter according to any one of Examples 33 to 45 above.

[0180] The upper hot box fasteners 218 enable the components of the upper hot box portion 110 to expand and contract due to the significant temperature range experienced by the upper hot box portion 110 when the thermoforming press 100 is in use and when the thermoforming press 100 is not in use.

[0181] In one or more examples, the upper hot box fasteners 218 are implemented so that they allow for expansion and contraction of the upper hot box portion 110 without causing damage thereto. Fig.13 The upper bolt 220 is composed of two parts, including a first upper bolt part 221 and a second upper bolt part 223 welded to the first upper bolt part 221. The first upper bolt part 221 includes a bolt head and is composed of a high temperature alloy (such as Supersam), and the second upper bolt part 223 is composed of a lower temperature and cheaper alloy (such as Inconel). As an example, the spring-loaded upper nut assembly 222 includes a stack of Belleville washers.

[0182] Generally speaking Figure 1A and Figure 1B , especially with reference to e.g. Fig.18 , the thermoforming press 100 further includes a gas pressure system 224. The gas pressure system 224 is configured to deliver gas to the inner cavity 226 of the workpiece 114 when the workpiece 114 is operably positioned between the lower die 106 and the upper die 112 and when the lower die 106 and the upper die 112 apply a forming pressure to the workpiece 114. The foregoing subject matter of this paragraph characterizes Example 47 of the present disclosure, wherein Example 47 also includes subject matter according to any one of Examples 1 to 46 above.

[0183] Including the gas pressure system 224 enables the thermoforming press 100 to form parts from multiple pieces of workpieces. More specifically, by delivering gas at elevated pressure to the interior cavity 226 of the workpiece 114 while the workpiece 114 is held between the lower die 106 and the upper die 112 and while the thermoforming press 100 applies tonnage, the lower die 106 and the upper die 112 may be used not only to bend the workpiece 114 into a desired shape, but also to use the lower die 106 and the upper die 112 as a forming piece as the gas pressure pushes the workpiece 114 radially into engagement with and conformity with the lower die 106 and the upper die 112.

[0184] refer to Fig.18 In one or more examples, workpiece 114 includes more than one sheet material 225. As an illustrative, non-exclusive example, workpiece 114 is comprised of titanium, and the gas introduced by gas pressure system 224 is argon or another gas suitable for reducing or eliminating oxidation of titanium.

[0185] As a more specific example, a part is formed from four sheets of titanium. Two inner sheets are first welded together (e.g., using resistance welding) to form a gap cavity between the sheets before the workpiece 114 is loaded into the hot forming press 100. The workpiece 114 is then loaded into the hot forming press 100, and gas is introduced between the inner sheets via the gas pressure system 224, thereby inflating one or more cavities within the sheets and forming a sandwich structure. Wherever the two inner sheets touch the two outer sheets, the titanium is diffusion bonded together.

[0186] In one or more examples, the gas pressure system 224 is configured to control the application of gas pressure in the range of 0 to 600 psi or higher depending on the desired application. As the gas pressure increases, the tonnage applied by the thermoforming press 100 must be increased by the same amount to keep the thermoforming press 100 in a closed configuration. In other words, the tonnage applied by the thermoforming press 100 when utilizing the gas pressure system 224 is directly related to the gas pressure applied by the gas pressure system 224.

[0187] In order to be able to apply gas pressure between the sheets of the workpiece 114 by the gas pressure system 224 , the workpiece 114 typically includes a gas tube welded to the sheets for conveying the gas pressure to the internal volume of the workpiece 114 .

[0188] In one or more examples, the gas pressure system 224 includes a pressure transducer for measuring the pressure of the gas applied to the inner cavity 226, and an electronic pressure regulator operated by a motor to control the gas pressure.

[0189] Fig.19 An example of the display 176 produced when the thermoforming press 100 includes the pneumatic system 224 is shown.

[0190] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 3 , Figure 4 and Figure 6-Figure 15 , a hot box 300 of a thermoforming press 100 is disclosed. The hot box 300 includes a lower hot box portion 104 and an upper hot box portion 110. The lower hot box portion 104 includes a lower shell 142, a lower heating plate 144, and a lower insulating layer 148. The lower heating plate 144 is housed within the lower shell 142 and is configured to support the lower mold 106. The lower insulating layer 148 is located between the lower shell 142 and the lower heating plate 144. The upper hot box portion 110 can be positioned above the lower hot box portion 104 and includes an upper shell 186, an upper heating plate 188, and an upper insulating layer 192. The upper heating plate 188 is housed within the upper shell 186 and is configured to support the upper mold 112. The upper insulating layer 192 is located between the upper shell 186 and the upper heating plate 188. When the lower heat box portion 104 and the upper heat box portion 110 contact each other, the lower heat box portion 104 and the upper heat box portion 110 provide a thermal barrier around the workpiece 114 received between the lower mold 106 and the upper mold 112. The foregoing subject matter of this paragraph characterizes Example 48 of the present disclosure.

[0191] When the thermoforming press 100 is operable to form a part from the workpiece 114, the heat box 300 provides a thermal barrier to maintain heat delivered to the lower die 106 and the upper die 112, and thus to the workpiece 114. The lower housing 142 provides a structure for supporting the other components of the lower heat box portion 104. The lower insulation layer 148 insulates the lower heating plate 144, which is configured to support the lower die 106 and conduct heat thereto, thereby facilitating efficient heating of the lower die 106 by limiting conduction away from the lower die 106. Similarly, the upper housing 186 provides a structure for supporting the other components of the upper heat box portion 110. The upper insulation layer 192 insulates the upper heating plate 188, which is configured to support the upper die 112 and conduct heat thereto, thereby facilitating efficient heating of the upper die 112 by limiting conduction away from the upper die 112.

[0192] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 3 , Figure 4 , Figure 6-Figure 11 , Fig.14 and Fig.15 , the lower housing 142 includes a lower substrate 302 and a lower sidewall 304 located above the lower substrate 302. The foregoing subject matter of this paragraph characterizes Example 49 of the present disclosure, wherein Example 49 also includes subject matter according to Example 48 above.

[0193] The lower base plate 302 provides support from underneath the other components of the lower hot box portion 104, and the lower sidewalls 304 provide lateral support to maintain the lower insulation layer 148 in an operative position between the lower shell 142 and the lower heating plate 144. Additionally, in examples of the lower hot box portion 104 that also include a lower cold plate 178, the two-piece construction of the lower shell 142 provides access to coolant lines connected to the lower cold plate 178.

[0194] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 , Figure 7 , Fig. 9 and Fig.14 , the lower base plate 302, the lower isolation layer 148, and the lower heating plate 144 collectively define at least one lower lift pin channel 306. The at least one lower lift pin channel 306 is configured to receive at least one lower mold lift pin 136 for operative engagement with the lower mold 106 and for separating the lower mold 106 from the lower hot box portion 104. The foregoing subject matter of this paragraph characterizes Example 50 of the present disclosure, wherein Example 50 also includes subject matter according to Example 49 above.

[0195] The at least one lower lift pin channel 306 provides a sliding conduit for the lower mold lift pins 136. More specifically, when the heat box 300 is a component of the thermoforming press 100, the at least one lower lift pin channel 306 and the lower mold lift pins 136 enable the thermoforming press 100 to move to a mold setting configuration, as discussed herein.

[0196] In examples of the lower heat box portion 104 that also includes a lower cold plate 178 , the lower cold plate 178 also defines at least one lower lift pin channel 306 in conjunction with the lower base plate 302 , the lower isolation layer 148 , and the lower heater plate 144 .

[0197] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 7 , Fig.10 , Fig.14 and Fig.15, the lower base plate 302, the lower insulation layer 148 and the lower heating plate 144 together define a lower bolt channel 308. The lower heat box portion 104 further includes a lower bolt 182 and a spring-loaded lower nut assembly 184. The lower bolt 182 extends through the lower bolt channel 308. The spring-loaded lower nut assembly 184 is operably coupled to the lower bolt 182 and is configured to allow the lower heat box portion 104 to expand and contract without damaging the lower heat box portion 104. The foregoing subject matter of this paragraph characterizes Example 51 of the present disclosure, wherein Example 51 also includes subject matter according to Example 49 or 50 above.

[0198] The lower bolt channel 308, the lower bolts 182, and the spring-loaded lower nut assembly 184 operably couple together the component parts of the lower hot box section 104 and enable the components of the lower hot box section 104 to expand and contract due to the significant temperature range experienced by the lower hot box section 104 when installed as part of the thermoforming press 100.

[0199] In examples of the lower heat box portion 104 that also includes the lower cold plate 178 , the lower cold plate 178 also defines a lower bolt channel 308 in conjunction with the lower base plate 302 , the lower insulation layer 148 , and the lower heater plate 144 .

[0200] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 7 , Fig. 9 , Fig.10 , Fig.14 and Fig.15 , the spring loaded lower nut assembly 184 is located within the lower base plate 302. The foregoing subject matter of this paragraph characterizes Example 52 of the present disclosure, wherein Example 52 also includes subject matter according to Example 51 above.

[0201] By being positioned within the lower base plate 302 , the spring loaded lower nut assembly 184 is shielded from the heat emanating from the lower heater plate 144 .

[0202] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 7 , Fig.10 , Fig.14 and Fig.15 , the lower bolt channel 308 includes a lower circular counterbore 310. The lower bolt 182 includes a lower round head 312, which is configured to cooperate with the lower circular counterbore 310. The foregoing subject matter of this paragraph characterizes Example 53 of the present disclosure, wherein Example 53 also includes subject matter according to Example 51 or 52 above.

[0203] The interface between the lower circular counterbore 310 and the lower rounded head 312 of the lower bolt 182 avoids the creation of stress risers that could cause crack formation due to thermal cycling experienced by the lower heater plate 144 and the lower bolt 182 .

[0204] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 7 , Fig.10 , Fig.14 and Fig.15 , the lower heating plate 144 defines a lower circular counterbore 310. A lower round head 312 is located within the lower heating plate 144. The foregoing subject matter of this paragraph characterizes Example 54 of the present disclosure, wherein Example 54 also includes subject matter according to Example 53 above.

[0205] By positioning the lower round head 312 of the lower bolt 182 within the lower heating plate 144, the lower round head 312 does not interfere with the engagement of the lower heating plate with the lower mold 106. In addition, the spring-loaded lower nut assembly 184 must be positioned away from the lower heating plate 144 and thus shielded from the heat emanating from the lower heating plate 144.

[0206] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 , Figure 7 , Fig. 9 and Fig.10 , the lower insulation layer 148 defines a lower insulation volume 314. The lower heating plate 144 is located within the lower insulation volume 314. The foregoing subject matter of this paragraph characterizes Example 55 of the present disclosure, wherein Example 55 also includes subject matter according to any one of Examples 49 to 54 above.

[0207] The lower insulating layer 148 insulates the lower heating plate 144 from the underside of the lower heating plate 144 and the sides of the lower heating plate 144 , thereby maximizing the insulating function of the lower insulating layer 148 with respect to heat conducted away from the lower heating plate 144 .

