Systems and methods for forming a panel of an interior cabin of a vehicle

Abstract

To provide an efficient and effective system and method for forming a panel usable in an interior cabin of a vehicle.SOLUTION: A system for forming a panel of an interior cabin of a vehicle includes one or more mounting plates 110,118 formed of one or more metals. The at least one molding plate 114,122 may be formed of the at least one metal. The at least one molding plate 114,122 may include at least one heating element 116,124. At least one base 112,120 is fixed between the at least one mounting plate 110,118 and the at least one molding plate 114,122. The one or more bases 112,120 are formed of a heat resistant plastic. The one or more forming plates 114,122 are configured to form a panel by pressing and heating.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] Examples of the present disclosure generally relate to systems and methods for forming panels for the interior cabin of a vehicle. [Background technology]

[0002] Aircraft are used to transport passengers and cargo between various locations, and many aircraft take off and land at a typical airport every day.

[0003] The interior cabin of an aircraft includes floors, side walls, and a ceiling. Various portions of such structures include panels that form surfaces.

[0004] Match dies are commonly used to form panels for aircraft interiors. Known match dies include upper and lower forming plates that form the panels. Upper and lower metal bases are secured to the upper and lower forming plates, respectively. Upper and lower metal mounting plates are secured to the upper and lower bases, respectively. During operation, steam is used to heat the forming plates. The metal bases absorb heat from the forming plates, resulting in significant heat transfer from the forming plates.

[0005] Typically, each of the forming plate, base, and mounting plate is machined from steel or aluminum. Because the panels are relatively large, the components of the match die are also large, bulky, and heavy. In particular, the metal components of the match die increase the overall weight and cost. Such heavy tools typically require complex equipment for storing and transporting the tools. Summary of the Invention

[0006] Therefore, there is a need for an efficient and effective system and method for forming panels that can be used within the interior cabin of a vehicle. Additionally, there is a need for lightweight, inexpensive tooling for manufacturing such panels.

[0007] With these needs in mind, some embodiments of the present disclosure provide a system including one or more mounting plates formed from one or more metals, one or more forming plates formed from the one or more metals, the one or more forming plates including one or more heating elements, one or more bases secured between the one or more mounting plates and the one or more forming plates, the one or more bases being formed from a heat-resistant plastic, and the one or more forming plates configured to form a panel by pressing and heating.

[0008] In at least one example, one or more presses are secured to the one or more mounting plates.

[0009] In at least one example, the one or more mounting plates include a first mounting plate and a second mounting plate. The one or more forming plates include a first forming plate and a second forming plate. The one or more bases include a first base secured between the first mounting plate and the first forming plate and a second base secured between the second mounting plate and the second forming plate. The first mounting plate, the first base, and the first forming plate are included in a first die. The second mounting plate, the second base, and the second forming plate are included in a second die. The first forming plate and the second forming plate are configured to press and heat the panel therebetween.

[0010] In at least one example, one of the first base or the second base includes a guide pin, and the other of the first base or the second base includes a corresponding groove, the guide pin configured to be received by the corresponding groove as the first die moves toward the second die.

[0011] In one example, the heat-resistant plastic includes polycarbonate.

[0012] In at least one example, the one or more bases are formed by additive manufacturing, hi one example, a three-dimensional (3D) printer is used to form the one or more bases.

[0013] In at least one example, the one or more bases include one or more retaining grooves, and the one or more shaped plates are secured within the one or more retaining grooves.

[0014] In at least one example, the one or more bases include one or more stop pads.

[0015] In at least one example, the one or more bases include parallel passages configured to receive lifting arms of a forklift.

[0016] In some embodiments of the present disclosure, a method is provided that includes forming one or more mounting plates from one or more metals, forming one or more molding plates from the one or more metals, providing one or more heating elements on the one or more molding plates, forming one or more bases from a heat-resistant plastic, and securing the one or more bases between the one or more mounting plates and the one or more molding plates, wherein the one or more molding plates are configured to form a panel under pressure and heat. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 is a block diagram illustrating a system according to one embodiment of the present disclosure. [Figure 2] FIG. 1 is a schematic block diagram illustrating a three-dimensional printer according to an embodiment of the present disclosure. [Figure 3] FIG. 1 is a flow diagram illustrating a method according to one embodiment of the present disclosure. [Figure 4] FIG. 1 is an isometric view of a system according to one embodiment of the present disclosure. [Figure 5] FIG. 10 is a bottom isometric view of a base according to one embodiment of the present disclosure. [Figure 6] FIG. 1 is a front perspective view of an aircraft. [Figure 7] FIG. 1 is an interior perspective view showing the interior cabin of an aircraft. DETAILED DESCRIPTION OF THE INVENTION

