Molding apparatus and method

Abstract

Disclosed herein is a method of manufacturing an article, the method comprising the steps of: providing a material; heating the material; confining an edge or region of the material within the frame element; the mold is moved toward the frame or the frame is moved toward the mold to bring the material into contact with the mold.

Description

Technical Field

[0001] This invention relates to the field of material forming technology, and more specifically to a process for thermoforming using frame elements. More specifically, this invention relates to a process for forming articles from a billet comprising multiple hollow parallel connecting tubes or other materials having a honeycomb structure. Such molded articles can be used in the field of safety equipment, such as personal protective equipment like cycling helmets. Background Technology

[0002] There is a current need to mold materials into components and products of various shapes, especially to manufacture protective components for helmets and other protective clothing / equipment.

[0003] Existing research has found that materials made from parallel connecting tubes are particularly suitable for absorbing impacts—because compacting these tubular structures requires a significant amount of energy, thus effectively absorbing impact forces. Therefore, this material is well-suited for molding into protective components, such as inner lining elements for helmets used in cycling, skiing, snowboarding, and other sports. These components can include partial protective blocks embedded in the helmet or as a complete inner shell layer serving as a structural layer within the helmet.

[0004] Currently, there are very few methods for molding such materials into specific shapes, and all existing methods have obvious drawbacks. Patent EP3900914B1 discloses a method for stereolithographic molding of thermoplastic honeycomb sheets using a membrane material and a three-dimensional molding die.

[0005] However, there are many problems with using membrane materials as a means to apply tensile force to the surface of preheated honeycomb materials to achieve three-dimensional shaping of the materials.

[0006] Although stretchable membrane materials are elastic, they gradually lose some of their resilience over time—especially when the membrane material is repeatedly heated, stretched, and relaxed during the manufacturing process.

[0007] To obtain shaped and dimensionally stable molded parts, the membrane material must always apply uniform tension to the surface of the honeycomb material.

[0008] When the elasticity or resilience of the membrane material decreases, the tension it exerts on the honeycomb material weakens, leading to relaxation on the surface of the molded part.

[0009] Another drawback of using a membrane to apply tensile force to the surface of a preheated honeycomb material to achieve three-dimensional molding is that the force generated between the three-dimensional molding die and the membrane cannot be evenly distributed on the surface of the honeycomb material. This problem still exists even if the membrane itself does not deform.

[0010] The membrane forming method generates a radial pressure / tension effect on the surface of the honeycomb material—the pressure is concentrated in the central area of ​​the membrane and decreases radially towards the outer edge, resulting in a significant reduction in force and pressure / tension in the edge area.

[0011] In some cases, the force at the edge of the membrane is so weak that the edge area of ​​the material can hardly obtain effective pressure / tension through the membrane.

[0012] This will lead to localized failure in material forming, with the edge areas failing to achieve the desired three-dimensional shape. Instead, the edges of the honeycomb material will flare outwards in an undesirable manner. This means that products manufactured using this method are unlikely to meet the requirements of protective equipment.

[0013] The present invention aims to solve the above-mentioned and related technical problems by providing a novel alternative material molding method. Summary of the Invention

[0014] Various aspects of the invention are set forth in the independent claims, and optional features are defined in the dependent claims.

[0015] According to a first aspect, a method for manufacturing an article of article is provided, the method comprising the following steps:

[0016] Provide materials;

[0017] Heating the material;

[0018] Constraining the edges or areas of the material within the frame element;

[0019] Move the mold toward the frame or move the frame toward the mold to bring the material into contact with the mold.

[0020] This method can be highly advantageous because it applies a uniform force to the material's edges—the very areas where the primary force is required during molding. The force exerted by the frame on the material's center is significantly reduced (although the mold still applies some force to that area). This design intentionally creates a non-uniform distribution of force across the frame components, making it particularly suitable for molding components such as helmet parts. This not only enables the production of stronger protective gear but also allows for a final shape that more closely approximates the intended design configuration.

[0021] Optionally, heating the material includes blowing hot air through the interior of the material. This not only heats the material but, more advantageously, allows for differentiated heating of the two sides of the material. This non-uniform heating method offers significant advantages because the inner side of the final shaped form has a greater degree of curvature.

[0022] Optionally, it further includes shaping the material through contact with the mold.

[0023] Optionally, the edge or region is any of the following:

[0024] The edge of the material portion formed by the mold, or the sidewall of the material. The first approach is suitable for forming large components, such as hemispherical components that serve as an integral layer of a helmet structure; the second approach is suitable for manufacturing segmented components that need to be embedded in a helmet, while minimizing material waste during the manufacturing process.

[0025] Optionally, the frame element is a fundamentally rigid element. This helps to effectively transfer forces to the edge portions of the material, thereby achieving the desired material forming effect.

[0026] Optionally, the frame element includes slits. This allows material to be pushed through the slits to aid in shaping.

[0027] Optionally, the cut is located at the center of the frame element. This ensures that the entire perimeter of the cut remains in contact with the edge of the material.

[0028] Optionally, the shape of the cut corresponds to the cross-sectional shape of the mold. This allows for the simple and efficient production of a final product with the desired shape (in conjunction with necessary pre-cutting steps).

[0029] Optionally, the frame element extends downwards by 5mm-20mm, preferably 6mm-12mm. This downward extension (i.e., perpendicular to the plane of the cut) provides additional tension as the material is pushed through the cut, effectively preventing deformation of the cross-sectional shape of the parallel connecting tube. Experiments show that this size range maximally suppresses such deformation modes.

[0030] Optionally, the downward extension is positioned at the midpoint of the frame cut in the longitudinal direction. When manufacturing hemispherical articles for head protection, this midpoint (roughly corresponding to the user's ear area) is where the cross-sectional aggregation or deformation of the parallel connecting tube is most significant. By applying additional tension only at this critical point, this deformation tendency can be effectively suppressed (or partially suppressed).

[0031] Optionally, it further includes positioning the material at any of the following locations before confining the material edges:

[0032] Top of frame components;

[0033] Bottom of the frame component;

[0034] Top of the mold;

[0035] The bottom of the mold. This allows material to be positioned between the frame elements and the mold before molding.

[0036] Optionally, the process further includes pushing at least a portion of the material through a cut in the frame, wherein as the material portion is pushed through the cut, its edges are constrained by the frame elements. This allows the material edges or edge regions to maintain continuous contact with the frame elements as the mold pushes the remaining material, thereby enabling the molding of other parts of the material.

[0037] Optionally, this further includes removing material outside the edges of the molded material portion. This removes burrs generated during the molding process to achieve the desired final shape.

[0038] Optionally, the process further includes forming scratches on the outer surface of the article. These scratches can be used to position elements inside the helmet, cut the article at predetermined points, or achieve mating with helmet components.

[0039] Optionally, the frame includes a scratching member and further includes a step of scratching the outer surface of the article during material forming using the scratching member.

[0040] Optionally, the frame includes a second molding element disposed at an angle to the first molding element, the second molding element being configured to mold the material in a plane different from the first molding element. This allows for the formation of complex shapes on the material (e.g., "humps" resembling a camel's hump).