[0208] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 , Figure 7 , Fig. 9 , Fig.10 and Fig.14, the lower isolation layer 148 includes a lower ceramic sheet 316 and at least one lower ceramic block 318. The lower ceramic sheet 316 is located between the lower heating plate 144 and the lower sidewall 304. The at least one lower ceramic block 318 is located between the lower heating plate 144 and the lower substrate 302. The foregoing subject matter of this paragraph characterizes Example 56 of the present disclosure, wherein Example 56 also includes subject matter according to Example 55 above.

[0209] The use of a lower ceramic sheet 316 and at least one lower ceramic block 318 facilitates assembly of the lower hot box portion 104 .

[0210] However, it is also within the scope of the present disclosure that the lower insulation layer 148 comprises a single unitary insulation block that defines the lower insulation volume 314 and thereby isolates the lower heating plate 144 from its underside and its sides.

[0211] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 , Figure 7 , Fig. 9 , Fig.10 and Fig.14 , the lower heating plate 144 defines a lower heating plate volume 320 that is sized to receive and operably position the lower mold 106. The foregoing subject matter of this paragraph characterizes Example 57 of the present disclosure, wherein Example 57 also includes subject matter according to any of Examples 49 to 56 above.

[0212] By having a lower heating plate volume 320 that receives the lower mold 106 , the lower heating plate 144 is able to heat the lower mold 106 not only from below the lower mold 106 , but also from the sides and ends of the lower mold 106 .

[0213] Generally speaking Figure 2A and Figure 2B , the lower hot box portion 104 has a lower front side 172 and a lower rear side 174. The lower heating plate volume 320 is positioned closer to the lower front side 172 than the lower rear side 174. The foregoing subject matter of this paragraph characterizes Example 58 of the present disclosure, wherein Example 58 also includes subject matter according to Example 57 above.

[0214] By positioning the lower heated plate volume 320 closer to the lower front side 172 than the lower rear side 174, the lower die 106 is therefore positioned closer to the lower front side 172 than the lower rear side 174. As a result, the lower die 106, along with the upper die 112 and the workpiece 114, is more easily accessible from the lower front side 172 by an operator of the thermoforming press 100 to facilitate insertion and removal of the workpiece 114.

[0215] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 , Figure 7 , Fig. 9 , Fig.10 , Fig.13 and Fig.14 , the lower heating plate 144 and the lower sidewall 304 together define a lower heating rod channel 152, which is configured to receive the lower heating rod 154. The foregoing subject matter of this paragraph characterizes Example 59 of the present disclosure, wherein Example 59 also includes subject matter according to any one of Examples 49 to 58 above.

[0216] The lower heating rod channel 152 provides a conduit for inserting the lower heating rod 154. As discussed herein, the lower heating rod 154 enables controlled heating of the lower heating plate 144 over the entire span of the lower heating plate 144, and therefore, the lower mold 106. As a result, the temperature of various portions of the lower heating plate 144 can be effectively and efficiently controlled.

[0217] In the example of the lower heat box portion 104 where the lower insulation layer 148 extends over the sides of the lower heating plate 144 , the lower insulation layer 148 together with the lower heating plate 144 and the lower sidewall 304 define a lower heating rod channel 152 .

[0218] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Fig.14 , the lower hot box portion 104 has a lower front side 172 and a lower rear side 174. The lower heating rod channel 152 extends through the lower side wall 304 only on the lower rear side 174. The foregoing subject matter of this paragraph characterizes Example 60 of the present disclosure, wherein Example 60 also includes subject matter according to Example 59 above.

[0219] The lower heater rod channel 152 is used to mount the corresponding lower heater rod from the rear side of the thermoforming press 100 by extending only through the lower side wall 304 on the lower rear side 174 of the lower hot box portion 104. Thus, the corresponding lower connecting cables are all arranged on the rear side of the thermoforming press 100, leaving the front side of the thermoforming press 100 open for an operator to insert and remove the workpiece 114 and otherwise access the hot box 300.

[0220] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 , Figure 7 , Fig. 9 , Fig.10 and Fig.14, the lower heating plate 144 defines a lower slot 322, which is configured to receive a lower coupler 324 for operably holding the lower mold 106 on the lower heating plate 144. The foregoing subject matter of this paragraph characterizes Example 61 of the present disclosure, wherein Example 61 also includes subject matter according to any one of Examples 49 to 60 above.

[0221] The lower slot 322 and lower coupler 324 allow the lower mold 106 to be coupled to and retained on the lower heating plate 144 .

[0222] In one or more examples, the lower slot 322 is described as or in the form of a T-slot, and the lower coupler 324 is described as or in the form of a T-hammer.

[0223] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 3 , Figure 4 , Figure 8 and Fig.14 , lower sidewall 304 defines a lower access passage 328 configured to provide access to lower slot 322 for operable insertion and removal of lower coupler 324. The foregoing subject matter of this paragraph characterizes Example 62 of the present disclosure, wherein Example 62 also includes subject matter according to Example 61 above.

[0224] As shown, the lower access passage 328 provides access to the lower slot 322 for operative insertion and removal of the lower coupler 324 .

[0225] In the example of the lower heat box portion 104 including the lower insulation layer 148 between the lower heating plate 144 and the lower side wall 304 , the lower insulation layer 148 defines a lower access channel 328 through the lower side wall 304 .

[0226] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 3 , Figure 4 , Figure 6-Figure 10 and Fig.14 , the lower base plate 302 includes a lower peripheral flange 326, which is configured to operably couple the lower hot box portion 104 to the lower backing plate 128 of the thermoforming press 100. The foregoing subject matter of this paragraph characterizes Example 63 of the present disclosure, wherein Example 63 also includes subject matter according to any of Examples 49 to 62 above.

[0227] The lower peripheral flange 326 provides a structure for coupling the lower hot box portion 104 to the lower backing plate 128 , such as the structure having a lower bolt bracket 327 .

[0228] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 3 , Figure 4 , Figure 6-Figure 10 , Fig.14 and Fig.15 , the lower hot box portion 104 further includes a lower cold plate 178, which is located between the lower insulation layer 148 and the lower base plate 302 and is configured to draw heat away from the hot box 300. The foregoing subject matter of this paragraph characterizes Example 64 of the present disclosure, wherein Example 64 also includes subject matter according to any one of Examples 49 to 63 above.

[0229] The lower cold plate 178 draws heat away from the lower hot box portion 104, which is conducted from the lower heated plate 144 through the lower insulation layer 148. Thus, the lower cold plate 178 prevents the lower housing 142 and the lower backing plate 128 from becoming too hot for an operator of the thermoforming press 100.

[0230] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 3 , Figure 4 , Figure 6-Figure 10 , Fig.14 and Fig.15 , the lower cold plate 178 extends between the lower base plate 302 and the lower sidewall 304. The foregoing subject matter of this paragraph characterizes Example 65 of the present disclosure, wherein Example 65 also includes subject matter according to Example 64 above.

[0231] By having the lower cold plate 178 extend between the lower base plate 302 and the lower sidewall 304 , coolant lines are easily connected to the lower cold plate 178 .

[0232] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 3 , Figure 4 , Figure 6 and Figures 8 to 12 , the upper housing 186 includes an upper top plate 330 and an upper side wall 332 located below the upper top plate 330. The foregoing subject matter of this paragraph characterizes Example 66 of the present disclosure, wherein Example 66 also includes subject matter according to any one of Examples 48 to 65 above.

[0233] The upper top plate 330 provides support from above the other components of the upper hot box portion 110, and the upper side walls 332 provide lateral support to maintain the upper insulation layer 192 in an operative position between the upper shell 186 and the upper heating plate 188. Additionally, in examples of the upper hot box portion 110 that also include an upper cold plate 216, the two-piece construction of the upper shell 186 provides access to coolant lines connected to the upper cold plate 216.

[0234] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 7-Figure 13 , the upper top plate 330, the upper insulation layer 192 and the upper heating plate 188 together define an upper bolt channel 334. The upper hot box portion 110 further includes an upper bolt 220 and a spring-loaded upper nut assembly 222. The upper bolt 220 extends through the upper bolt channel 334. The spring-loaded upper nut assembly 222 is operably coupled to the upper bolt 220 and is configured to allow the upper hot box portion 110 to expand and contract without damaging the upper hot box portion 110. The foregoing subject matter of this paragraph characterizes Example 67 of the present disclosure, wherein Example 67 also includes subject matter according to Example 66 above.

[0235] The upper bolt channels 334, upper bolts 220, and spring loaded upper nut assemblies 222 operably couple the component parts of the upper hot box section 110 together and enable the components of the upper hot box section 110 to expand and contract due to the significant temperature range experienced by the upper hot box section 110 when installed as part of the thermoforming press 100.

[0236] In examples of the upper hot box portion 110 that also includes the upper cold plate 216 , the upper cold plate 216 also defines an upper bolt channel 334 in conjunction with the upper top plate 330 , the upper insulation layer 192 , and the upper heating plate 188 .

[0237] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Fig. 9 , Fig.10 and Fig.13 , the spring loaded upper nut assembly 222 is located within the upper top plate 330. The foregoing subject matter of this paragraph characterizes Example 68 of the present disclosure, wherein Example 68 also includes subject matter according to Example 67 above.

[0238] By being positioned within the upper top plate 330 , the spring loaded upper nut assembly 222 is shielded from the heat emanating from the upper heating plate 188 .

[0239] Generally speaking Figure 2A and Figure 2B, especially with reference to e.g. Figure 7 and Figure 10-13 , upper bolt channel 334 includes an upper circular counterbore 336. Upper bolt 220 includes an upper round head 338 configured to cooperate with upper circular counterbore 336. The foregoing subject matter of this paragraph characterizes Example 69 of the present disclosure, wherein Example 69 also includes subject matter according to Example 67 or 68 above.

[0240] The interface between the upper circular counterbore 336 and the upper rounded head 338 of the upper bolt 220 avoids stress risers that could cause crack formation due to thermal cycling experienced by the upper heater plate 188 and the upper bolt 220 .

[0241] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 7 , Fig.10 and Fig.13 , the upper heating plate 188 defines an upper circular counterbore 336. The upper round head 338 is located within the upper heating plate 188. The foregoing subject matter of this paragraph characterizes Example 70 of the present disclosure, wherein Example 70 also includes subject matter according to Example 69 above.

[0242] By positioning the upper round head 338 of the upper bolt 220 within the upper heating plate 188, the upper round head 338 does not interfere with the engagement of the upper heating plate with the upper mold 112. In addition, the spring-loaded upper nut assembly 222 must be positioned away from the upper heating plate 188 and is therefore shielded from the effects of heat emanating from the upper heating plate 188.

[0243] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 , Figure 7 , Fig. 9 and Fig.10 , the upper insulation layer 192 defines an upper insulation volume 340, and the upper heating plate 188 is located within the upper insulation volume 340. The foregoing subject matter of this paragraph characterizes Example 71 of the present disclosure, wherein Example 71 also includes subject matter according to any one of Examples 66 to 70 above.