[0018] The above summary of the invention and the following detailed description of some embodiments will be more clearly understood by reference to the accompanying drawings. In this specification, the use of "a" or "an" element or step in the singular does not necessarily exclude the presence of a plurality of elements or steps. Furthermore, a reference to "one embodiment" is not intended to exclude the existence of other embodiments that incorporate the features described in that embodiment. In addition, unless otherwise specified, an embodiment that "includes" or "has" one or more elements that satisfy a particular condition may also include other elements that do not satisfy that condition.

[0019] 1 is a block diagram illustrating a system 100 according to one embodiment of the present disclosure. The system 100 includes a first die 102 (e.g., a lower or bottom die) and a second die 104 (e.g., an upper or top die). The first die 102 and the second die 104 are configured to form a panel 106 therebetween. As an example, the first die 102 and the second die 104 are configured as match dies for forming panels for vehicles such as aircraft.

[0020] In at least one example, the panel 106 can be formed from plastic. As another example, the panel 106 can be formed from a composite material, which may include a honeycomb core sandwiched between outer plastic skins. The panel 106 can be used within the interior cabin of a vehicle, such as a commercial aircraft. For example, the panel 106 can be used to form part of a wall, floor, ceiling, or other surface within the interior cabin. Optionally, the panel 106 can also be used in various other structures, components, devices, and the like.

[0021] A press 108 is secured to the second die 104. The press 108 may be a mechanical press configured to move the second die 104 in the direction of arrow A toward the first die 102 to press the panel 106 therebetween. In at least one example, the press 108 may be manually operated, such as with a hand wheel. In other examples, the press 108 may be automatically operated, such as with one or more motors.

[0022] Optionally, press 108 may be secured to first mounting plate 110 and configured to move first die 102 upwardly toward second die 104 in a direction opposite to arrow A. Also optionally, a first press may be operatively connected to first die 102 and a second press may be operatively connected to second die 104.

[0023] The first die 102 includes a first mounting plate 110, such as a lower or bottom mounting plate. The first mounting plate 110 is formed of a metal such as steel or aluminum. A first base 112, such as a lower or bottom base, is secured to the first mounting plate 110, for example, via one or more fasteners, adhesive, or the like. The first base 112 is formed of a different material from the first mounting plate 110. In at least one example, the first base 112 is formed of a material that can withstand the temperature and pressure of the panel molding process. For example, the first base 112 can be formed of a heat-resistant resin. In at least one example, the first base 112 is formed of plastic. For example, the first base 112 can be formed of resin. In at least one example, the first base 112 is formed of polycarbonate.

[0024] A first forming plate 114, such as a lower or bottom forming plate, is secured to the first base 112 via, for example, one or more fasteners, adhesive, etc. The first base 112 is secured between the first mounting plate 110 and the first forming plate 114.

[0025] The first forming plate 114 is formed of a different material from the first base 112. For example, the first forming plate 114 is formed of a metal such as steel or aluminum. The first forming plate 114 includes one or more heating elements 116. The heating elements 116 may be embedded in the first forming plate 114 or attached to its surface. For example, the heating elements 116 may be internal pipes that form a fluid circuit on or within the first forming plate 114. The fluid circuit is configured to pass a heating fluid, such as steam or a heated liquid, through the circuit to heat the first forming plate 114. As another example, the heating elements 116 may be electric heating elements.

[0026] The second die 104 includes a second mounting plate 118, such as an upper or top mounting plate. The second mounting plate 118 is formed of a metal, such as steel or aluminum. The second mounting plate 118 is secured to the press 108 via one or more magnetic couplings, mechanical clamps, or the like. A second base 120, such as an upper or top base, is secured to the second mounting plate 118 via one or more fasteners, adhesives, or the like. The second base 120 is formed of a different material from the second mounting plate 118. In at least one example, the second base 120 is formed of a material that can withstand the temperatures and pressures of the panel molding process. For example, the second base 120 can be formed of a heat-resistant resin. In at least one example, the second base 120 is formed of plastic. For example, the second base 120 can be formed of resin. In at least one example, the second base 120 is formed of polycarbonate.

