Patent ID: 8309009

Claim:
A method for rapid press forming and consolidation of a sheet of thermoformable material having peripheral edges, comprising the steps of: providing a part-forming hydraulic press having a rapidly movable piston with a punch affixed at one end of the rapidly movable piston, said punch being formed of a deformable elastomeric material; providing a die mold in opposing relationship with said part-forming hydraulic press configured to receive said punch of said part-forming hydraulic press, said part-forming hydraulic press and said die mold defining a molding and consolidation position between said part-forming hydraulic press and said die mold; providing a sheet of thermoformable material having peripheral edges; providing a preheating and preconsolidation station for heating said sheet of thermoformable material; providing a track extending between said preheating and preconsolidation station and said molding and consolidation position between said punch of said part-forming hydraulic press and said die mold; providing a movable frame having an interior channel formed around a perimeter of the movable frame, the movable frame being mounted on said track, and said movable frame being indexed to be movable along said track between a preheating and preconsolidation station and a molding and consolidation position between said punch of said part-forming hydraulic press and said die mold, the movable frame including an inner plate suspended from the interior channel, and the inner plate having an aperture configured to receive at least a portion of a sheet of thermoformable molding composite material; removably securing the peripheral edges of the sheet of thermoformable material within the interior channel to suspend the sheet of thermoformable material over said aperture of said inner plate; heating the sheet of thermoformable material on said movable frame at said preheating and preconsolidation station to provide a heated sheet of thermoformable material suspended on said movable frame; transferring the heated sheet of thermoformable material suspended on said movable frame to said molding and consolidation position between said punch of said part-forming hydraulic press and said die mold; rapidly punching the heated sheet of thermoformable material with said punch of said part-forming hydraulic press by moving said punch of said part-forming hydraulic press into said molding engagement with said die mold with said heated sheet of thermoformable material therebetween to form a consolidated, molded sheet of thermoformable material; releasing said consolidated, molded sheet of thermoformable material from between said punch of said part-forming hydraulic press and said die mold; and allowing said consolidated, molded sheet of thermoformable material to cool.