[0041] Alternatively, the frame element can be a flexible component, such as an inflatable component. This can be highly advantageous because it allows for control and adjustment of the constraint state on the material edges or edge regions as needed during the molding process.

[0042] Optionally, the flexible / inflatable member becomes annular after inflation, with a cavity forming at its center. This cavity allows it to function as a slit.

[0043] Optionally, it may further include positioning the material on top or bottom of the flexible / inflatable member before restricting the material edges.

[0044] Optionally, the process further includes pushing at least a portion of the material through a cavity at the center of the flexible / inflatable member, wherein, when the material is partially formed, its edges are constrained by the flexible / inflatable member. This allows the fixed edges or edge regions to maintain continuous contact with the inflatable member as the material is pushed through the cavity. This allows the edges or edge regions to receive a significant amount of force from the inflatable member, thereby achieving effective material forming.

[0045] Optionally, it further includes expanding the flexible / inflatable member after the material has been at least partially formed; and optionally further includes continuing to shape the material after the flexible / inflatable member has been expanded. This allows for the manufacture of complex geometries with multiple curves or edges.

[0046] Optionally, the flexible / inflatable member expands around the sidewalls of the material to confine the material edges within the frame. This allows for the molding of small articles with less material waste.

[0047] Optionally, the diameter of the internal cavity decreases when the flexible / inflatable member expands. This can therefore increase the curvature of the molding material.

[0048] Alternatively, the mold shapes the material when it comes into contact with it, and all of the material is shaped.

[0049] Optionally, the process may further include a first or second pre-cutting step to cut the material into the desired planar shape, such as a triangle. For example, the blank may be cut into multiple triangular parts, each of which can be used to manufacture small articles, thereby minimizing material waste.

[0050] Optionally, this further includes reducing the cross-sectional area of ​​the material during molding. For example, when the material becomes curved, its cross-sectional area will decrease accordingly.

[0051] Optionally, the flexible / inflatable member has a spherical bulge in the middle, such that the cross-sectional dimension of the cavity at the top / bottom is larger than that at the middle of the flexible / inflatable member. This allows for the creation of complex shapes by varying the effective size of the cut during the molding process.

[0052] Optionally, it further includes moving the material from the top / bottom of the cavity toward the spherical center of the inflatable component during the material forming process.

[0053] Alternatively, the material edges are consistently constrained by flexible / inflatable components throughout the material movement. This allows the forces applied during the molding process to remain concentrated in the edge region.

[0054] Optionally, the frame element is a funnel-shaped structure with a tapering cross-sectional area, for example, containing a central cavity with a first cross-sectional area at the top, and the cross-sectional area of ​​the cavity below the top decreasing. This allows the material to be formed into complex shapes by changing the effective cross-sectional area of ​​the cut during the molding process.

[0055] Optionally, the surface roughness of the funnel sidewall is between 0.025 Ra and 25 Ra. Compared to higher roughness, this can advantageously reduce the resistance during material movement, thereby reducing material deformation. In addition, this roughness ensures adequate forming (while too low roughness may lead to poor forming results).

[0056] Optionally, it further includes shaping the material by contacting it with a mold, thereby reducing the cross-sectional area of ​​the material.

[0057] Optionally, it further includes the material passing downward through the funnel as the cross-sectional area of ​​the material decreases.

[0058] Alternatively, as the material descends into the funnel, it is further shaped by the mold until it exits the funnel or reaches the desired cross-sectional area. This allows for the efficient creation of complex shapes that would otherwise require a long time to form.

[0059] Optionally, prior to implementing the method, the material comprises a plurality of hollow, parallel connecting tubes. This gives the material a honeycomb structure suitable for absorbing impact energy.

[0060] Optionally, the material comprises a first surface and a second surface connected by parallel connecting pipes.

[0061] Optionally, the process further includes positioning the material on a compressible block before heating, allowing heat to pass through the compressible block to heat the material. The compressible block may be a foam material that allows hot air to pass through. This allows the material to be directly transferred to the molding station after heating on the block, thereby minimizing the overall process time and increasing the product yield per unit time.

[0062] Alternatively, the material is placed on a compressible block between the mold and the frame element, with the compressible block held between the frame element and the mold. This avoids direct contact between the frame element and the material, but the frame element still provides restraint through the compressible block. Since the mold applies compressive force to the compressible block during the molding stage, the tension exerted by the block on the material surface is negligible.

[0063] Optionally, the method further includes positioning the first surface closer to the heat source and bringing the mold into contact with the second surface. This allows the first surface to become more ductile due to the higher heating temperature, thereby enabling a greater degree of molding of the surface opposite the mold contact surface.

[0064] Optionally, the temperature of the first surface is higher than that of the second surface.

[0065] According to a second aspect of the present invention, an apparatus for thermoforming a material into an article is provided, the apparatus comprising:

[0066] Heat source;

[0067] frame;

[0068] Mold;

[0069] The frame element is configured to confine the edge or region of the material within the frame element;

[0070] The mold is configured to move toward the frame, or the frame moves toward the mold, to bring the material into contact with the mold. This equipment allows molded articles to more accurately conform to the intended shape and better preserves the material's impact absorption properties. Using this equipment can reduce the number of articles scrapped due to failing quality control tests.

[0071] Optionally, the frame element is a fundamentally rigid element. This helps to effectively transfer forces to the edge portions of the material, thereby achieving the desired material forming effect.

[0072] Optionally, the frame element includes slits. This allows material to be pushed through the slits to aid in shaping.

[0073] Optionally, the cut is located at the center of the frame element. This ensures that the entire perimeter of the cut remains in contact with the edge of the material.

[0074] Optionally, the shape of the cut corresponds to the cross-sectional shape of the mold. This allows for the simple and efficient production of a final product with the desired shape (in conjunction with necessary pre-cutting steps).

[0075] Optionally, the frame element extends downwards by 5mm-20mm, preferably 6mm-12mm. This downward extension (i.e., perpendicular to the plane of the cut) provides additional tension as the material is pushed through the cut, effectively preventing deformation of the cross-sectional shape of the parallel connecting tube. Experiments show that this specific extension dimension can maximally suppress such deformation modes.

[0076] Optionally, the downward extension is positioned at the midpoint of the frame cut in the longitudinal direction. When manufacturing hemispherical articles for head protection, this midpoint (roughly corresponding to the user's ear area) is where the cross-sectional aggregation or deformation of the parallel connecting tube is most significant. By applying additional tension only at this critical point, this deformation tendency can be effectively suppressed (or partially suppressed).

[0077] Optionally, the system further includes a compressible block configured to be positioned between the frame elements and the material before the mold moves toward the frame. This allows for material transfer and shaping by moving the block, eliminating the need for direct contact with the material, thus offering significant advantages.

[0078] Optionally, the frame includes a second molding element disposed at an angle to the first molding element, the second molding element being configured to mold material in a plane different from the first molding element. This allows for the formation of complex shapes.

[0079] Optionally, the frame element is a flexible member, such as an inflatable member. This allows for the formation of complex shapes.

[0080] Optionally, the flexible / inflatable member becomes annular after inflation, with a cavity forming at its center. This cavity allows it to function as a slit.