[0244] The upper insulating layer 192 insulates the upper heating plate 188 from above and from the sides of the upper heating plate 188 , thereby maximizing the insulating function of the upper insulating layer 192 with respect to heat conducted away from the upper heating plate 144 .

[0245] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 , Figure 7 and Figure 9-13, the upper isolation layer 192 includes an upper ceramic sheet 342 and at least one upper ceramic block 344. The upper ceramic sheet 342 is located between the upper heating plate 188 and the upper side wall 332. At least one upper ceramic block 344 is located between the upper heating plate 188 and the upper top plate 330. The foregoing subject matter of this paragraph characterizes Example 72 of the present disclosure, wherein Example 72 also includes the subject matter according to Example 71 above.

[0246] The use of an upper ceramic sheet 342 and at least one upper ceramic block 344 facilitates assembly of the upper hot box portion 110 .

[0247] However, it is also within the scope of the present disclosure that the upper insulation layer 192 comprises a single unitary insulation block that defines the upper insulation volume 340 and thereby isolates the upper heating plate 188 from below and from the sides thereof.

[0248] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 , Figure 7 , Fig. 9 , Fig.10 and Fig.12 , the upper heating plate 188 defines an upper heating plate volume 346 that is sized to receive and operably position the upper mold 112. The foregoing subject matter of this paragraph characterizes Example 73 of the present disclosure, wherein Example 73 also includes subject matter according to any of Examples 66 to 72 above.

[0249] By having an upper heating plate volume 346 that receives the upper mold 112 , the upper heating plate 188 is able to heat the upper mold 112 not only from above the upper mold 112 , but also from the sides and ends of the upper mold 112 .

[0250] Generally speaking Figure 2A and Figure 2B , the upper hot box portion 110 has an upper front side 208 and an upper rear side 210. The upper heating plate volume 346 is positioned closer to the upper front side 208 than the upper rear side 210. The foregoing subject matter of this paragraph characterizes Example 74 of the present disclosure, wherein Example 74 also includes subject matter according to Example 73 above.

[0251] By positioning the upper heated plate volume 346 closer to the upper front side 208 than the upper rear side 210, the upper die 112 is therefore positioned closer to the upper front side 208 than the upper rear side 210. As a result, the upper die 112, along with the lower die 106 and the workpiece 114, are more easily accessible from the upper front side 208 by an operator of the thermoforming press 100 to facilitate insertion and removal of the workpiece 114.

[0252] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 , Figure 7 and Figure 9-13 , the upper heating plate 188 and the upper sidewall 332 together define an upper heating rod channel 194, which is configured to receive an upper heating rod 196. The foregoing subject matter of this paragraph characterizes Example 75 of the present disclosure, wherein Example 75 also includes subject matter according to any one of Examples 66 to 74 above.

[0253] The upper heating rod channel 194 provides a conduit for inserting the upper heating rod 196. As discussed herein, the upper heating rod 196 enables controlled heating of the upper heating plate 188, and therefore the upper mold 112, across the entire span of the upper heating plate 188. As a result, the temperature of various portions of the upper heating plate 188 can be effectively and efficiently controlled.

[0254] In the example of the upper heat box portion 104 where the upper insulation layer 192 extends over the sides of the upper heating plate 188 , the upper insulation layer 192 together with the upper heating plate 188 and the upper sidewall 332 define an upper heating rod channel 194 .

[0255] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Fig.11 and Fig.12 , the upper hot box portion 110 has an upper front side 208 and an upper rear side 210. The upper heating rod channel 194 extends through the upper side wall 332 only on the upper rear side 210. The foregoing subject matter of this paragraph characterizes Example 76 of the present disclosure, wherein Example 76 also includes subject matter according to Example 75 above.

[0256] The upper heating rod channel 194 is used to install the corresponding upper heating rod from the rear side of the thermoforming press 100 by extending only through the upper side wall 332 on the upper rear side 210 of the upper hot box portion 110. Therefore, the corresponding upper connecting cables are all arranged on the rear side of the thermoforming press 100, leaving the front side of the thermoforming press 100 open for the operator to insert and remove the workpiece 114 and otherwise access the hot box 300.

[0257] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 , Figure 7 , Fig. 9 , Fig.10 and Fig.12, the upper heating plate 188 defines an upper slot 348, which is configured to receive an upper coupler 350 for operably retaining the upper mold 112 on the upper heating plate 188. The foregoing subject matter of this paragraph characterizes Example 77 of the present disclosure, wherein Example 77 also includes subject matter according to any one of Examples 66 to 76 above.

[0258] The upper slots 348 and upper couplers 350 allow the upper mold 112 to be coupled to and retained on the upper heating plate 188 .

[0259] In one or more examples, the upper slot 348 is described as or in the form of a T-slot, and the upper coupler 350 is described as or in the form of a T-hammer.

[0260] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 3 , Figure 4 , Figure 8 , Fig.11 and Fig.12 , upper sidewall 332 defines an upper access passage 352 configured to provide access to upper slot 348 for operable insertion and removal of upper coupler 350. The foregoing subject matter of this paragraph characterizes Example 78 of the present disclosure, wherein Example 78 also includes subject matter according to Example 77 above.

[0261] As shown, the upper access passage 352 provides access to the upper slot 348 for operative insertion and removal of the upper coupler 350 .

[0262] In the example of an upper heat box portion 110 including an upper insulation layer 192 between the upper heating plate 188 and the upper sidewall 332 , the upper insulation layer 192 defines an upper access channel 352 through the upper sidewall 332 .

[0263] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 6 and Figure 8-Figure 12 , the upper top plate 330 includes an upper peripheral flange 354, which is configured to operably couple the upper hot box portion 110 to the upper backing plate 130 of the thermoforming press 100. The foregoing subject matter of this paragraph characterizes Example 79 of the present disclosure, wherein Example 79 also includes subject matter according to any one of Examples 66 to 78 above.

[0264] The upper peripheral flange 354 provides a structure for coupling the upper hot box portion 110 to the upper backing plate 130 , such as with an upper bolt bracket 355 .

[0265] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 3 , Figure 4 , Figure 6 and Figure 8-Figure 13 , the upper hot box portion 110 further includes an upper cold plate 216. The upper cold plate 216 is positioned between the upper insulation layer 192 and the upper top plate 330, and is configured to draw heat away from the hot box 300. The foregoing subject matter of this paragraph characterizes Example 80 of the present disclosure, wherein Example 80 also includes subject matter according to any one of Examples 66 to 79 above.

[0266] The upper cold plate 216 draws heat away from the upper hot box section 110, which is conducted from the upper heated plate 188 through the upper insulation layer 192. Thus, the upper cold plate 216 prevents the upper housing 186 and the upper backing plate 130 from becoming too hot for an operator of the thermoforming press 100.

[0267] Generally speaking Figure 2A and Figure 2B , especially with reference to e.g. Figure 3 , Figure 4 , Figure 6 and Figure 8-Figure 13 , the upper cold plate 216 extends between the upper top plate 330 and the upper side wall 332. The foregoing subject matter of this paragraph characterizes Example 81 of the present disclosure, wherein Example 81 also includes subject matter according to Example 80 above.

[0268] By extending the upper cold plate 216 between the upper top plate 330 and the upper side walls 332 , coolant lines are easily connected to the upper cold plate 216 .

[0269] Generally speaking Fig. 20A and Fig. 20B , especially for example Figure 1A , Figure 1B , Figure 3 , Figure 4 and Figure 6, a method 400 for hot forming a workpiece 114 is disclosed. The method 400 includes the step of vertically moving the lower press assembly 102 and the upper press assembly 108 to a loading configuration (frame 402), in which the lower press assembly 102 and the upper press assembly 108 are spaced apart to receive the workpiece 114. The method 400 also includes the step of positioning the workpiece 114 between the lower die 106 of the lower press assembly 102 and the upper die 112 of the upper press assembly 108 (frame 404). The method 400 further includes the step of vertically moving the lower press assembly 102 and the upper press assembly 108 to a closed configuration (frame 406), in which the lower press assembly 102 and the upper press assembly 108 are positioned to apply forming pressure to the workpiece 114. The method 400 additionally includes the step of securing the upper press assembly 108 (frame 408). The method 400 further includes the step of moving the lower press assembly 102 toward the upper press assembly 108 to apply a forming pressure to the workpiece 114 (block 410). The method 400 also includes the step of heating the workpiece 114 (block 412). The foregoing subject matter of this paragraph characterizes Example 82 of the present disclosure.

[0270] By vertically moving the lower press assembly 102 and the upper press assembly 108 between the loading configuration and the closed configuration, the components of the thermoforming press 100 that apply the forming force to generate the forming pressure (i.e., the tonnage of the thermoforming press 100) for application to the workpiece 114 do not need to have a significant stroke length that takes into account both the operational placement of the workpiece 114 and the removal of the formed part from the thermoforming press 100, as well as the application of the forming force. Similarly, the components of the thermoforming press 100 that apply the forming force to generate the forming pressure do not need to have a stroke length that also takes into account the removal and replacement of the lower die 106 and the upper die 112. Therefore, the components of the thermoforming press 100 that apply the forming force to generate the forming pressure are subjected to less stress over the same number of cycles as the thermoforming presses of the prior art, and therefore require less maintenance and repairs over the life of the thermoforming press 100.

[0271] By fixing the upper press assembly 108, the components associated with the vertically moving upper press assembly 108 do not need to be able to apply a forming force sufficient to generate the required forming pressure to operably deform the workpiece 114. Instead, only the components associated with the vertically moving lower press assembly 102 need to be able to apply a forming force sufficient to generate the required forming pressure to operably deform the workpiece 114. As a result, in one or more examples, the components associated with the vertically moving upper press assembly 108 are significantly less expensive than the components associated with the vertically moving lower press assembly 102.

[0272] Generally speaking Fig. 20A and Fig. 20BAccording to method 400, the step of heating the workpiece 114 (block 412) includes heating the workpiece 114 to at least 250 ℃ , at least 500 ℃ or at least 750 ℃ or heated to 250-1000 ℃ The aforementioned subject matter of this paragraph characterizes Example 83 of the present disclosure, wherein Example 83 also includes the subject matter according to Example 82 above.

[0273] Heating the workpiece 114 to a desired temperature can control the yield strength, hardness, and ductility of the workpiece 114, and ultimately the yield strength, hardness, and ductility of the part formed from the workpiece 114. That is, depending on the material selection of the workpiece 114, in one or more examples, a temperature or temperature range above the recrystallization temperature of the material is selected to avoid wire hardening of the material during the forming process. Moreover, heating the workpiece 114 allows high-strength materials to be formed at lower forming pressures than required for cold forming processes.