[0027] A second forming plate 122, such as an upper or top forming plate, is secured to the second base 120 via, for example, one or more fasteners, adhesive, or the like. The second base 120 is secured between the second mounting plate 118 and the second forming plate 122. The second forming plate 122 is formed of a different material from the second base 120. For example, the second forming plate 122 is formed of a metal such as steel or aluminum. The second forming plate 122 includes one or more heating elements 124. The heating elements 124 may be embedded in the second forming plate 122 or attached to its surface. For example, the heating elements 124 may be internal pipes forming a fluid circuit on or within the second forming plate 122. The fluid circuit is configured to pass a heating fluid, such as steam or a heated liquid, through the circuit to heat the second forming plate 122. As another example, the heating elements 124 may be electric heating elements.

[0028] FIG. 2 is a schematic block diagram illustrating a three-dimensional (3D) printer 130 according to one embodiment of the present disclosure. Referring to FIGS. 1 and 2 , in at least one example, the first base 112 and the second base 120 are formed by additive manufacturing. For example, the 3D printer 130 is operated to deposit layers 132 of material to form the first base 112 and the second base 120. Additional layers 132 are deposited on the underlying layers 132 until the first base 112 and the second base 120 are fully formed. While the first base 112 and the second base 120 may be relatively large, the molding process for the first base 112 and the second base 120 can be performed efficiently and effectively because it does not require large and expensive molding molds. Instead, the first base 112 and the second base 120 are additively manufactured by 3D printing. Alternatively, the first base 112 and the second base 120 can be formed using a mold, such as injection-molded thermoplastic resin.

[0029] As described above, the first base 112 and the second base 120 are formed from plastic, such as resin or polycarbonate. Unlike conventional match dies, the first base 112 and the second base 120 are not formed from metal. The plastic construction of the first base 112 and the second base 120 allows for a lighter, less expensive tooling system to be used to form the panel 106.

[0030] During operation, the press 108 moves the second die 104 toward the first die 102 in the direction of arrow A. As the panel 106 is sandwiched and compressed between the first die 102 and the second die 104, the heating elements 116 and 124 are activated to heat the first and second forming plates 114 and 122, respectively, and transfer heat to the compressed panel 106, thereby further shaping the panel 106 (e.g., by hardening the inner and / or outer portions). Because the first and second bases 112 and 120 are formed of plastic (and not metal), the entire first and second dies 102 and 104 are not heated. Instead, only the first and second forming plates 114 and 122 are heated, thereby conserving energy and reducing the time required to form the panel 106. Because the first base 112 and the second base 120 are formed from a plastic such as polycarbonate (rather than metal), the first base 112 and the second base 120 can minimize or reduce heat transfer from the first molding plate 114 and the second molding plate 122 to the first mounting plate 110 and the second mounting plate 118, respectively.

[0031] Forming the first base 112 and the second base 120 from plastic, such as by 3D printing, can reduce the overall weight and cost of the system 100. Furthermore, additively manufacturing the first base 112 and the second base by 3D printing can provide the flexibility to incorporate features that are not easily achieved with standard metal processing. In general, forming the first base 112 and the second base 120 by 3D printing can reduce energy consumption and shorten the heating time of the first forming plate 114 and the second forming plate 122. Furthermore, the first forming plate 114 and the second forming plate 122 can have a significantly reduced mass (compared to the bulky metal dies of conventional forming tools).

[0032] As described herein, the system 100 includes one or more bases, such as a first base 112 and a second base 120, that can be additively manufactured by a 3D printer 130. The first base 112 and the second base 120 are formed from a heat-resistant plastic, such as a heat-resistant resin. The first base 112 and the second base 120 are configured to withstand heat, function as insulators to block heat transfer between other components, and reduce energy consumption of the system 100.