[0081] Optionally, the flexible / inflatable member has a spherical bulge in the middle, such that the cross-sectional dimension of the cavity at the top / bottom is larger than that at the middle of the flexible / inflatable member. This allows the material to undergo gradual shaping as it passes through the member.

[0082] Optionally, the frame element is a funnel-shaped structure with a gradually decreasing cross-sectional area, for example, having a central cavity with a first cross-sectional area at the top, and the cross-sectional area of ​​the cavity below the top decreasing.

[0083] Optionally, the material comprises multiple hollow parallel connecting tubes. This gives the material a honeycomb-like structural characteristic.

[0084] Optionally, the device is configured to perform the method described in the first aspect.

[0085] Optionally, the heat source is a hot air source. Alternatively, the heat source is an infrared light source or other lamps used for heating.

[0086] According to a third aspect of the invention, a product made of material for constituting protective equipment is provided. Optionally, the product may be manufactured using the method steps of the first aspect. Optionally, the product may be personal protective equipment (e.g., a helmet).

[0087] Optionally, the product may be an automotive component that enhances protective performance by improving crumple zone safety. The product may be manufactured in any manner, optionally using the method described in the first aspect. Its thickness may exceed 5 cm, and optionally exceed 10 cm.

[0088] According to a third aspect of the invention, a framework is described. This framework is consistent with the framework described in the second aspect and may have the same optional features as those in the second aspect. Attached Figure Description

[0089] Figure 1 The material shown has a honeycomb-like structure and is optionally composed of parallel connecting tubes.

[0090] Figure 2 The heating plate used to heat the material is shown.

[0091] Figure 3 This shows a second embodiment of the heating plate.

[0092] Figure 4 The material positioned on the heating plate is displayed.

[0093] Figure 5 The image shows a pre-cut section of material positioned on the heating plate.

[0094] Figure 6 The display material and heating plate are positioned within the heating system.

[0095] Figure 7 Displays the heating plates and materials within the heating system.

[0096] Figure 8 This displays the cross-section of the material within the heating system.

[0097] Figure 9 instruct Figure 8 The direction of hot air flow in the cross-section.

[0098] Figure 10 This shows a mold and frame element according to one embodiment.

[0099] Figure 11 show Figure 10 The mold and frame components are shown, with the material positioned between them.

[0100] Figure 12 The mold and frame components are shown, with the material and heating plate positioned between them.

[0101] Figure 13 show Figure 10 The mold and frame components are shown, with the material positioned between them.

[0102] Figure 14 The mold moves down to contact the material, allowing the mold and frame components to work together to shape the material.

[0103] Figure 15 This shows the material located within the frame elements after molding.

[0104] Figure 16 This shows a material blank that has undergone the same forming process.

[0105] Figures 17a to 17e The three stages of material forming are shown in an embodiment where the cut size of the frame element gradually decreases with depth.

[0106] Figures 18a to 18d The four stages of material forming are shown in embodiments where the cut size remains constant (e.g., in this embodiment, the frame element may be a basic thin-walled structure with a depth of less than 2 cm, and in some cases less than 5 mm).

[0107] Figure 19 Display molds and frame elements formed from flexible or inflatable components.

[0108] Figure 20 show Figure 19 The mold and frame are shown, with the material placed between them.

[0109] Figure 21 The display shows the mold moving towards the frame element to shape the material.

[0110] Figure 22 Show experience Figure 21 The molded materials and frame components after the process.

[0111] Figure 23 show Figure 19 The pre-cut material portion is placed between the frame and the mold shown.

[0112] Figure 24 Displayed Figure 23 The material formed within the inflatable frame element shown.

[0113] Figure 25 The third embodiment is shown, wherein the material is positioned between the mold and the frame element, which is funnel-shaped and whose cut cross-sectional area decreases as the depth of the frame element increases.

[0114] Figure 26 The display mold and the compressible block are shown. The compressible block can be used in place of the frame element, or in conjunction with the frame element, or it can be used in place of the heating plate.

[0115] Figure 27 show Figure 26 The mold and compressible block are shown, wherein the pre-cut material is positioned between the compressible block and the mold.

[0116] Figure 28 show Figure 26 The mold and compressible block are shown, wherein the material blank is positioned between the compressible block and the mold.

[0117] Figure 29 show Figure 28 The component shown depicts a mold that has moved to contact and shape the material. In practical applications, the block may be compressed.

[0118] Figure 30 Completed. Figure 29 The material blank that has been formed after the steps.

[0119] Figure 31 This shows a pre-cut portion of material that has been formed on a compressible block.

[0120] Figure 32 This flowchart summarizes the usage of the above-mentioned equipment.

[0121] Figure 33a and Figure 33b This displays equipment capable of simultaneously molding multiple material parts. Figure 33a This is a perspective breakdown view from above. Figure 33bThis is a perspective exploded view from below.

[0122] Figure 34a The display shows a heating plate with multiple material components, which will be positioned between a frame element with multiple cutouts and a mold with multiple forming parts.

[0123] Figure 34b show Figure 34a The heating plate is already in place between the middle frame component and the mold.

[0124] Figure 35a The mold part comes into contact with the material part to achieve material forming.

[0125] Figure 35b The mold is shown after it has been removed.

[0126] Figure 36a The mold and multiple molding material parts are shown.

[0127] Figure 36b This shows the molding material on the heating plate located between the frame element and the mold.

[0128] Figure 37 This is a view of a frame element with multiple cutouts.

[0129] Figure 38a Shows the outline of the product to be manufactured.

[0130] Figure 38b Two such products are shown side by side (the one on the left and the one on the right).

[0131] Figure 38c The display can be used to form Figure 38b The outline of a single product in two halves is shown.

[0132] Figure 39a Displays a 3D view of a single product.

[0133] Figure 39b and Figure 39c Display three-dimensional views of the products on the left and right sides of the assembly (e.g.) Figure 38c (As shown).

[0134] Figure 39d and Figure 39e show Figure 39b and Figure 39c The process of dividing and trimming the product shown is to obtain... Figure 39a The product shown.

[0135] Figure 40a This shows the starting position of the alternative molding method, where the mold is placed above the material, the frame is located below the material, and the bottom of the frame is connected to a bowl-shaped groove.

[0136] Figure 40b show Figure 40a The state of the equipment in the later stages of the molding process, at which point the mold begins to contact the material and push it through the frame.

[0137] Figure 40c Display and Figure 40a , Figure 40b The same equipment, in the final stage of the process, has the material, after being formed by the frame, at least partially located within the bowl-shaped groove of the frame. Detailed Implementation

[0138] Figure 1 The material 1 shown has a honeycomb-like structure, which is optionally composed of parallel connecting tubes 5. This material has extremely high strength and can absorb the enormous energy generated by impacts acting on the material surface (i.e., the open end 3 of the tube). Although it has high compressive strength in this direction, the tubular structure can be torn under relatively small external forces. Therefore, the material must be molded to ensure that the material surface 3 can withstand the main impact loads during use.

[0139] For example, this material can be used to manufacture personal protective equipment such as helmets, knee pads, and elbow pads. When a wearer (such as a cyclist) falls, the material absorbs impact energy through deformation, thereby effectively reducing the risk of serious injury to the user.

[0140] To manufacture usable protective equipment, the material blanks need to be cut and / or thermoformed.