[0274] Generally speaking Fig. 20A and Fig. 20B According to method 400, the forming pressure is generated by a forming force of at least 50 metric tons, at least 100 metric tons, at least 300 metric tons, at least 500 metric tons, at least 700 metric tons, at least 1000 metric tons, or at least 2000 metric tons, or by a forming force in the range of 50-2250 metric tons. The foregoing subject matter of this paragraph characterizes Example 84 of the present disclosure, wherein Example 84 also includes subject matter according to Example 82 or 83 above.

[0275] The molding pressure is selected based on the material properties of the workpiece 114 and the complexity of the part formed from the workpiece 114. Additionally, in one or more examples, a higher molding pressure provides a lower temperature requirement to produce the desired material properties of the part formed from the workpiece 114.

[0276] Generally speaking Fig. 20A and Fig. 20B , especially with reference to e.g. Figure 1A , Figure 1B and Figure 7 , the method 400 further includes the step of vertically moving the lower press assembly 102 to a die setting configuration (block 414) in which the lower die 106 is spaced apart from the lower hot box portion 104 of the lower press assembly 102. When the lower press assembly 102 is in the die setting configuration, the method 400 also includes the step of removing and replacing the lower die 106 from the lower hot box portion 104 (block 416). The foregoing subject matter of this paragraph characterizes Example 85 of the present disclosure, wherein Example 85 also includes subject matter according to any one of Examples 82 to 84 above.

[0277] In the mold setting configuration, in one or more examples, the lower mold 106 is removed and replaced from the lower hot box portion 104. Thus, the thermoforming press 100 can be selectively configured for forming a variety of parts.

[0278] Generally speaking Fig. 20A and Fig. 20B , especially with reference to e.g. Figure 1A , Figure 1B and Figure 7 According to method 400, the step of vertically moving the lower press assembly 102 to the die setting configuration (block 414) includes lowering the lower hot box portion 104 relative to at least one lower die lift pin 136 (block 418), the at least one lower die lift pin 136 extending into the lower hot box portion 104 and operably engaging the lower die 106 to prevent the lower die 106 from descending with the lower hot box portion 104. The foregoing subject matter of this paragraph characterizes Example 86 of the present disclosure, wherein Example 86 also includes subject matter according to Example 85 above.

[0279] Preventing the lower mold 106 from descending with the lower hot box portion 104 causes the lower mold 106 to be positioned above the lower hot box portion 104. Thus, in one or more examples, the lower mold 106 is removed and replaced, such as with a forklift.

[0280] Generally speaking Fig. 20A and Fig. 20B , especially with reference to e.g. Figure 1A , Figure 1B , Figure 3 , Figure 4 and Figure 6 According to method 400, the step of vertically moving the lower press assembly 102 and the upper press assembly 108 to the loading configuration (frame 402) and the step of vertically moving the lower press assembly 102 and the upper press assembly 108 to the closed configuration (frame 406) include vertically moving the lower press assembly 102 (frames 420 and 422) using at least one hydraulic cylinder 124. The foregoing subject matter of this paragraph characterizes Example 87 of the present disclosure, wherein Example 87 also includes subject matter according to any one of Examples 82 to 86 above.

[0281] The hydraulic cylinder is capable of applying the necessary forming force to generate the desired forming pressure for operable deformation of the workpiece 114. Therefore, in one or more examples, at least one hydraulic cylinder 124 is used both to apply the forming pressure and to reconfigure the lower press assembly 102 between the loading configuration and the closed configuration. Additionally, when Example 87 also includes subject matter according to Example 86, in one or more examples, at least one hydraulic cylinder 124 is used to reconfigure the lower press assembly 102 to the die setting configuration.

[0282] Generally speaking Fig. 20A and Fig. 20B , especially with reference to e.g. Figure 1A , Figure 1B and Figure 3-Figure 6 According to method 400, the step of vertically moving the lower press assembly 102 and the upper press assembly 108 to the loading configuration (frame 402) and the step of vertically moving the lower press assembly 102 and the upper press assembly 108 to the closed configuration (frame 406) include vertically moving the upper press assembly 108 (frames 424 and 426) using the single drive screw assembly 132. The foregoing subject matter of this paragraph characterizes Example 88 of the present disclosure, wherein Example 88 also includes subject matter according to any one of Examples 82 to 87 above.

[0283] By using a single drive screw assembly 132, the cost of components for vertically moving the upper press assembly 108 is significantly reduced compared to prior art thermoforming presses. In addition, in one or more examples, the single drive screw assembly 132 is positioned in the center of the upper press assembly 108, thereby shielding the single drive screw assembly 132 from radiant heat emitted from the hot box 300, including radiant heat emitted from the lower mold 106, the upper mold 112, and the workpiece 114 during molding, such as when the lower press assembly 102 and the upper press assembly 108 are in a loading configuration for removing molded parts and loading the workpiece 114.

[0284] Generally speaking Fig. 20A and Fig. 20B , especially with reference to e.g. Figure 1A and Figure 1B According to the method 400, the step of heating the workpiece 114 (block 412) includes the step of sensing the temperature of different lower regions 146 of the lower heating plate 144 of the lower hot box portion 104 of the lower press assembly 102 (block 428). The step of heating the workpiece 114 (block 412) also includes the step of actively and independently controlling the amount of heat delivered to the different lower regions 146 in response to the sensed temperature of the different lower regions 146 (block 430). The foregoing subject matter of this paragraph characterizes Example 89 of the present disclosure, wherein Example 89 also includes subject matter according to any one of Examples 82 to 88 above.

[0285] In one or more examples, by sensing the temperature of different lower regions 146 of the lower heating plate 144, the heat delivered to the different lower regions 146 is based on the sensed temperature to ensure that the different lower regions 146 of the lower heating plate 144 and therefore the corresponding regions of the lower mold 106 are heated to the desired temperature for a particular operation.

[0286] Generally speaking Fig. 20A and Fig. 20B , especially with reference to e.g. Figure 1A and Figure 1B According to method 400, different lower regions 146 include outer lower regions 228 and inner lower regions 230 located between outer lower regions 228. The step of actively and independently controlling the amount of heat delivered to different lower regions 146 (block 430) includes delivering a greater amount of heat to outer lower regions 228 than to inner lower regions 230 (block 432). The foregoing subject matter of this paragraph characterizes example 90 of the present disclosure, wherein example 90 also includes subject matter according to example 89 above.

[0287] In one or more examples, the outer lower region 228 loses heat faster than the inner lower region 230 due to conduction away from the lower heating plate 144, thereby establishing a uniform or desired temperature distribution across the span of the lower heating plate 144 by delivering a greater amount of heat to the outer lower region 228 than to the inner lower region 230.

[0288] Generally speaking Fig. 20A and Fig. 20B , especially with reference to e.g. Figure 1A and Figure 1B According to the method 400, the step of heating the workpiece 114 (block 412) includes the step of sensing the temperature of different upper regions 190 of the upper heating plate 188 of the upper hot box portion 110 of the upper press assembly 108 (block 434). The step of heating the workpiece 114 (block 412) also includes the step of actively and independently controlling the amount of heat delivered to the different upper regions 190 in response to the sensed temperature of the different upper regions 190 (block 436). The foregoing subject matter of this paragraph characterizes Example 91 of the present disclosure, wherein Example 91 also includes subject matter according to any one of Examples 82 to 90 above.

[0289] In one or more examples, by sensing the temperature of different upper regions 190 of the upper heating plate 188, the heat delivered to the different upper regions 190 is based on the sensed temperature to ensure that the different upper regions 190 of the upper heating plate 188 and therefore the corresponding regions of the upper mold 112 are heated to the desired temperature for a particular operation.

[0290] Generally speaking Fig. 20A and Fig. 20B , especially with reference to e.g. Figure 1A and Figure 1BAccording to method 400, different upper regions 190 include outer upper regions 232 and inner upper regions 234 located between outer upper regions 232. The step of actively and independently controlling the amount of heat delivered to different upper regions 190 (block 436) includes delivering a greater amount of heat to outer upper regions 232 than to inner upper regions 234 (block 438). The foregoing subject matter of this paragraph characterizes example 92 of the present disclosure, wherein example 92 also includes subject matter according to example 91 above.

[0291] In one or more examples, the outer upper region 232 loses heat faster than the inner upper region 234 due to conduction away from the upper heating plate 188, thereby establishing a uniform or desired temperature distribution across the span of the upper heating plate 188 by delivering a greater amount of heat to the outer upper region 232 than to the inner upper region 234.

[0292] Generally speaking Fig.21 , especially with reference to e.g. Figure 1A and Figure 1B , a method 500 for thermoforming a workpiece 114 is disclosed. The method 500 includes the step of delivering actively determined heat to different lower regions 146 of a lower heating plate 144 of a lower heating box portion 104 of a heating box 300 of a thermoforming press 100 or to different upper regions 190 of an upper heating plate 188 of an upper heating box portion 110 of the heating box 300 (block 502). The foregoing subject matter of this paragraph characterizes Example 93 of the present disclosure, wherein Example 93 also includes subject matter according to Example 92 above.

[0293] In one or more examples, by delivering actively determined amounts of heat to the different lower regions 146 and / or the different upper regions 190, the temperatures of the different lower regions 146 and / or the different upper regions 190 are controlled to provide desired heating of corresponding regions of the workpiece 114. For example, in some cases, it may be desirable to heat portions of the workpiece 114 that correspond to tighter bends to be formed in the workpiece 114. Additionally or alternatively, in some cases, it may be desirable to deliver greater amounts of heat to outer regions of the workpiece 114 than to inner regions of the workpiece 114 due to conduction and radiation heat losses from the periphery of the workpiece 114.

[0294] Generally speaking Fig.21 According to method 500, the step of delivering the actively determined amount of heat (block 502) includes heating the workpiece 114 to at least 250 ℃ , at least 500 ℃ or at least 750 ℃ or heated to 250-1000 ℃The foregoing subject matter of this paragraph characterizes Example 94 of the present disclosure, wherein Example 94 also includes subject matter according to Example 93 above.

[0295] Heating the workpiece 114 to a desired temperature can control the yield strength, hardness, and ductility of the workpiece 114, and ultimately the yield strength, hardness, and ductility of the part formed from the workpiece 114. That is, depending on the material selection of the workpiece 114, in one or more examples, a temperature or temperature range above the recrystallization temperature of the material is selected to avoid wire hardening of the material during the forming process. Moreover, heating the workpiece 114 allows high-strength materials to be formed at lower forming pressures than required for cold forming processes.

[0296] Generally speaking Fig.21 , method 500 further includes the step of applying a forming force of at least 50 metric tons, at least 100 metric tons, at least 300 metric tons, at least 500 metric tons, at least 700 metric tons, at least 1000 metric tons, at least 2000 metric tons, or 50-2250 metric tons to workpiece 114 (block 506). The foregoing subject matter of this paragraph characterizes example 95 of the present disclosure, wherein example 95 also includes subject matter according to example 93 or 94 above.

[0297] The molding pressure is selected based on the material properties of the workpiece 114 and the complexity of the part formed from the workpiece 114. Additionally, in one or more examples, a higher molding pressure provides a lower temperature requirement to produce the desired material properties of the part formed from the workpiece 114.