[0033] As described herein, the system 100 includes one or more mounting plates (e.g., first mounting plate 110 and second mounting plate 118) formed from one or more metals (e.g., steel or aluminum). One or more forming plates (e.g., first forming plate 114 and second forming plate 122) are also formed from one or more of the metals described above. The one or more forming plates include one or more heating elements (e.g., heating elements 116, 124). One or more bases (e.g., first base 112 and second base 120) are secured between the one or more mounting plates and the one or more forming plates. The one or more bases are formed from a heat-resistant plastic. The one or more forming plates are configured to form the panel 106 by applying pressure and heat. In at least one example, one or more presses 108 are secured to the one or more mounting plates.

[0034] FIG. 3 is a flow diagram illustrating a method according to one embodiment of the present disclosure. Referring to FIGS. 1-3, at 150, one or more bases (e.g., first base 112 and second base 120) are formed from a heat-resistant plastic such as polycarbonate. In at least one example, the forming at 150 includes additive manufacturing via 3D printing. At 152, each base is secured between a forming plate (e.g., first forming plate 114 or second forming plate 122) and a mounting plate (e.g., first mounting plate 110 or second mounting plate 118). The forming plate and mounting plate are formed from a different material than the bases. For example, the forming plate and mounting plate are formed from a metal such as steel or aluminum. In at least one example, a method includes forming one or more mounting plates from one or more metals, forming one or more molded plates from the one or more metals, providing one or more heating elements on the one or more molded plates, forming one or more bases from a heat-resistant plastic, and securing the one or more bases between the one or more mounting plates and the one or more molded plates.

[0035] FIG. 4 is an isometric view of the system 100 according to one embodiment of the present disclosure. FIG. 5 is a bottom isometric view of the base 120 according to one embodiment of the present disclosure. Referring to FIGS. 4 and 5 , the first base 112 has a retention groove 160 formed in its upper surface 162. The retention groove 160 is configured to receive and retain the first molded plate 114, which can be secured within the retention groove 160 using one or more fasteners, adhesive, or the like. For example, the first molded plate 114 can be secured to the first base 112 using fasteners 165 (e.g., screws, bolts, etc.). Similarly, the second base 120 has a retention groove 164 formed in its lower surface 166. The retention groove 164 is configured to receive and retain the second molded plate 122, which can be secured within the retention groove 164 using fasteners, adhesive, or the like.

[0036] Guide pins 170 extend upward from one or more portions of the upper surface 162 of the first base 112. The guide pins 170 may be located outside of the retaining grooves 160. As an example, the guide pins 170 may extend upward from each corner of the first base 112. The guide pins 170 are configured to be received in corresponding grooves 172 formed in the lower surface 166 of the second base 120. As the first die 102 moves toward the second die 104, the guide pins 170 enter the corresponding grooves 172 to properly align the first die 102 with respect to the second die 104. Alternatively, the system 100 may not include the guide pins 170 and grooves 172.

[0037] One or more stop pads 180 are fixed to the surface of the first base 112 and / or the second base 120. As shown, the stop pads 180 are disposed on exterior ledges 181 located outside the retaining grooves. The size and shape of the stop pads 180 are configured to prevent the first forming plate 114 from contacting the second forming plate 122 when the first die 102 and the second die 104 are fully pressed against each other. That is, the stop pads 180 form a separation structure that prevents the first forming plate 114 from contacting the second forming plate 122. This ensures that the stop pads 180 can reliably prevent unnecessary contact between the first forming plate 114 and the second forming plate 122. Alternatively, the system 100 may not include stop pads.

[0038] As shown, first base 110 may include parallel passageways 190 extending through and between opposing sides 192 and 194. Passageways 190 may be configured to receive the lifting arms of, for example, a forklift, which may be used to lift and move system 100. Optionally, first base 110 may not include passageways 190.

[0039] 6 is a front perspective view of an aircraft 200 that may include panels formed according to the systems and methods described herein. The aircraft 200 includes a propulsion system 212 that includes, for example, engines 214. Optionally, the propulsion system 212 may include more engines 214 than shown in the illustrated example. The engines 214 are mounted on wings 216 of the aircraft 200. In other examples, the engines 214 may be mounted on a fuselage 218 and / or a tail section 220. The tail section 220 may also support a horizontal stabilizer 222 and a vertical stabilizer 224.

[0040] The fuselage 218 of the aircraft 200 defines an interior cabin that includes a flight deck or cockpit, one or more work sections (e.g., galleys, crew baggage areas, etc.), one or more passenger sections (e.g., first class, business class, and economy class sections), one or more lavatories, etc. The interior cabin includes panels formed by the systems and methods described herein.