[0141] Figure 2 The heating plate 7 used for heating materials is shown. (Example) Figure 1 The material 1 blank shown can be placed on the surface of the heating plate for heating.

[0142] The heating plate includes multiple through holes 9, allowing hot air to pass through the heating plate 7 to heat the material.

[0143] The heating plate 7 can be made of any suitable material that can withstand high temperatures, such as ceramics, metals, certain polymers, treated wood, etc. The heating temperature of the material is typically between 100 degrees Celsius and 200 degrees Celsius.

[0144] Figure 3 This shows a second embodiment of the heating plate 7. It is related to... Figure 2 The first heating plate 7 shown is similar. The difference is that the heating plate does not use a material with through holes 9, but instead has a mesh structure 11 or a mesh-like device. This design can increase the flow rate of hot air passing through the heating plate.

[0145] In some embodiments, the mesh structure 11 may be compressible or flexible. This allows the heating plate to be positioned between the mold and the frame elements during the molding process. The fact that the heating plate does not need to be removed accelerates the manufacturing process.

[0146] In such embodiments, the mesh structure 11 does not exert significant tension on the material surface during the molding stage, thereby avoiding unexpected deformation or damage to the material surface.

[0147] Figure 4 The material 1 positioned on the heating plate 7 is displayed, showing the state in which the uncut whole material 1 blank covers the airflow channel (through hole) of the heating plate.

[0148] Figure 5 This displays a pre-cut material 1 portion positioned on the heating plate 7, which can be cut to any size or shape according to the requirements of the target product. This material 1 portion covers the airflow channel area with through holes 9.

[0149] Figure 4 and Figure 5 The first heating plate 7 is shown in use, but in other embodiments, the second heating plate can be used in the same way.

[0150] Figure 6 The display shows that material 1 and heating plate 7 are being positioned within the heating system 13. The heating system 13 is equipped with a feed inlet 15 configured to accommodate the heating plate 7 and material 1, through which the heating plate 7 will enter the heating system 13.

[0151] Hot air will be blown in from below material 1 and pass through heating plate 7, so that the bottom surface of material 1 is heated more fully than the top surface.

[0152] It should be noted that any suitable heating method can be used, such as using infrared lamps or other lighting fixtures to heat the material, or immersing material 1 in a heating liquid that maintains a set temperature.

[0153] Figure 7 The display shows the heating plate 7 and material 1 within the heating system. It is evident that material 1 and heating plate 7 are located within the airflow path, and the plane containing heating plate 7 and material 1 is perpendicular to the airflow direction.

[0154] Figure 8 The diagram shows a cross-section of material 1 within the heating system 13. The illustrated airflow path forms a circulating flow, with air being driven upward through material 1 and heated within the heating chamber 17.

[0155] Figure 9 instruct Figure 8 The cross-section shows the direction of hot air flow, as well as the airflow direction (counterclockwise from this perspective, passing upward through material 1 and heating plate 7) and the position of the heating element 17 that heats the airflow within the heating chamber 17.

[0156] Figure 10 This shows the components of an equipment used for thermoforming materials into articles. The equipment includes a heat source (optional, such as...). Figures 6 to 9As shown), frame 23, and mold 19 containing molding element 21, wherein frame element 23 is configured to confine the edge or area of ​​material 1 inside the frame element, and mold 19 is configured to move toward frame 23 (or vice versa) so that material 1 comes into contact with mold 19 / 21.

[0157] Figure 10 This shows a mold 19 and a frame element 23 according to one embodiment. Generally, the frame element 23 includes a body 29 and a cutout 25.

[0158] The frame element 23 can be any suitable frame element. It is configured to constrain the edges or edge regions of the material as the mold pushes the material through the frame element cutout 25. After the edges of the material 1 are constrained, its surface area will experience a non-uniformly distributed force—specifically, the top surface 3 will not experience an approximately equal force across its entire surface. Instead, the frame element 23 concentrates the force only on the edges or edge regions of the material 1, and primarily applies the main force through the edge 27. If the material is further pushed into the cutout 25, the inner surface of the cutout will provide the force.

[0159] The mold 21 is any suitable mold approximating the shape of the target article, and is configured to move downward through the cut 25 of the frame element 23. However, in other embodiments, the frame element 23 may also be used to wrap upward around the mold 21.

[0160] The depth of the specific frame element 23 is at least 20 mm, and optionally ranges from 20 mm to 250 mm. This forms a funnel-shaped structure within the cut 25, and an un-tapered section may exist below the funnel. In this embodiment, the radius of the cut 25 varies with the depth, causing the frame element 23 to function as a funnel. In this embodiment, the frame element 23 is a basically rigid structure.

[0161] Figure 11 show Figure 10 The mold 21 and frame element 23 are shown, with material 1 positioned between them. Material 1 is pre-cut to a predetermined shape.

[0162] Figure 12 Display mold 21 and frame element 23, wherein material 1 and heating plate 7 are positioned between the two.

[0163] In this embodiment, the heating plate 7 may include a generally flexible or compressible mesh structure 11. Therefore, after the material 1 has been heated on the heating plate 7, it can be directly transferred from the heating device 13 to the molding device (the combination of the mold 21 and the frame element 23). This embodiment does not require the removal of the heating plate 7.

[0164] This means that material 1 (especially when it is hot) can be handled less, thus reducing the risk of breakage. It also eliminates the need to remove the heating plate 7 during manufacturing, helping to increase production speed.

[0165] Figure 13 Show again Figure 10 The mold 21 and frame element 23 shown are provided, wherein a pre-cut material 1 is positioned.

[0166] Figure 14 The mold 21 moves down to contact the material 1, so that the mold 21 and the frame element 23 together shape the material 1.

[0167] The mold 21 can be moved downward by any suitable means (such as hydraulic, pneumatic, etc.).

[0168] The mold 21 pushes material 1 through the cut 25 of the frame element 23. The edge or edge region of material 1 remains in contact with the edge 27 of the cut 25 of the frame element 23, thus continuously constraining the edge region of material 1 throughout the forming process. This means that the portion of material within the edge is formed by the mold 21, while the portion in contact with the edge remains essentially stationary. The portion outside the edge is not formed (or not shaped according to the mold 21). For pre-cut material 1, this edge may correspond to the material's own boundary. For a blank of material 1, the edge is typically distributed along the front side of the blank.

[0169] Figure 15 The material 1, after molding, is located within the frame element 23, and the induced curvature of the material 1 is visible. For example, this shape can correspond to the inner lining of a helmet such as a bicycle helmet or a snow sports helmet.

[0170] Figure 16 The uncut material 1, after undergoing the same molding process, is shown, clearly demonstrating the position of the edge 33 constrained by the frame element 23, while the unmolded outer portion 35 and the inner molded product 31 are also visible. The unmolded portion 35 can be removed before the product is completed.

[0171] Figures 17a to 17e The five stages of material forming in an embodiment where the size of the cut 25 of the frame element 23 tapers with depth are shown in cross-sectional form (the last two stages may be omitted). In this embodiment, the frame element 23 is funnel-shaped, and the funnel includes an additional non-tapered section 26 (this section is a completely optional structure).