[0298] Generally speaking Fig.21 , especially with reference to e.g. Figure 1A and Figure 1B , method 500 further includes a step of sensing the temperature of different lower regions 146 or different upper regions 190 (block 508). The actively determined heat is based at least in part on the temperature. The foregoing subject matter of this paragraph characterizes example 96 of the present disclosure, wherein example 96 also includes subject matter according to any of the above examples 93 to 95.

[0299] In one or more examples, by sensing the temperature of different lower regions 146 and / or different upper regions 190, heat delivered to different lower regions 146 and / or different upper regions 190 is based on the sensed temperature to ensure that different lower regions 146 and / or different upper regions 190 are heated to the temperature required for a particular operation.

[0300] Generally speaking Fig.21 , especially with reference to e.g. Figure 1A and Figure 1BAccording to method 500, different lower regions 146 include outer lower regions 228 and inner lower regions 230 located between outer lower regions 228. Different upper regions 190 include outer upper regions 232 and inner upper regions 234 located between outer upper regions 232. The step of delivering actively determined heat (box 502) includes delivering a greater portion of actively determined heat to outer lower regions 228 than to inner lower regions 230 (box 510) or delivering a greater portion of actively determined heat to outer upper regions 232 than to inner upper regions 234 (box 512). The foregoing subject matter of this paragraph characterizes Example 97 of the present disclosure, wherein Example 97 also includes subject matter according to Example 96 above.

[0301] In one or more examples, the outer lower region 228 and the outer upper region 232 lose heat faster than the inner lower region 230 and the inner upper region 234 due to conduction away from the lower heating plate 144 and the upper heating plate 188, so a uniform or desired temperature distribution is established across the workpiece 114 by delivering a greater amount of heat to the outer lower region 228 and / or the outer upper region 232 than to the inner lower region 230 and / or the inner upper region 234.

[0302] The present disclosure further includes the following illustrative, non-exhaustive enumerated examples, which may or may not be claimed:

[0303] 1. A thermoforming press (100), comprising:

[0304] A lower press assembly (102) movable along a vertical axis and comprising:

[0305] a lower mold (106); and

[0306] a lower hot box portion (104) configured to receive a lower mold (106); and

[0307] An upper press assembly (108) movable along a vertical axis above the lower press assembly (102) and comprising:

[0308] an upper mold (112); and

[0309] an upper hot box portion (110) configured to receive an upper mold (112) such that the upper mold (112) is positioned relative to the lower mold (106); and

[0310] in:

[0311] The lower die (106) and the upper die (112) are configured to apply a molding pressure to a workpiece (114) received between the lower die (106) and the upper die (112);

[0312] as well as

[0313] The lower heat box section (104) and the upper heat box section (110) are configured to heat a workpiece (114).

[0314] 2. A thermoforming press (100) according to Example 1, wherein the lower hot box section (104) and the upper hot box section (110) are configured to heat the workpiece (114) to a temperature of at least 250° Celsius (C), at least 500°C or at least 750°C, or to a temperature in the range of 250-1000°C.

[0315] 3. A thermoforming press (100) according to Example 1 or 2, wherein the forming pressure is generated by a forming force of at least 50 metric tons, at least 100 metric tons, at least 300 metric tons, at least 500 metric tons, at least 700 metric tons, at least 1000 metric tons or at least 2000 metric tons, or by a forming force in the range of 50-2250 metric tons.

[0316] 4. The thermoforming press (100) according to any one of Examples 1 to 3, wherein:

[0317] The lower press assembly (102) and the upper press assembly (108) are configured to move vertically to a loading configuration in which the lower press assembly (102) and the upper press assembly (108) are spaced apart to receive a workpiece (114) between the lower die (106) and the upper die (112); and

[0318] The lower press assembly (102) and the upper press assembly (108) are configured to move vertically to a closed configuration in which the lower press assembly (102) and the upper press assembly (108) are positioned to apply forming pressure to a workpiece (114) between a lower die (106) and an upper die (112).

[0319] 5. The thermoforming press (100) of example 4, wherein the upper press assembly (108) is configured to be selectively locked in a closed configuration.

[0320] 6. The thermoforming press (100) according to example 5, further comprising:

[0321] an upper press head (134), wherein the upper press assembly (108) is vertically movable relative to the upper press head (134);

[0322] at least one locking bar (138) secured to the upper press assembly (108); and

[0323] At least one rod clamp (140) is secured to the upper ram (134) and is configured to selectively clamp at least one locking rod (138) to secure the upper press assembly (108) relative to the upper ram (134).

[0324] 7. The thermoforming press (100) of any one of Examples 1 to 6, further comprising a vertical support (116), wherein:

[0325] The lower press assembly (102) is movable along the vertical support (116); and

[0326] The upper press assembly (108) is movable along the vertical support (116).

[0327] 8. The thermoforming press (100) of example 7, wherein:

[0328] The lower press assembly (102) further includes a lower pad (128) located below the lower hot box section (104) and vertically supporting the lower hot box section; and

[0329] The vertical support member (116) extends through the lower pad (128).

[0330] 9. The thermoforming press (100) of example 7 or 8, wherein:

[0331] The upper press assembly (108) further includes an upper pad (130) positioned above the upper hot box section (110) and vertically supporting the upper hot box section; and

[0332] The vertical supports (116) extend through the upper pad (130).

[0333] 10. The thermoforming press (100) according to any one of Examples 1 to 9, further comprising:

[0334] a lower translation mechanism (118) operably coupled to the lower press assembly (102) and configured to move the lower press assembly (102) along a vertical axis; and

[0335] An upper translation mechanism (120) is configured to vertically move the upper pressure assembly (108) along a vertical axis.

[0336] 11. The thermoforming press (100) of example 10, wherein the lower translation mechanism (118) is configured to apply a forming force to generate a forming pressure.

[0337] 12. The thermoforming press (100) of examples 10 or 11, wherein the upper translation mechanism (120) is not configured to apply a forming force to generate a forming pressure.

[0338] 13. The thermoforming press (100) of any one of Examples 10 to 12, wherein the lower translation mechanism (118) comprises at least one hydraulic cylinder (124).

[0339] 14. The thermoforming press (100) of example 13, further comprising a lower press head (126), and wherein:

[0340] The lower press assembly (102) is vertically movable relative to the lower press head (126); and

[0341] At least one hydraulic cylinder (124) is operably coupled between the lower press assembly (102) and the lower ram (126) to vertically move the lower press assembly (102) relative to the lower ram (126) and apply forming pressure to the workpiece (114).

[0342] 15. The thermoforming press (100) of any one of Examples 10 to 14, wherein the upper translation mechanism (120) comprises a single drive screw assembly (132).

[0343] 16. The thermoforming press (100) of example 15, further comprising an upper press head (134), and wherein:

[0344] The upper press assembly (108) is vertically movable relative to the upper press head (134); and

[0345] A single drive screw assembly (132) is operably coupled between the upper press assembly (108) and the upper ram (134) to vertically move the upper press assembly (108) relative to the upper ram (134).

[0346] 17. A thermoforming press (100) according to any one of Examples 1 to 16, wherein the lower press assembly (102) is configured to move vertically to a mold setting configuration in which the lower mold (106) is spaced apart from the lower hot box portion (104) for selective removal and replacement of the lower mold (106).

[0347] 18. The thermoforming press (100) of example 17, further comprising at least one lower mold lift pin (136) extending into the lower hot box portion (104) and positioned to operably engage the lower mold (106), and wherein:

[0348] The lower press assembly (102) is vertically movable relative to at least one lower die lift pin (136); and

[0349] When the lower press assembly (102) is moved vertically to a mold setting configuration, at least one lower mold lift pin (136) positions the lower mold (106) above the lower hot box section (104) for selective removal and replacement of the lower mold (106).

[0350] 19. The thermoforming press (100) of any one of Examples 1 to 18, wherein:

[0351] The lower heat box section (104) comprises:

[0352] A lower housing (142);

[0353] a lower heating plate (144) housed in the lower housing (142) and configured to contact the lower mold (106) and including a different lower region (146); and a lower insulating layer (148) located between the lower housing (142) and the lower heating plate (144)

[0354] between; and

[0355] The lower press assembly (102) further includes a lower heat source (150) configured to deliver actively determined amounts of heat to different lower regions (146) of the lower heating plate (144).

[0356] 20. The thermoforming press (100) of example 19, wherein the lower heated platen (144) defines a lower heated platen volume (320), and the lower mold (106) is located within the lower heated platen volume.

[0357] 21. The thermoforming press (100) of example 19 or 20, wherein:

[0358] The lower heating plate (144) and the lower housing (142) together define a lower heating rod channel (152); and

[0359] The lower heat source (150) includes a lower heating rod (154) extending into the lower heating rod channel (152).

[0360] 22. The thermoforming press (100) of example 21, wherein the lower heating rod (154) is straight along the entire length of the lower heating rod (154).

[0361] 23. The thermoforming press (100) of example 21 or 22, wherein:

[0362] The lower heat source (150) further comprises:

[0363] a lower connection box (158); and

[0364] a lower connecting cable (160) interconnecting the lower heating rod (154) to the lower connecting box (158);

[0365] The lower press assembly (102) further includes a lower pad (128) located below the lower hot box section (104) and vertically supporting the lower hot box section (104); and

[0366] The lower connection box (158) is mounted on the lower base plate (128).

[0367] 24. The thermoforming press (100) of example 23, wherein when heat is radiated from the lower hot box portion (104), the lower backing plate (128) shields the lower connection box (158) from heat.

[0368] 25. The thermoforming press (100) of any one of Examples 21 to 24, wherein:

[0369] The lower heating rods (154) each include a lower heating region (162);

[0370] The temperature of the lower heating zone (162) is independently controlled; and

[0371] The lower heating zone (162) coincides with a different lower zone (146) of the lower heating plate (144).

[0372] 26. The thermoforming press (100) of example 25, wherein:

[0373] The lower heating zone (162) includes outer lower zones (168) and at least one inner lower zone (170) located between the outer lower zones (168); and

[0374] The outer lower region (168) has a higher heating capacity than the at least one inner lower region (170).

[0375] 27. The thermoforming press (100) of example 26, wherein:

[0376] The lower hot box portion (104) has a lower front side (172) and a lower rear side (174);

[0377] The lower hot box portion (104) is configured to receive the lower mold (106) at a position closer to the lower front side (172) than to the lower rear side (174); and

[0378] An outer lower region (168) proximate the lower front side (172) has a higher heating capacity than an outer lower region (168) proximate the lower rear side (174).

[0379] 28. The thermoforming press (100) of any one of Examples 19 to 27, further comprising:

[0380] a lower temperature sensor (164) configured to sense the temperature of different lower regions (146) of the lower heating plate (144); and

[0381] A controller (156) is operably coupled to the lower connection box (158) and is configured to control an actively determined amount of heat delivered to the different lower regions (146) of the lower heating plate (144) based at least in part on the temperature of the different lower regions (146) of the lower heating plate (144).