[0041] It should be noted that embodiments of the present disclosure may be used in a variety of other vehicles in addition to aircraft. Suitable vehicles may include automobiles, buses, trucks, locomotive and rail cars, ships, spacecraft, etc. Alternatively, embodiments of the present disclosure may be used to form panels used in the manufacture of structures, components, devices, etc., whether within a vehicle or not.

[0042] FIG. 7 is an interior perspective view of an aircraft interior cabin 300. The interior cabin 300 may be located within the aircraft 200 shown in FIG. 6. The interior cabin 300 includes a floor assembly 308 extending from a first side 302 of the interior cabin 300 to a second side 303 of the interior cabin 300. The first and second sides 302, 303 are at least partially defined by side walls that connect to the ceiling 304. The interior cabin 300 includes windows 306 along the first and second sides 302, 303. The floor assembly 308 supports rows 312 of seats 310. In the illustrated example, each row 312 includes three seats 310 on each side of a single aisle 313. The rows 312 are spaced apart along the length of the interior cabin 300. In alternative configurations, at least some rows may include more or less than three seats, or may include at least two aisles. One or more portions of interior cabin 300, such as floor assembly 308, sides 302, 303, and / or ceiling 304, include panels formed by the systems and methods described herein.

[0043] Furthermore, the present disclosure includes examples according to the following appendices.

[0044] Appendix 1. One or more mounting plates formed of one or more metals; one or more shaped plates formed from said one or more metals and including one or more heating elements; one or more bases fixed between the one or more mounting plates and the one or more molding plates and formed of a heat-resistant plastic; The system, wherein the one or more forming plates are configured to form a panel by applying pressure and heat.

[0045] Clause 2. The system of clause 1, further comprising one or more presses secured to the one or more mounting plates.

[0046] Appendix 3. The system of Appendix 1 or 2, wherein the one or more mounting plates include a first mounting plate and a second mounting plate, the one or more forming plates include a first forming plate and a second forming plate, the one or more bases include a first base fixed between the first mounting plate and the first forming plate and a second base fixed between the second mounting plate and the second forming plate, the first mounting plate, the first base, and the first forming plate are included in a first die, the second mounting plate, the second base, and the second forming plate are included in a second die, and the first forming plate and the second forming plate are configured to press and heat the panel therebetween.

[0047] Appendix 4. The system of Appendix 3, wherein one of the first base or the second base includes a guide pin and the other of the first base or the second base includes a corresponding groove, and the guide pin is configured to be received by the corresponding groove as the first die moves toward the second die.

[0048] Appendix 5. The system of any one of appendices 1 to 4, wherein the heat-resistant plastic comprises polycarbonate.

[0049] Appendix 6. The system of any one of Appendixes 1-5, wherein the one or more bases are formed by additive manufacturing.

[0050] Appendix 7. The system of any one of Appendixes 1 to 6, wherein a three-dimensional (3D) printer is used to form the one or more bases.

[0051] Appendix 8. The system of any of Appendixes 1-7, wherein the one or more bases include one or more retaining grooves, and the one or more shaped plates are secured within the one or more retaining grooves.

[0052] Appendix 9. The system of any of Appendixes 1-8, wherein the one or more bases include one or more stop pads.

[0053] Appendix 10. The system of any of Appendixes 1-9, wherein the one or more bases include parallel passages configured to receive lifting arms of a forklift.

[0054] Appendix 11. One or more mounting plates formed from one or more metals; forming one or more shaped plates from said one or more metals; providing one or more heating elements on said one or more forming plates; forming one or more bases from a heat resistant plastic; and securing the one or more bases between the one or more mounting plates and the one or more shaped plates; The method, wherein the one or more forming plates are configured to form a panel by applying pressure and heat.

[0055] Clause 12. The method of clause 11, further comprising securing one or more presses to the one or more mounting plates.

[0056] Addendum 13. The method of Addendum 11 or 12, wherein the one or more mounting plates include a first mounting plate and a second mounting plate, the one or more forming plates include a first forming plate and a second forming plate, the one or more bases include a first base fixed between the first mounting plate and the first forming plate and a second base fixed between the second mounting plate and the second forming plate, the first mounting plate, the first base, and the first forming plate are included in a first die, and the second mounting plate, the second base, and the second forming plate are included in a second die, and the first forming plate and the second forming plate are configured to press and heat the panel therebetween.