[0172] Figure 17a In the middle, material 1 covers the cut 25 of frame element 23, and mold 21 is positioned above the material, but has not yet started forming.

[0173] Figure 17bIn the process, mold 21 contacts material 1 and pushes material 1 through the cut 25 of the frame element. Material 1 is bending during the molding process.

[0174] The edge refers to the portion of material 1 that contacts the edge 27 of the cut 25 of frame element 23.

[0175] Figure 17c As the mold 21 continuously pushes material through the cut 25 of the frame element 23, the material 1 (particularly the edge portion 33) moves downwards along the funnel-shaped structure of the frame element. This changes the contact position between the edge 27 of the frame element and the material 1 (the material edge region 33 contracts towards the center as the material moves downwards through the funnel), thereby altering the material region being formed. As shown, this creates a composite curve: the central region continues to form, while the outer periphery 35 of the formed portion maintains a linear shape. Compared to other methods, this technique reduces material waste and allows for steeper curves (known as deep drawing).

[0176] For embodiments that use only the funnel structure without the additional linear section 26, the process may be terminated at this stage.

[0177] Figure 17d Material 1 is pushed into the constant cross-sectional section 26 of the funnel. The linear shape portion 35 is located outside the forming edge 33. As the material continues to be pushed into the constant cross-sectional section 26, the edge of the forming area 33 expands outward until all or at least the expected amount of material 1 is formed.

[0178] Figure 17e The display shows that material 1 has completely entered the constant cross-sectional section 26 of the funnel. At this point, material 1 has been fully formed.

[0179] Therefore, the combination of this funnel structure with a two-stage section with a constant cross-section can form an efficient molding method that maximizes the molding angle while minimizing material waste.

[0180] Figures 18a to 18d The four stages of material forming are shown in an embodiment where the size of the cut 25 is constant (e.g., in this embodiment, the frame element 23 may be a basic thin-walled structure).

[0181] Figure 18a In the middle, material 1 covers the cut 25 of frame element 23, and mold 21 is positioned above material 1.

[0182] Figure 18b In the process, mold 21 contacts material 1 and pushes material 1 through the cut 25 of frame element 23. Material 1 is bending during the molding process, and the material portion 35 outside the edge region 33 is not molded.

[0183] Edge 33 refers to the part of the material that comes into contact with the edge 27 of the cut 25 of the frame element 23.

[0184] Figure 18c In the process, the material is further pushed into the cut 25, which further shapes the already formed area 31. Outside the formed area is still the unformed area 35 (this area may come into contact with the mold). Figure 18b and Figure 18c The position of the material edge 33 along the longitudinal direction of the material remains basically unchanged.

[0185] Figure 18d As shown, when the mold 21 pushes completely past the cut 25 of the frame element 23, the position of the material 1 edge 33 constrained by the frame element 23 remains approximately constant. Although slight slippage (causing minor warping) may occur as more material enters the molding area, this can be minimized by slowing down the speed at which the mold 21 pushes past the cut 25.

[0186] It should be noted that the non-molded part of the mold may press the unmolded area 35 against the top of the frame element 23, so the included angle between the molded area 31 and the unmolded area 35 at the edge 33 is crucial.

[0187] In this embodiment, the stretching depth may be less than that of the funnel-shaped frame element embodiment. However, both solutions can efficiently utilize the relevant materials to manufacture various thermoformed products. Furthermore, the thin-walled frame solution reduces breakage or scrap rates compared to the funnel-shaped one. Its stretching depth is still superior to products formed by the film method described in the prior art, and the formed products are closer to the desired shape.

[0188] It should be noted that the frame element 23 may include additional features. For example, the basic thin-walled frame element 23 may have increased depth at specific locations: in the middle section of the frame element cut, the depth may be increased by 5-20 mm (preferably 6-12 mm). This provides additional tension and force to the material forming edge at this location. Since the middle section has proven to be more prone to deformation due to forming, this increased depth can effectively suppress or partially suppress deformation at this location. For hemispherical helmet components, this location corresponds precisely to the area above the user's ears.

[0189] Another optional feature of frame element 23 is the availability of a second frame element at an angle to the cutting plane of the first frame element. For example, the second frame element could be perpendicular to the plane, allowing for the formation of complex shapes, such as hump-shaped ridges or multiple crest-and-trough structures. In some embodiments, the second frame element may include a scratching element positioned such that it comes into contact with the material when fully formed. This slightly deforms the outer surface of the material without altering its overall shape, creating scratches that can be used to mark cut locations or to adapt the article to other objects with protrusions or other structures.

[0190] Figure 19The display mold 21 and the frame element 23 formed of a flexible or inflatable component have their rigid structure replaced by a tire-like structure. This component may be made of rubber or other elastic materials (such as silicone) that deform upon inflation or expansion / stretching.

[0191] Frame element 41 is shown placed on support 45 for stability, but this configuration is entirely optional.

[0192] At this point, the cut transforms into cavity 43 at the center of the frame element. The frame element 41 employs a ring structure to form this cavity 43.

[0193] The shape of the cavity 43 depends on the configuration of the frame element 41: in some embodiments the cavity may be approximately cylindrical so that its cross-sectional area does not change with the depth of the frame element; in other embodiments the middle part of the frame element 41 may be designed to be raised, thereby forming a funnel-shaped frame element 41.

[0194] Small, inflatable components can be used as frame elements 41, allowing them to inflate around the sides of the material (especially pre-cut small pieces). This design constrains the sides of the material as the mold 21 pushes through the cavity. While only a relatively shallow molding depth can be achieved, this approach, which minimizes material waste, is more advantageous for small parts such as elbow pads or parts that need to be embedded in key points of a helmet but do not form a complete continuous layer.

[0195] In this embodiment, pre-cutting the material 1 blank into triangular pieces can significantly reduce the scrap rate during the preforming stage. Further material loss can be reduced by molding the triangular pieces as described above using small, inflatable components that inflate around the material's side edges. Such triangular molded parts can be used as embedded components in cycling helmets.

[0196] Figure 20 show Figure 19 The mold 21 and frame 41 shown are provided, in which material 1 is placed.

[0197] The material 1 shown in the figure is an uncut whole blank, but pre-cut material part 1 can also be used in practice.

[0198] Figure 21 The mold 21 moves toward the frame element 41 to shape the material 1.

[0199] Material 1 within the edge 33 region is formed by the mold through the cavity.

[0200] The outer material 35 remains largely unformed (or has slight wrinkles as shown in the figure).

[0201] Figure 22 Show experience Figure 21 The molded material 31 and frame element 41 after the process.

[0202] It can be seen that the portion of the material within the edge 33 constrained by the frame element has been formed 31, while the outer portion 35 remains essentially unformed. This outer portion 35 can be removed as waste before the finished product is completed.

[0203] Figure 23 show Figure 19 The pre-cut material 1 portion is placed between the frame 41 and the mold 21.

[0204] The same process is then repeated, but this time the operation targets pre-cut material portions, rather than the entire material blank as shown before.

[0205] Figure 24 show Figure 23 The molding result of material 1 in the inflatable frame element 41 shows that the pre-cut material 1 has been molded into the expected shape.