[0382] 29. The thermoforming press (100) of example 28, further comprising a lower mold temperature sensor (166) configured to sense a temperature of the lower mold (106), and wherein:

[0383] The controller (156) is configured to record or display the temperature of the lower mold (106); and

[0384] The controller (156) is configured to control the actively determined amount of heat delivered to the different lower zones (146) of the lower heating plate (144) not based on the temperature of the lower mold (106).

[0385] 30. The thermoforming press (100) of examples 28 or 29, further comprising a display (176) operably coupled to the controller (156) and configured to display the temperature of different lower regions (146) of the lower heating plate (144).

[0386] 31. A thermoforming press (100) according to any one of Examples 19 to 30, wherein the lower hot box portion (104) further includes a lower cold plate (178) that is at least partially located between the lower insulation layer (148) and the lower shell (142) and is configured to draw heat away from the lower hot box portion (104).

[0387] 32. The thermoforming press (100) of any one of Examples 19 to 31, wherein:

[0388] The lower heat box portion (104) further includes a lower heat box fastener (180) operably interconnecting the lower housing (142), the lower heating plate (144), and the lower insulation layer (148); and

[0389] The lower hot box fastener (180) includes:

[0390] a lower bolt (182); and

[0391] A spring loaded lower nut assembly (184) is operably coupled to the lower bolt (182) and is configured to allow the lower hot box portion (104) to expand and contract without damaging the lower hot box portion (104).

[0392] 33. The thermoforming press (100) of any one of Examples 1 to 32, wherein:

[0393] The upper heat box section (110) comprises:

[0394] Upper housing (186);

[0395] an upper heating plate (188) housed within the upper housing (186) and configured to contact the upper mold (112) and including a distinct upper region (190);

[0396] as well as

[0397] An upper insulating layer (192) located between the upper shell (186) and the upper heating plate (188)

[0398] between; and

[0399] The upper press assembly (108) further includes an upper heat source (122) configured to deliver actively determined amounts of heat to different upper regions (190) of the upper heating plate (188).

[0400] 34. The thermoforming press (100) of example 33, wherein the upper heating plate (188) defines an upper heating plate volume (346), and the upper mold (112) is located within the upper heating plate volume (346).

[0401] 35. The thermoforming press (100) of example 33 or 34, wherein:

[0402] The upper heating plate (188) and the upper housing (186) together define an upper heating rod channel (194); and

[0403] The upper heat source (122) includes an upper heating rod (196) extending into the upper heating rod channel (194).

[0404] 36. The thermoforming press (100) of example 35, wherein the upper heating rod (196) is straight along the entire length of the upper heating rod (196).

[0405] 37. The thermoforming press (100) of example 35 or 36, wherein:

[0406] The upper heat source (122) further comprises:

[0407] an upper connection box (198); and

[0408] an upper connection cable (200) interconnecting the upper heating rod (196) to the upper connection box (198);

[0409] The upper press assembly (108) further includes an upper pad (130) located above the upper hot box section (110) and vertically supporting the upper hot box section (110); and

[0410] The upper connection box (198) is mounted on the upper pad (130).

[0411] 38. The thermoforming press (100) of example 37, wherein when heat is radiated from the upper hot box portion (110), the upper backing plate (130) shields the upper connecting box (198) from heat.

[0412] 39. The thermoforming press (100) of any one of Examples 35 to 38, wherein:

[0413] The upper heating rods (196) each include an upper heating region (202);

[0414] The temperature of the upper heating zone (202) is independently controlled; and

[0415] The upper heating zone (202) coincides with a different upper zone (190) of the upper heating plate (188).

[0416] 40. The thermoforming press (100) of example 39, wherein:

[0417] The upper heating zone (202) includes outer upper zones (204) and at least one inner upper zone (206) located between the outer upper zones (204); and

[0418] The outer upper region (204) has a higher heating capacity than the at least one inner upper region (206).

[0419] 41. The thermoforming press (100) of example 40, wherein:

[0420] The upper hot box portion (110) has an upper front side (208) and an upper rear side (210);

[0421] The upper hot box portion (110) is configured to receive the upper mold (112) at a position closer to the upper front side (208) than the upper rear side (210); and

[0422] An outer upper region (204) proximate the upper front side (208) has a higher heating capacity than an outer upper region (204) proximate the upper rear side (210).

[0423] 42. The thermoforming press (100) of any one of Examples 33 to 41, further comprising:

[0424] an upper temperature sensor (212) configured to sense the temperature of different upper regions (190) of the upper heating plate (188); and

[0425] A controller (156) is operably coupled to the upper connection box (198) and is configured to control an actively determined amount of heat delivered to different upper zones (190) of the upper heating plate (188) based at least in part on the temperature of the different upper zones (190) of the upper heating plate (188).

[0426] 43. The thermoforming press (100) of example 42, further comprising an upper mold temperature sensor (214) configured to sense a temperature of the upper mold (112), and wherein:

[0427] The controller (156) is configured to record or display the temperature of the upper mold (112); and

[0428] The controller (156) is configured to control the actively determined amount of heat delivered to the different upper zones (190) of the upper heating plate (188) not based on the temperature of the upper mold (112).

[0429] 44. The thermoforming press (100) of Examples 42 or 43, further comprising a display (176) operably coupled to the controller (156) and configured to display the temperature of different upper regions (190) of the upper heating plate (188).

[0430] 45. A thermoforming press (100) according to any one of Examples 33 to 44, wherein the upper hot box portion (110) further includes an upper cold plate (216) that is at least partially located between the upper insulation layer (192) and the upper shell (186) and is configured to draw heat away from the upper hot box portion (110).

[0431] 46. ​​The thermoforming press (100) of any one of Examples 33 to 45, wherein:

[0432] The upper heat box portion (110) further includes an upper heat box fastener (218) operably interconnecting the upper housing (186), the upper heating plate (188), and the upper insulation layer (192); and

[0433] The upper hot box fasteners (218) include:

[0434] an upper bolt (220); and

[0435] A spring loaded upper nut assembly (222) is operably coupled to the upper bolt (220) and is configured to enable the upper hot box portion (110) to expand and contract without damaging the upper hot box portion (110).

[0436] 47. The thermoforming press (100) according to any one of Examples 1 to 46 further includes a pneumatic system (224) configured to deliver gas to an inner cavity (226) of the workpiece (114) when the workpiece (114) is operably positioned between the lower mold (106) and the upper mold (112) and when the lower mold (106) and the upper mold (112) apply forming pressure to the workpiece (114).

[0437] 48. A hot box (300) of a thermoforming press (100), the hot box (300) comprising:

[0438] The lower heat box section (104) comprises:

[0439] A lower housing (142);

[0440] a lower heating plate (144) housed within the lower housing (142) and configured to support the lower mold (106); and

[0441] A lower insulating layer (148) located between the lower shell (142) and the lower heating plate (144)

[0442] between; and

[0443] An upper heat box section (110) positionable above the lower heat box section (104) and comprising:

[0444] Upper housing (186);

[0445] an upper heating plate (188) housed within the upper housing (186) and configured to support the upper mold (112); and

[0446] An upper insulating layer (192) located between the upper shell (186) and the upper heating plate (188)

[0447] between; and

[0448] Wherein, when the lower heat box portion (104) and the upper heat box portion (110) contact each other, the lower heat box portion (104) and the upper heat box portion (110) provide a thermal barrier around a workpiece (114) contained between a lower mold (106) and an upper mold (112).

[0449] 49. The heat box (300) of Example 48, wherein the lower housing (142) includes a lower base plate (302) and a lower side wall (304) located above the lower base plate (302).

[0450] 50. A heat box (300) according to Example 49, wherein the lower base plate (302), the lower isolation layer (148) and the lower heating plate (144) jointly define at least one lower lift pin channel (306), which is configured to receive at least one lower mold lift pin (136) for operably engaging with the lower mold (106) and for separating the lower mold (106) from the lower heat box portion (104).

[0451] 51. The heat box (300) of example 49 or 50, wherein:

[0452] The lower base plate (302), the lower insulation layer (148) and the lower heating plate (144) collectively define a lower bolt channel (308); and

[0453] The lower heat box section (104) further comprises:

[0454] a lower bolt (182) extending through a lower bolt passage (308); and

[0455] A spring loaded lower nut assembly (184) is operably coupled to the lower bolt (182) and is configured to allow the lower hot box portion (104) to expand and contract without damaging the lower hot box portion (104).

[0456] 52. The heat box (300) of example 51, wherein a spring-loaded lower nut assembly (184) is positioned within the lower base plate (302).

[0457] 53. The heat box (300) of example 51 or 52, wherein:

[0458] The lower bolt channel (308) includes a lower circular counterbore (310); and

[0459] The lower bolt (182) includes a lower round head (312) configured to mate with the lower circular counterbore (310).

[0460] 54. The heat box (300) of example 53, wherein:

[0461] The lower heating plate (144) defines a lower circular counterbore (310); and

[0462] The lower round head (312) is located within the lower heating plate (144).

[0463] 55. The heat box (300) of any one of examples 49 to 54, wherein:

[0464] A lower insulation layer (148) defines a lower insulation volume (314); and

[0465] The lower heating plate (144) is located within the lower insulation volume (314).

[0466] 56. The heat box (300) of example 55, wherein the lower insulation layer (148) comprises:

[0467] a lower ceramic sheet (316) located between the lower heating plate (144) and the lower side wall (304); and

[0468] At least one lower ceramic block (318) is located between the lower heating plate (144) and the lower base plate (302).

[0469] 57. The heat box (300) of any one of Examples 49 to 56, wherein the lower heating plate (144) defines a lower heating plate volume (320) sized to receive and operably position the lower mold (106).

[0470] 58. The heat box (300) of example 57, wherein:

[0471] The lower hot box portion (104) has a lower front side (172) and a lower rear side (174); and

[0472] The lower heating plate volume (320) is positioned closer to the lower front side (172) than the lower rear side (174).

[0473] 59. A heat box (300) according to any one of Examples 49 to 58, wherein the lower heating plate (144) and the lower side wall (304) together define a lower heating rod channel (152) configured to receive a lower heating rod (154).

[0474] 60. The heat box (300) of example 59, wherein:

[0475] The lower hot box portion (104) has a lower front side (172) and a lower rear side (174); and

[0476] The lower heater rod channel (152) extends through the lower side wall (304) only on the lower rear side (174).

[0477] 61. A heat box (300) according to any one of Examples 49 to 60, wherein the lower heating plate (144) defines a lower groove (322) configured to receive a lower connector (324) for operably holding the lower mold (106) to the lower heating plate (144).

[0478] 62. The hot box (300) of Example 61, wherein the lower side wall (304) defines a lower access channel (328) configured to provide access to the lower slot (322) for operable insertion and removal of the lower connector (324).

[0479] 63. A heat box (300) according to any one of Examples 49 to 62, wherein the lower base plate (302) includes a lower peripheral flange (326) configured to operably connect the lower heat box portion (104) to a lower pad (128) of a thermoforming press (100).