[0057] Appendix 14. The method of Appendix 13, wherein one of the first base or the second base includes a guide pin and the other of the first base or the second base includes a corresponding groove, the guide pin configured to be received by the corresponding groove as the first die moves toward the second die.

[0058] Appendix 15. The method of any one of Appendixes 11 to 14, wherein the heat-resistant plastic comprises polycarbonate.

[0059] Addendum 16. The method of any of Addendums 11-15, wherein forming the one or more bases comprises additively manufacturing the one or more bases.

[0060] Addendum 17. The method of any of Addendums 11-16, wherein forming the one or more bases includes forming the one or more bases using a three-dimensional (3D) printer.

[0061] Addendum 18. The method of any of Addendums 11-17, wherein the one or more bases include one or more retaining grooves, the one or more shaped plates are secured within the one or more retaining grooves, and the one or more bases include one or more stop pads.

[0062] Appendix 19. A method for manufacturing a semiconductor device, comprising: a first die and a second die; The first die is a first mounting plate formed from one or more metals; a first forming plate formed from said one or more metals and including one or more first heating elements; a first base fixed between the first mounting plate and the first molding plate, the first base being formed of heat-resistant plastic, and a three-dimensional (3D) printer being used to form the first base; The second die is a second mounting plate formed from said one or more metals; a second molding plate formed from said one or more metals and including one or more second heating elements; a second base fixed between the second mounting plate and the second molding plate, the second base being formed from heat-resistant plastic, and the 3D printer being used to form the second base; The system, wherein the first forming plate and the second forming plate are configured to form a panel by applying pressure and heat.

[0063] Clause 20. The system of Clause 19, further including one or more presses secured to one or both of the first mounting plate or the second mounting plate, wherein one of the first base or the second base includes a guide pin and the other of the first base or the second base includes a corresponding groove, the guide pin configured to be received by the corresponding groove as the first die moves toward the second die, and the first base and the second base further include stop pads.

[0064] As described herein, embodiments of the present disclosure provide efficient and effective systems and methods for forming panels usable in the interior cabin of a vehicle. Additionally, embodiments of the present disclosure provide lightweight, inexpensive tooling for manufacturing such panels.

[0065] Although various spatial and directional terms such as top, bottom, bottom, center, side, horizontal, vertical, and front have been used to describe the embodiments of the present disclosure, these terms are used only in relation to the orientation shown in the drawings. These orientations may be reversed, rotated, or otherwise altered, such that an upper portion may become a lower portion, and vice versa, and a horizontal orientation may become a vertical orientation.

[0066] As used herein, a structure, limitation, or element that is "configured" to perform a process or operation is one that is specifically formed, configured, or adapted to perform that process or operation. For clarity and to avoid doubt, something that can merely be modified to perform that process or operation is not "configured" to perform that process or operation as used herein.

[0067] The foregoing description is illustrative and should not be construed as limiting. For example, the above-described embodiments (and / or aspects thereof) can be used in combination with each other. In addition, many modifications can be made to adapt these teachings to a particular situation or material without departing from the scope of the various embodiments of the present disclosure. While the dimensions and types of materials described herein are intended to define aspects of the various embodiments of the present disclosure, these embodiments are not intended to be limiting and are merely exemplary embodiments. Many other embodiments will be apparent to those skilled in the art upon reviewing the above description. Therefore, the scope of the various embodiments of the present disclosure should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. As used herein in the appended claims and the detailed description, terms such as "comprising" and "wherein" are used interchangeably, respectively. Furthermore, the terms "first," "second," "third," etc. are used merely as labels and are not intended to impose numerical requirements on the objects they refer to.

[0068] This description uses examples to disclose various embodiments, including the best mode, and also enables those skilled in the art to practice various embodiments of the present disclosure, including making and using any devices or systems, and performing the incorporated methods. The patentable scope of various embodiments of the present disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples should be considered within the scope of the claims if they contain elements that are indistinguishable from the literal language of the claims, or if they contain equivalent elements that have only insubstantial differences from the literal language of the claims.