[0206] The choice between pre-cutting or post-forming cutting to reduce material waste depends on the specific product and its shape / size parameters.

[0207] It should be noted that in embodiments where the frame element is an inflatable component 41, the inflation / deflation of the inflatable component can be adjusted during the molding process.

[0208] This adjustment alters the cross-sectional area of ​​cavity 43 (decreasing when inflated and increasing when deflated), while also changing the force exerted on the edges of material 33, thus enabling the creation of complex shapes. For example, inflation during molding allows for deeper stretching.

[0209] Figure 25 The third embodiment is shown, in which material 1 is positioned between mold 21 and frame element 23. The frame element 23 is funnel-shaped, and the cross-sectional area of ​​its cut 25 decreases as the depth 29 of the frame element 23 increases.

[0210] It is important to note that there is an optimal range of surface roughness for the funnel sidewall 27: if the roughness is too low, it will weaken the molding effect and prevent the target shape from being achieved (for example, silicone-coated plastic sheets may be too smooth, affecting proper molding); if the surface is too rough, it may cause abnormal material deformation (for example, untreated medium-density fiberboard is excessively rough in some embodiments). A surface roughness range of 0.025 Ra to 25 Ra can achieve the desired molding effect.

[0211] In this example, material 1 may be designed with increased thickness, which would affect its formability. Such designs could be used in alternative applications such as automotive parts, improving protective performance by enhancing crumple zone safety.

[0212] Figure 26The mold 21 and the compressible block 61 are displayed. The compressible block 61 can be used in place of the frame element 23, or in conjunction with the frame element 23, or it can replace the heating plate 7.

[0213] Therefore, the compressible block 61 can be directly transferred from the heating station 13 to the forming station without disassembly, which can effectively improve process efficiency.

[0214] When the compressible block 61 is placed above the frame element 23, the molding process can be started as described above, and the block will not interfere with the molding process—since the block is under compression rather than tension, it will not generate tension on the surface of material 1.

[0215] The compressible block 61 allows hot air to pass through its interior, thus serving as a substitute for the heating plate 7. In some embodiments, the compressible block 61 may be made of foam, sponge, or similar materials.

[0216] Figure 27 show Figure 26 The mold 21 and the compressible block 61 are shown, wherein the pre-cut material 1 is positioned between the compressible block and the mold.

[0217] In this example, no frame element is used, so the mold 21 will move to contact the material 1 and compress the compressible element 61.

[0218] Figure 28 show Figure 26 The mold 21 and compressible block 61 are shown, wherein the material 1 blank is positioned between the compressible block 61 and the mold 21 (this configuration is similar to...). Figure 28 Same, but uses a whole blank instead of a pre-cut material (part 1).

[0219] Figure 29 show Figure 28 The component is shown in its current state, at which point the mold 21 has moved to contact and form the material 1. In practical applications, as the material is formed, the block 61 may experience at least partial compression.

[0220] Figure 30 Completed. Figure 29 The material blank 1 that has been formed after the steps has a shape that is basically the same as the aforementioned formed material.

[0221] Figure 31 This displays a pre-cut portion of material that has been formed on the compressible block 61. Figure 28 The resulting shape of the device layout shown.

[0222] Figure 32 The diagram shows a flowchart summarizing the usage method of the aforementioned equipment. The first step involves providing material 71, which can be in any form (such as a monolithic blank or a pre-cut portion) and can be any type of honeycomb structure material or... Figure 1The material of the parallel connecting pipes shown.

[0223] The next step involves heating material 73, which can be heated by any method: for example, using a liquid bath such as a water bath, irradiation by lamps, or blowing hot air through the material. The hot air method is the preferred option. Figures 4 to 9 A preferred embodiment of it is shown.

[0224] The next step involves moving the mold toward the frame (or vice versa) to bring the material into contact with the mold at a 75° angle. This operation can be performed by pressing... Figures 10 to 31 Any of the embodiments shown. It should be noted that there may be a spacer (such as a covering layer) between the material to be molded and the mold, as long as the mold applies molding force, it still constitutes contact with the material.

[0225] The next step involves confining the material edges or edge regions within the frame element 77. In practice, this step can occur simultaneously with the mold contacting the material, or it can be performed slightly earlier or later.

[0226] The edge can refer to the boundary of the portion of material being molded: when molding a monolithic material blank, this edge is typically located within the surface of the blank (e.g., ...). Figure 30 (As shown); for pre-cut materials, the edge may be the boundary of the material's front side or even the sidewall. Sidewall constraints are particularly suitable for certain inflatable frame component embodiments, especially when the molding depth is shallow or the product size is small (such as elbow pads or helmet internal components).

[0227] The final step involves shaping the material 79, a process that can actually begin when or immediately after the mold comes into contact with the material, and involves pushing the mold (at least partially) through the cutouts in the frame element.

[0228] Additional steps to remove excess waste may be added as needed.

[0229] Figure 33a The display shows a mold component 19 containing multiple molding elements 21, which can simultaneously mold multiple material parts, thereby improving manufacturing efficiency.

[0230] Also on display is a frame element 23 with multiple cutouts 25, each cutout corresponding to a molded element 21.

[0231] A heating plate 7 with multiple material portions 1 is provided between the frame element 23 and the mold 21. It should be emphasized that, as described in the aforementioned single-piece molding embodiment, the heating plate 7 is entirely optional, but it can improve manufacturing efficiency. The number of material portions 1 can be equal to the number of cuts 25 in the frame element 23.

[0232] The material 1 part, the cut 25 of the frame element 23 and the forming element 21 of the mold 19 can be aligned with each other.

[0233] Figure 33bDisplay and Figure 33a The same components, but the viewing angle is changed to be viewed from below, so material 1 is not directly visible (it can only be observed through the heating plate 7).

[0234] Figure 34a The heating plate 7 is positioned between the mold 19 and the frame element 23. In an alternative embodiment, part of material 1 can be placed directly on the frame element 23 without the heating plate 7.

[0235] Figure 34b This displays the equipment status before molding begins.

[0236] Figure 35a The mold 19 moves toward the frame element 23, causing at least a portion of the forming element 21 to enter the cutout 25 of the frame element 23, thereby completing the forming of the material 1.

[0237] Figure 35b The mold 19 is removed from the frame element 23 after the material 1 is formed, and it can be seen that part of the material 1 is recessed in the cut 25 of the frame element 23.

[0238] Figure 36a The mold and the formed material 1 portion are shown. These formed portions may be shaped material 1 blanks, or material 1 portions as shown in the figure, with a stretching depth less than that shown in Figures 17 and 18.

[0239] Figure 36b The display material 1 is the molding material located on the heating plate 7 after it is removed from the frame element 23.

[0240] Figure 37 An example of a frame element 23 with multiple cutouts is shown, supporting the simultaneous manufacture of multiple elements. This frame element 23 includes cutouts with a constant cross-sectional area; other embodiments may employ a thinner frame element 23 similar to that shown in Figure 18. Alternatively, the frame element 23 may be replaced with a flexible / inflatable member 41 with multiple cavities 43; its cutouts 25 may also be designed as funnel-shaped structures; or a constant cross-sectional area segment 26 may be connected to the end of the funnel as shown in Figure 17; combinations of the above features may also be used.