[0480] 64. A heat box (300) according to any one of Examples 49 to 63, wherein the lower heat box portion (104) further includes a lower cold plate (178) located between the lower insulation layer (148) and the lower base plate (302) and configured to draw heat away from the heat box (300).

[0481] 65. The heat box (300) of example 64, wherein the lower cold plate (178) extends between the lower base plate (302) and the lower side wall (304).

[0482] 66. The heat box (300) of any one of Examples 48 to 65, wherein the upper housing (186) includes an upper top plate (330) and an upper side wall (332) located below the upper top plate (330).

[0483] 67. The heat box (300) of example 66, wherein:

[0484] The upper top plate (330), the upper insulation layer (192) and the upper heating plate (188) collectively define an upper bolt channel (334); and

[0485] The upper heat box section (110) further comprises:

[0486] an upper bolt (220) extending through an upper bolt passage (334); and

[0487] A spring loaded upper nut assembly (222) is operably coupled to the upper bolt (220) and is configured to allow the upper hot box portion (110) to expand and contract without damaging the upper hot box portion (110).

[0488] 68. The hot box (300) of example 67, wherein the spring-loaded upper nut assembly (222) is positioned within the upper top plate (330).

[0489] 69. The heat box (300) of example 67 or 68, wherein:

[0490] The upper bolt channel (334) includes an upper circular counterbore (336); and

[0491] The upper bolt (220) includes an upper round head (338) configured to mate with the upper circular counterbore (336).

[0492] 70. The heat box (300) of example 69, wherein:

[0493] The upper heating plate (188) defines an upper circular counterbore (336); and

[0494] The upper round head (338) is located within the upper heating plate (188).

[0495] 71. The heat box (300) of any one of examples 66 to 70, wherein:

[0496] The upper insulation layer (192) defines an upper insulation volume (340); and

[0497] An upper heating plate (188) is located within the upper insulation volume (340).

[0498] 72. The heat box (300) of example 71, wherein the upper insulation layer (192) comprises:

[0499] an upper ceramic sheet (342) located between the upper heating plate (188) and the upper side wall (332); and

[0500] At least one upper ceramic block (344) is located between the upper heating plate (188) and the upper top plate (330).

[0501] 73. The heat box (300) of any of Examples 66 to 72, wherein the upper heating plate (188) defines an upper heating plate volume (346) sized to receive and operably position the upper mold (112).

[0502] 74. The heat box (300) of example 73, wherein:

[0503] The upper hot box portion (110) has an upper front side (208) and an upper rear side (210); and

[0504] The upper heating plate volume (346) is positioned closer to the upper front side (208) than the upper rear side (210).

[0505] 75. A heat box (300) according to any one of Examples 66 to 74, wherein the upper heating plate (188) and the upper side wall (332) together define an upper heating rod channel (194) which is configured to receive an upper heating rod (196).

[0506] 76. The heat box (300) of example 75, wherein:

[0507] The upper hot box portion (110) has an upper front side (208) and an upper rear side (210); and

[0508] The upper heater rod channel (194) extends through the upper side wall (332) only on the upper rear side (210).

[0509] 77. A heat box (300) according to any of Examples 66 to 76, wherein the upper heating plate (188) defines an upper groove (348) configured to receive an upper connector (350) for operably holding the upper mold (112) to the upper heating plate (188).

[0510] 78. The hot box (300) of Example 77, wherein the upper side wall (332) defines an upper access channel (352) configured to provide access to the upper slot (348) for operable insertion and removal of the upper connector (350).

[0511] 79. A hot box (300) according to any one of Examples 66 to 78, wherein the upper top plate (330) includes an upper peripheral flange (354) configured to operably connect the upper hot box portion (110) to an upper pad (130) of a thermoforming press (100).

[0512] 80. A hot box (300) according to any one of Examples 66 to 79, wherein the upper hot box portion (110) further includes an upper cold plate (216) located between the upper insulation layer (192) and the upper top plate (330) and configured to draw heat away from the hot box (300).

[0513] 81. The hot box (300) of example 80, wherein the upper cold plate (216) extends between the upper top plate (330) and the upper side wall (332).

[0514] 82. A method (400) of thermoforming a workpiece (114), the method (400) comprising the steps of:

[0515] vertically moving the lower press assembly (102) and the upper press assembly (108) to a loading configuration in which the lower press assembly (102) and the upper press assembly (108) are spaced apart to receive a workpiece (114);

[0516] Positioning a workpiece (114) between a lower die (106) of a lower press assembly (102) and an upper die (112) of an upper press assembly (108);

[0517] vertically moving the lower press assembly (102) and the upper press assembly (108) to a closed configuration in which the lower press assembly (102) and the upper press assembly (108) are positioned to apply forming pressure to the workpiece (114);

[0518] securing the upper press assembly (108);

[0519] moving the lower press assembly (102) toward the upper press assembly (108) to apply forming pressure to the workpiece (114); and

[0520] The workpiece (114) is heated.

[0521] 83. The method (400) of example 82, wherein the step of heating the workpiece (114) comprises heating the workpiece (114) to at least 250°C. ℃ , at least 500 ℃ or at least 750 ℃ or heated to a temperature in the range of 250-1000°C.

[0522] 84. The method (400) of Example 82 or 83, wherein the molding pressure is generated by a molding force of at least 50 metric tons, at least 100 metric tons, at least 300 metric tons, at least 500 metric tons, at least 700 metric tons, at least 1000 metric tons, or at least 2000 metric tons, or by a molding force in the range of 50-2250 metric tons.

[0523] 85. The method (400) of any one of Examples 82 to 84, further comprising:

[0524] vertically moving the lower press assembly (102) to a mold setting configuration in which the lower mold (106) is spaced apart from the lower hot box portion (104) of the lower press assembly (102); and

[0525] With the lower press assembly (102) in the die setting configuration, the lower die (106) is removed and replaced from the lower hot box section (104).

[0526] 86. A method (400) according to Example 85, wherein the step of vertically moving the lower press assembly (102) to a mold setting configuration includes lowering the lower hot box portion (104) relative to at least one lower mold lift pin (136), which extends into the lower hot box portion (104) and is operably engaged with the lower mold (106) to prevent the lower mold (106) from descending with the lower hot box portion (104).

[0527] 87. A method (400) according to any one of Examples 82 to 86, wherein the step of vertically moving the lower press assembly (102) and the upper press assembly (108) to a loading configuration and the step of vertically moving the lower press assembly (102) and the upper press assembly (108) to a closed configuration include using at least one hydraulic cylinder (124) to vertically move the lower press assembly (102).

[0528] 88. A method (400) according to any one of Examples 82 to 87, wherein the step of vertically moving the lower press assembly (102) and the upper press assembly (108) to a loading configuration and the step of vertically moving the lower press assembly (102) and the upper press assembly (108) to a closed configuration include vertically moving the upper press assembly (108) using a single drive screw (132).

[0529] 89. The method (400) of any one of examples 82 to 88, wherein the step of heating the workpiece (114) comprises the steps of:

[0530] sensing the temperature of different lower regions (146) of a lower heating plate (144) of a lower hot box portion (104) of a lower press assembly (102); and

[0531] The amount of heat delivered to the different lower zones (146) is actively and independently controlled in response to the sensed temperatures of the different lower zones (146).

[0532] 90. The method (400) of example 89, wherein:

[0533] The different lower regions (146) include outer lower regions (228) and inner lower regions (230) located between the outer lower regions (228); and

[0534] The step of actively and independently controlling the amount of heat delivered to the different lower zones (146) includes delivering a greater amount of heat to the outer lower zone (228) than to the inner lower zone (230).

[0535] 91. The method (400) of any one of examples 82 to 90, wherein the step of heating the workpiece (114) comprises the following steps:

[0536] sensing the temperature of different upper regions (190) of an upper heating plate (188) of an upper hot box portion (110) of an upper press assembly (108); and

[0537] The heat delivered to the different upper zones (190) is actively and independently controlled in response to the sensed temperatures of the different upper zones (190).

[0538] 92. The method (400) of example 91, wherein:

[0539] The different upper regions (190) include outer upper regions (232) and inner upper regions (234) located between the outer upper regions (232); and

[0540] The step of actively and independently controlling the amount of heat delivered to the different upper zones (190) includes delivering a greater amount of heat to the outer upper zone (232) than to the inner upper zone (234).

[0541] 93. A method (500) for thermoforming a workpiece (114), the method (500) comprising the steps of delivering actively determined heat to different lower regions (146) of a lower heating plate (144) of a lower hot box portion (104) of a hot box (300) of a hot box (100) or to different upper regions (190) of an upper heating plate (188) of an upper hot box portion (110) of the hot box (300).

[0542] 94. The method (500) of example 93, wherein the step of delivering the actively determined amount of heat comprises heating the workpiece (114) to at least 250°C. ℃ , at least 500 ℃ or at least 750 ℃ temperature, or heated to a temperature in the range of 250-1000°C.

[0543] 95. The method (500) of Example 93 or 94 further comprises the step of applying a forming force of at least 50 metric tons, at least 100 metric tons, at least 300 metric tons, at least 500 metric tons, at least 700 metric tons, at least 1000 metric tons, at least 2000 metric tons or 50-2250 metric tons to the workpiece (114).

[0544] 96. The method (500) of any one of Examples 93 to 95, further comprising the step of sensing the temperature of different lower regions (146) or different upper regions (190), and wherein the heat actively determined is based at least in part on the temperature.

[0545] 97. The method (500) of example 96, wherein:

[0546] The different lower regions (146) include outer lower regions (228) and inner lower regions (230) located between the outer lower regions (228);

[0547] The different upper regions (190) include outer upper regions (232) and inner upper regions (234) located between the outer upper regions (232); and

[0548] The step of delivering the actively determined heat includes delivering a greater portion of the actively determined heat to the outer lower region (228) than to the inner lower region (230) or delivering a greater portion of the actively determined heat to the outer upper region (232) than to the inner upper region (234).

[0549] You can Fig. 22 Aircraft manufacturing and service method 1100 and the like are shown Fig.23 Examples of the present disclosure are described in the context of the aircraft 1102 shown. During pre-production, the illustrative method 1100 may include specification and design of the aircraft 1102 (block 1104) and material procurement (block 1106). During production, component and subassembly manufacturing (block 1108) and system integration (block 1110) of the aircraft 1102 may be performed. Thereafter, the aircraft 1102 may be certified and delivered (block 1112) to be placed in service (block 1114). While in service, the aircraft 1102 may be scheduled for routine maintenance and servicing (block 1116). Routine maintenance and servicing may include modification, reconfiguration, refurbishment, etc. of one or more systems of the aircraft 1102.