Claims

1. one or more mounting plates formed from one or more metals; one or more formed plates formed from said one or more metals and including one or more heating elements; one or more bases fixed between the one or more mounting plates and the one or more molding plates and formed of a heat-resistant plastic; The one or more forming plates are configured to form a panel by applying pressure and heat.

2. The system of claim 1 , further comprising one or more presses secured to the one or more mounting plates.

3. 2. The system of claim 1, wherein the one or more mounting plates include a first mounting plate and a second mounting plate, the one or more forming plates include a first forming plate and a second forming plate, the one or more bases include a first base secured between the first mounting plate and the first forming plate and a second base secured between the second mounting plate and the second forming plate, the first mounting plate, the first base, and the first forming plate being included in a first die, the second mounting plate, the second base, and the second forming plate being included in a second die, and the first forming plate and the second forming plate being configured to press and heat the panel therebetween.

4. 4. The system of claim 3, wherein one of the first base or the second base includes a guide pin and the other of the first base or the second base includes a corresponding groove, the guide pin configured to be received by the corresponding groove as the first die moves toward the second die.

5. The system of claim 1 , wherein the heat resistant plastic comprises polycarbonate.

6. The system of claim 1 , wherein the one or more bases are formed by additive manufacturing.

7. The system of claim 1 , wherein a three-dimensional (3D) printer is used to form the one or more bases.

8. The system of claim 1 , wherein the one or more bases include one or more retaining grooves, and the one or more shaped plates are secured within the one or more retaining grooves.

9. The system of claim 1 , wherein the one or more bases include one or more stop pads.

10. The system of claim 1 , wherein the one or more bases include parallel passages configured to receive lifting arms of a forklift.

11. forming one or more mounting plates from one or more metals; forming one or more shaped plates from said one or more metals; providing one or more heating elements on the one or more forming plates; forming one or more bases from a heat resistant plastic; and securing the one or more bases between the one or more mounting plates and the one or more molding plates; The method, wherein the one or more forming plates are configured to form a panel under pressure and heat.

12. The method of claim 11 , further comprising securing one or more presses to the one or more mounting plates.

13. 12. The method of claim 11, wherein the one or more mounting plates include a first mounting plate and a second mounting plate, the one or more forming plates include a first forming plate and a second forming plate, the one or more bases include a first base secured between the first mounting plate and the first forming plate and a second base secured between the second mounting plate and the second forming plate, the first mounting plate, the first base, and the first forming plate being included in a first die, and the second mounting plate, the second base, and the second forming plate being included in a second die, and the first forming plate and the second forming plate being configured to press and heat the panel therebetween.

14. 14. The method of claim 13, wherein one of the first base or the second base includes a guide pin and the other of the first base or the second base includes a corresponding groove, the guide pin configured to be received by the corresponding groove as the first die moves toward the second die.

15. The method of claim 11 , wherein the heat resistant plastic comprises polycarbonate.

16. The method of claim 11 , wherein forming the one or more bases comprises additively manufacturing the one or more bases.

17. The method of claim 11 , wherein forming the one or more bases comprises forming the one or more bases using a three-dimensional (3D) printer.

18. 12. The method of claim 11, wherein the one or more bases include one or more retention grooves, the one or more molded plates are secured within the one or more retention grooves, and the one or more bases include one or more stop pads.

19. a first die and a second die; The first die is a first mounting plate formed from one or more metals; a first mold plate formed from the one or more metals and including one or more first heating elements; a first base fixed between the first mounting plate and the first molding plate, the first base being formed of a heat-resistant plastic, and the first base being formed using a three-dimensional (3D) printer; The second die is a second mounting plate formed from said one or more metals; a second molding plate formed from said one or more metals and including one or more second heating elements; a second base fixed between the second mounting plate and the second molding plate, the second base being formed from a heat-resistant plastic, and the 3D printer being used to form the second base; The system, wherein the first forming plate and the second forming plate are configured to form a panel under pressure and heat.

20. 20. The system of claim 19, further comprising one or more presses secured to one or both of the first mounting plate or the second mounting plate, wherein one of the first base or the second base includes a guide pin and the other of the first base or the second base includes a corresponding groove, the guide pin configured to be received by the corresponding groove as the first die moves toward the second die, and the first base and the second base further include stop pads.

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