[0241] Figure 38a The outline of the article 91 to be manufactured is shown; it can be of any shape / size. Such articles typically form partial components of a helmet rather than a complete hemisphere, and are therefore commonly found in pairs on symmetrical sides of a helmet (essentially optical isomers, such as...). Figure 38b (As shown). The number of components can be arbitrary, but is usually even. An odd number may also occur if left and right components and a separate forehead / front component are included.

[0242] In this example, shape 91 is approximately a hemisphere with an asymmetrical profile. While the aforementioned method can be used to manufacture it in some cases, this asymmetry exacerbates material deformation. Therefore, the method described in this paper utilizes the mirror principle to achieve simultaneous manufacturing of multiple parts.

[0243] Figure 38b Two such articles 91 and 92 are shown side by side (left and right parts), which are optical isomers of each other. As shown below, these two parts can be formed from a single sheet of material.

[0244] Figure 38c The display can be used to form Figure 38b The outline of the single product 94, shown in two halves. The shape is symmetrical, so molding this single element first and then dividing it into two halves can reduce the deformation of material 1.

[0245] Figure 39a A three-dimensional view of a single piece 81 is shown, revealing a half-side component that can be placed inside a helmet, with an asymmetrical outline.

[0246] Figure 39b and Figure 39c Display 83 three-dimensional views of the products on the left and right sides of the assembly (e.g.) Figure 38c As shown in the figure, its outline is symmetrical along the central longitudinal line.

[0247] Figure 39d and Figure 39e The display will Figure 39b and Figure 39c The 83 products are divided and trimmed to obtain Figure 39a The manufacturing process. Individual parts can be cut / segmented along the line of symmetry to obtain the final left-handed 81 and right-handed 82 parts. In this case, an additional trimming step is required on the inner contour of the formed shape to conform to the required helmet shape. The removed material is shown by juxtaposing the two halves to illustrate the missing material 96.

[0248] This finishing process can be carried out by any suitable means, such as using planing tools, sanders, or cutting devices.

[0249] Figure 40a The starting position of the alternative molding method is shown, wherein the mold 21 is placed above the material 1, the frame 7 is located below the material, and a bowl-shaped groove 99 is formed at the bottom of the frame.

[0250] Frame 7 is composed of a funnel 27 with a central cavity. This funnel can have any angle of inclination, but in the specific embodiment shown, the angle between the funnel and the horizontal plane is greater than 15 degrees. The cross-sectional area of ​​the central cavity gradually decreases towards the base of the funnel. A step is provided at the base of the funnel; in this example, the step includes a vertical surface 97. A joint exists between the funnel and the vertical surface; the joint is illustrated as a vertex, but in other embodiments, this joint can be arc-shaped. It should be noted that the vertical surface 97 can deviate from the vertical direction (e.g., approach vertical) as long as it does not affect the function of the vertical surface. Specifically, the function of the vertical surface is related to… Figure 17d The function demonstrated in the constant cross-section funnel section is the same: even if the edge of the material forming area moves outward and causes the material to begin to bend. In other embodiments, the step may comprise a horizontal step, or a step having an equivalent function to a horizontal step. It should be noted that the step in this embodiment is relatively short. In some embodiments, the length of the vertical or horizontal plane 97 is approximately 0.5 mm to 5 mm. Therefore, the amount of bending of the material 1 caused by the vertical or horizontal plane 97 may be less than that shown in Figure 17.

[0251] Figure 40 also shows that the frame includes a bowl-shaped structure. This bowl-shaped structure may form the entire lower surface of the frame (as shown in this embodiment), or it may contain one or more holes on the lower surface. When the material is pushed through the funnel, it reaches the bowl-shaped structure and conforms to its shape.

[0252] It should be noted that steps, whether horizontal or vertical, are optional structural elements. The funnel can be directly connected to the bowl-shaped structure without requiring a vertical surface. Horizontal or vertical surfaces reduce the risk of unintended material deformation at the interface between the funnel and the bowl-shaped structure.

[0253] Figure 40a The mold 21 is positioned above the material, and the frame 7 is positioned below the material. Either the frame or the mold can be configured as a movable part, and the relative movement between the two will result in the forming, shaping, and molding of the material.

[0254] Figure 40b show Figure 40a The state of the equipment in the later stages of the molding process, where the mold begins to contact the material and push it through the frame. This stage is similar to... Figure 17b The molding stage is shown. In Figure 40b In this process, the material only comes into contact with the funnel, which begins to shape the material by inducing bending / forming through the interaction of the funnel with the mold 21, and the material edges are constrained / restricted by the sidewalls of the funnel.

[0255] Figure 40c Display and Figure 40a and Figure 40b The same equipment, but in the final stages of the process, molds material 1 through frame 7, with at least a portion of the material located within the bowl-shaped recess 99 of the frame. Figure 40b and Figure 40c Between the steps shown, material 1 may have been shaped or bent through vertical plane 97.

[0256] Figure 40c The mold 21 is fully inserted into the frame 7. In this embodiment, the mold 21 has the required internal curvature of material 1, and the bowl-shaped groove 99 has the required external curvature of material 1. The material conforms to the shape of the bowl-shaped structure and the mold, so the radius of the mold is smaller than the radius of the bowl-shaped structure.

[0257] In some embodiments, the mold can be configured to stop moving relative to the frame once it reaches a predetermined distance from the base of the bowl-shaped structure. This predetermined distance may be equal to the material thickness (with tolerances added in some embodiments). This ensures minimal deformation of the top or bottom surface structure of the material during molding.

[0258] It should be understood that the above embodiments are merely illustrative. Those skilled in the art can also conceive of other embodiments. It should be understood that any feature described for any embodiment can be used alone, in combination with other described features, or in combination with one or more features of any other embodiment, or any combination of other embodiments.

[0259] Furthermore, without departing from the scope of the invention as defined by the appended claims, equivalent solutions and modifications not described above may be employed.

[0260] It should be noted that the above method can be automated in some embodiments. Therefore, the method steps can be executed by robotic means, and the relevant instructions can be stored in media such as controllers and data storage devices.

[0261] In some examples, one or more storage elements may store data and / or program instructions for implementing the methods described herein. Embodiments of this disclosure provide a tangible, non-transitory storage medium comprising program instructions operable to program a processor to perform the methods described herein and / or the methods of the claims.

[0262] The processor / controller of such devices (and any methods, activities, or instructions outlined herein) may be implemented using fixed logic (such as a set of logic gates) or programmable logic (such as software and / or computer program instructions executed by a processor). Other types of programmable logic include programmable processors, programmable digital logic (such as field-programmable gate arrays (FPGAs), erasable programmable read-only memory (EPROMs), electrically erasable programmable read-only memory (EEPROMs), application-specific integrated circuits (ASICs), or any other type of digital logic, software, code, electronic instructions, flash memory, optical discs, CD-ROMs, DVD-ROMs, magnetic cards or optical cards, other types of machine-readable media suitable for storing electronic instructions, or any suitable combination thereof. Such data storage media may also serve as data storage components in manufacturing equipment.

Claims

1. A method for manufacturing an article of articles, the method comprising the following steps: Provide materials; Heating the material; Confine the edges or areas of the material within the frame element; Move the mold toward the frame or move the frame toward the mold to bring the material into contact with the mold.