[0550] Each process of the illustrative method 1100 may be completed or performed by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of marketers, subcontractors, and suppliers; and an operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0551] like Fig.23As shown, an aircraft 1102 produced by the illustrative method 1100 may include a frame 222 having a plurality of high-level systems 1120 and an interior 1122. Examples of high-level systems 1120 include one or more of a propulsion system 1124, an electrical system 1126, a hydraulic system 1128, and an environmental system 1130. Any number of other systems may be included. Although an aerospace example is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. Therefore, in addition to the aircraft 1102, the principles disclosed herein may be applied to other vehicles, such as land vehicles, marine vehicles, space vehicles, etc.

[0552] The apparatus and methods shown or described herein may be employed during any one or more stages of the manufacturing and maintenance method 1100. For example, the components or subassemblies corresponding to the component and subassembly manufacturing stage (block 1108) may be manufactured or processed in a manner similar to the components or subassemblies produced when the aircraft 1102 is in service (block 1114). Moreover, one or more examples of the apparatus, method, or combination thereof may be utilized during the production stages 1108 and 1110, for example, to significantly speed up the assembly of the aircraft 1102 or reduce the cost of the aircraft 1102. Similarly, one or more examples of the apparatus or method implementation or combination thereof may be utilized, for example, but not limited to, when the aircraft 1102 is in service (block 1114) and / or during maintenance and service (block 1116).

[0553] The different examples of the apparatus and methods disclosed herein include various components, features, and functions. It should be understood that the various examples of the apparatus and methods disclosed herein may include any combination of any components, features, and functions of any other examples of the apparatus and methods disclosed herein, and all of these possibilities are within the scope of the present disclosure.

[0554] Many modifications of the examples set forth herein will come to mind to one skilled in the art to which the present disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings.

[0555] Therefore, it should be understood that the present disclosure is not limited to the specific examples shown, and modifications and other examples are intended to be included within the scope of the appended claims. In addition, although the foregoing description and related drawings describe examples of the present disclosure in the context of certain illustrative combinations of elements and / or functions, it should be understood that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the appended claims. Therefore, the reference numerals in parentheses in the appended claims are presented for illustrative purposes only and are not intended to limit the scope of the claimed subject matter to the specific examples provided in the present disclosure.

Claims

1. A hot box (300) of a thermoforming press (100), the hot box (300) comprising: A lower hot box portion (104) comprising: a lower shell (142); a lower heating plate (144) received in the lower shell (142) and configured to support a lower mold (106); and a lower insulating layer (148) located between the lower shell (142) and the lower heating plate (144); and an upper heat box section (110) positionable above the lower heat box section (104) and comprising: an upper housing (186); an upper heating plate (188) received within the upper housing (186) and configured to support an upper mold (112); and an upper insulating layer (192) located between the upper housing (186) and the upper heating plate (188); and wherein when the lower heat box portion (104) and the upper heat box portion (110) are in contact with each other, the lower heat box portion (104) and the upper heat box portion (110) provide a thermal barrier around a workpiece (114) received between the lower mold (106) and the upper mold (112); The lower housing (142) includes a lower base plate (302) and a lower side wall (304) located above the lower base plate (302); The lower base plate (302), the lower insulation layer (148) and the lower heating plate (144) together define a lower bolt channel (308); The lower hot box portion (104) further includes: a lower bolt (182) extending through the lower bolt passage (308); and a spring-loaded lower nut assembly (184) operatively coupled to the lower bolt (182) and configured to allow the lower hot box portion (104) to expand and contract without damaging the lower hot box portion (104); And the spring loaded lower nut assembly (184) is positioned within the lower base plate (302).

2. The heat box (300) according to claim 1, wherein: The lower base plate (302), the lower isolation layer (148) and the lower heating plate (144) collectively define at least one lower lift pin channel (306), the at least one lower lift pin channel being configured to receive at least one lower mold lift pin (136) for operatively engaging the lower mold (106) and for separating the lower mold (106) from the lower hot box portion (104).

3. The heat box (300) according to claim 1, wherein: The lower bolt channel (308) includes a lower circular counterbore (310); and The lower bolt (182) includes a lower round head (312) configured to mate with the lower circular counterbore (310).

4. The heat box (300) according to claim 3, wherein: The lower heating plate (144) defines the lower circular counterbore (310); and The lower round head (312) is located inside the lower heating plate (144).

5. The heat box (300) according to claim 1, wherein: The lower insulation layer (148) defines a lower insulation volume (314); and The lower heating plate (144) is located within the lower insulation volume (314).

6. The heat box (300) according to claim 5, wherein: The lower isolation layer (148) comprises: a lower ceramic sheet (316) located between the lower heating plate (144) and the lower side wall (304); and At least one lower ceramic block (318) is located between the lower heating plate (144) and the lower base plate (302).

7. The heat box (300) according to claim 1, wherein: The lower heating plate (144) defines a lower heating plate volume (320) that is sized to receive and operatively position the lower mold (106).

8. The heat box (300) according to claim 7, wherein: The lower heat box portion (104) has a lower front side (172) and a lower rear side (174); and The lower heating plate volume (320) is positioned closer to the lower front side (172) than to the lower rear side (174).

9. The heat box (300) according to claim 1, wherein: The lower heating plate (144) and the lower sidewall (304) together define a lower heating rod channel (152) configured to receive a lower heating rod (154).

10. The heat box (300) according to claim 9, wherein: The lower heat box portion (104) has a lower front side (172) and a lower rear side (174); and The lower heater rod channel (152) extends through the lower side wall (304) only on the lower rear side (174).

11. The heat box (300) according to claim 1, wherein: The lower heating plate (144) defines a lower slot (322) configured to receive a lower coupler (324) for operatively retaining the lower mold (106) to the lower heating plate (144).

12. The heat box (300) according to claim 11, wherein: The lower sidewall (304) defines a lower access passage (328) configured to provide access to the lower slot (322) for operative insertion and removal of the lower coupler (324).

13. The heat box (300) according to claim 1, wherein: The lower base plate (302) includes a lower peripheral flange (326) configured to operatively couple the lower hot box portion (104) to a lower backing plate (128) of the thermoforming press (100).

14. The hot box (300) according to claim 1, wherein: The lower hot box portion (104) further includes a lower cold plate (178) located between the lower insulation layer (148) and the lower base plate (302) and configured to draw heat away from the hot box (300).

15. The heat box (300) according to claim 14, wherein: The lower cold plate (178) extends between the lower base plate (302) and the lower sidewall (304).

16. The heat box (300) according to claim 1, wherein: The upper shell (186) includes an upper top plate (330) and an upper side wall (332) located below the upper top plate (330).

17. The heat box (300) according to claim 16, wherein: The upper top plate (330), the upper insulation layer (192) and the upper heating plate (188) collectively define an upper bolt channel (334); and The upper heat box portion (110) further includes: an upper bolt (220) extending through the upper bolt channel (334); and a spring-loaded upper nut assembly (222) operatively coupled to the upper bolt (220) and configured to allow the upper heat box portion (110) to expand and contract without damaging the upper heat box portion (110).

18. The heat box (300) according to claim 17, wherein: The spring loaded upper nut assembly (222) is positioned within the upper top plate (330).

19. The heat box (300) according to claim 17 or 18, wherein: The upper bolt channel (334) includes an upper circular counterbore (336); and The upper bolt (220) includes an upper round head (338) configured to mate with the upper circular counterbore (336).

20. The heat box (300) according to claim 19, wherein: The upper heating plate (188) defines the upper circular counterbore (336); and The upper round head (338) is located within the upper heating plate (188).

21. The heat box (300) of claim 16, wherein: The upper insulation layer (192) defines an upper insulation volume (340); and The upper heating plate (188) is located within the upper insulation volume (340).

22. The hot box (300) according to claim 21, wherein: The upper isolation layer (192) comprises: an upper ceramic sheet (342) located between the upper heating plate (188) and the upper side wall (332); and At least one upper ceramic block (344) is located between the upper heating plate (188) and the upper top plate (330).

23. The hot box (300) according to claim 16, wherein: The upper heating plate (188) defines an upper heating plate volume (346) sized to receive and operatively position the upper mold (112).

24. The heat box (300) according to claim 23, wherein: The upper heat box portion (110) has an upper front side (208) and an upper rear side (210); and The upper heating plate volume (346) is positioned closer to the upper front side (208) than to the upper rear side (210).

25. The hot box (300) of claim 16, wherein: The upper heating plate (188) and the upper sidewall (332) together define an upper heating rod channel (194) configured to receive an upper heating rod (196).

26. The heat box (300) of claim 25, wherein: The upper heat box portion (110) has an upper front side (208) and an upper rear side (210); and The upper heater rod channel (194) extends through the upper side wall (332) only on the upper rear side (210).

27. The hot box (300) of claim 16, wherein: The upper heating plate (188) defines an upper slot (348) configured to receive an upper coupler (350) for operatively retaining the upper mold (112) to the upper heating plate (188).

28. The heat box (300) according to claim 27, wherein: The upper sidewall (332) defines an upper access passage (352) configured to provide access to the upper slot (348) for operative insertion and removal of the upper coupler (350).

29. The hot box (300) of claim 16, wherein: The upper top plate (330) includes an upper peripheral flange (354) configured to operatively couple the upper hot box portion (110) to an upper backing plate (130) of the thermoforming press (100).

30. The hot box (300) of claim 16, wherein: The upper hot box portion (110) further includes an upper cold plate (216) located between the upper insulation layer (192) and the upper top plate (330) and configured to draw heat away from the hot box (300).

31. The heat box (300) according to claim 30, wherein: The upper cold plate (216) extends between the upper top plate (330) and the upper side wall (332).

32. A method (500) for thermoforming a workpiece (114) using a hot box (300) of a thermoforming press (100) according to claim 1, the method (500) comprising the step of delivering actively determined heat to different lower regions (146) of a lower heating plate (144) of a lower hot box portion (104) of the hot box (300) of the thermoforming press (100) or to different upper regions (190) of an upper heating plate (188) of an upper hot box portion (110) of the hot box (300).

33. The method (500) of claim 32, wherein: The step of delivering an actively determined amount of heat includes heating the workpiece (114) to at least 250 ℃ , at least 500 ℃ or at least 750 ℃ temperature, or heated to a temperature in the range of 250-1000°C.

34. The method (500) according to claim 32 or 33 further includes the step of applying a forming force of at least 50 metric tons, at least 100 metric tons, at least 300 metric tons, at least 500 metric tons, at least 700 metric tons, at least 1000 metric tons, at least 2000 metric tons or 50-2250 metric tons to the workpiece (114).

35. The method (500) of claim 32 or 33, further comprising the step of sensing the temperature of the different lower region (146) or the different upper region (190), and wherein: The actively determined heat is based at least in part on the temperature.

36. The method (500) of claim 35, wherein: The different lower regions (146) include outer lower regions (228) and inner lower regions (230) located between the outer lower regions (228); The different upper regions (190) include an outer upper region (232) and an inner upper region (234) located between the outer upper regions (232); and the step of delivering actively determined heat includes delivering a larger portion of the actively determined heat to the outer lower region (228) than to the inner lower region (230) or delivering a larger portion of the actively determined heat to the outer upper region (232) than to the inner upper region (234).

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