2. The method of claim 1, further comprising shaping the material by contact with the mold.

3. The method according to any of the preceding claims, wherein, The edge or region is any of the following: The edge of the material portion formed by the mold, or the sidewall of the material.

4. The method according to any of the preceding claims, wherein, The frame element is a basic rigid element.

5. The method according to any of the preceding claims, wherein, The frame element includes a cutout, optionally located at the center of the frame element, and optionally, the shape of the cutout corresponds to the cross-sectional shape of the mold.

6. The method according to any of the preceding claims, wherein, The frame element extends 5mm-20mm, and preferably 6mm-12mm, in a direction perpendicular to the cut plane. Optionally, the downward extension is located at the middle of the longitudinal direction of the cut in the frame.

7. The method according to any of the preceding claims further comprises positioning the material at any of the following locations before limiting the edge of the material: The top of the frame element; The bottom of the frame element; The top of the mold; The bottom of the mold; optionally, Further includes pushing at least a portion of the material through the cut in the frame, wherein, When the formed material portion is pushed through the cut, the edge of the material portion is restricted by the frame element.

8. The method according to any of the preceding claims, further comprising removing the material outside the edge of the formed material portion.

9. The method according to any preceding claim, further comprising forming scratches on the outer surface of the article, optionally, wherein, The frame includes a scratching member, and further includes the step of scratching the outer surface of the article by means of the scratching member during the molding of the material.

10. The method according to any of the preceding claims, wherein, The frame includes a second molding element disposed at an angle to the first molding element, the second molding element being configured to mold the material in a plane different from the first molding element.

11. The method according to any one of claims 1-3, 5, 7 or 8-10, wherein, The frame element is a flexible component, such as an inflatable component. Optionally, the flexible / inflatable component is annular after inflation, and a cavity is formed at its center.

12. The method of claim 11, further comprising positioning the material at the top or bottom of the flexible / inflatable member before confining the material edges; optionally, further comprising pushing at least a portion of the material at least partially through the cavity at the center of the flexible / inflatable member, wherein, The edges of the formed material portion are constrained by the flexible / inflatable member; optionally further comprising expanding the flexible / inflatable member after the material has been at least partially formed; and optionally further comprising continuing to form the material after the flexible / inflatable member has expanded.

13. The method according to claim 11 or 12, wherein, The flexible / inflatable member expands around the sidewall of the material to confine the edge of the material within the frame; optionally, the flexible / inflatable member reduces the diameter of its internal cavity as it expands; and / or optionally, the material is shaped when the mold contacts it, and all of the material is shaped; and / or optionally, the process further includes reducing the cross-sectional area of ​​the material when it is shaped by the mold; optionally, the process further includes a first or second pre-cutting step to cut the material into a desired planar shape, such as a triangle.

14. The method according to any one of claims 11-13, wherein, The flexible / inflatable member has a spherical bulge in the middle, such that the cross-sectional dimension of the cavity at the top / bottom is larger than that at the middle of the flexible / inflatable member; optionally, it further includes moving the material from the top / bottom of the cavity toward the spherical center of the inflatable member during the material forming process; optionally, the material edge is always constrained by the flexible / inflatable member throughout the material movement.

15. The method according to any one of claims 1-3, 5, 7, 8-13 or 14, wherein, The frame element is a funnel-shaped structure with a gradually decreasing cross-sectional area. For example, the top includes a central cavity with a first cross-sectional area, and the cross-sectional area of ​​the cavity below the top decreases. Optionally, it further includes shaping the material by contacting it with the mold, thereby reducing the cross-sectional area of ​​the material. Optionally, it further includes the material passing downward through the funnel as the cross-sectional area of ​​the material decreases. Optionally, as the material descends into the funnel, it is further shaped by the mold until the material is discharged from the funnel or reaches the desired cross-sectional area.

16. The method according to claim 15, wherein, The frame element includes a bowl-shaped structure disposed below the funnel.

17. The method of claim 16, the method comprising the step of pushing the material through the funnel and into the bowl-shaped structure.

18. The method according to claim 17, wherein, The method further includes shaping the material into the shape of the bowl-shaped structure.

19. The method according to any one of claims 15-18, further comprising providing a step at the base of the funnel.

20. The method according to claim 19, wherein, The method includes pushing the material to the junction of the funnel and the vertical plane.

21. The method according to claim 19 or 20, wherein, when claim 16 is referenced, The bowl-shaped structure is located below the step.

22. The method according to any of the preceding claims, wherein, Before implementing the method, the material comprises a plurality of hollow parallel connecting tubes; optionally, the material comprises a first surface and a second surface connected by the parallel connecting tubes; optionally, the first surface is positioned closer to a heat source, and the mold is brought into contact with the second surface; optionally, the temperature of the first surface is higher than that of the second surface; optionally, heating the material comprises blowing hot air through the interior of the material.

23. The method according to any of the preceding claims, further comprising positioning the material on a compressible block prior to heating such that the material is heated through the compressible block; optionally, placing the material on the compressible block between the mold and the frame element such that the compressible block is held between the frame element and the mold.

24. An apparatus for thermoforming materials into articles, the apparatus comprising: Heat source; frame; Mold; The frame element is configured to confine the material edge or region within the frame element; The mold is configured to move toward the frame, or the frame moves toward the mold, so that the material comes into contact with the mold.

25. The device according to claim 24, wherein, The frame element is a basic rigid element; optionally, the frame element includes a cutout; optionally, the cutout is located at the center of the frame element; optionally, the shape of the cutout corresponds to the cross-sectional shape of the mold; optionally, the frame element extends downward by 5mm-20mm, and preferably 6mm-12mm; optionally, the downward extension is located at the middle section of the frame cutout in the longitudinal direction; optionally, the frame includes a second forming element arranged at an angle to the first forming element, the second forming element being configured to form the material in a plane different from the first forming element.

26. The device according to claim 24, wherein, The frame element is a flexible component, such as an inflatable component; optionally, the flexible / inflatable component is annular after inflation, and a cavity is formed in its center; optionally, the flexible / inflatable component has a spherical bulge in the middle, such that the cross-sectional dimension of the cavity at the top / bottom is larger than that at the middle of the flexible / inflatable component.

27. The device according to claim 24, wherein, The frame element is a funnel-shaped structure with a gradually decreasing cross-sectional area, for example, the top includes a central cavity with a first cross-sectional area, and the cross-sectional area of ​​the cavity decreases below the top.

28. The device according to claim 27, further comprising a bowl-shaped structure disposed below the central cavity of the funnel.

29. The device according to claim 27 or 28, further comprising a step disposed at the base of the funnel; optionally, wherein, The bowl-shaped structure is located below the vertical plane.

30. The device according to any one of claims 24-29, further comprising a compressible block configured to be positioned between the frame element and the material prior to the mold moving toward the frame.

31. The device according to any one of claims 24-30, wherein, The material comprises multiple hollow parallel connecting tubes.

32. The device according to any one of claims 24-31, wherein, The heat source is a hot air source.

33. The device according to any one of claims 24-32, wherein, The device is configured to perform the method of any one of claims 1-23.

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