Molding method and support system for thermoformable sheet material

A method of molding a thermoformable sheet material having opposed sides, comprising:

• providing a mold having a first section and a second section, said first section including a compliant mold member, said second section including a rigid mold base configured to releasably receive said first section;
• providing a selectively pressurizable diaphragm in said first section for coaction with said compliant mold member;
• positioning said sheet material between said first section and said second section and closing said mold;
• adjusting sheet material tension during molding to prevent inconsistencies in the molded sheet;
• and
• pressurizing said diaphragm to urge said compliant member against said sheet to mold said sheet into a shape of said second section.

A method of molding a thermoformable sheet material having opposed sides, comprising:

• providing a mold having a first section and a second section, said first section including a compliant mold member and a selectively pressurizable diaphragm, said second section including a rigid mold base configured to releasably receive said first section;
• positioning said thermoformable sheet material between said first section and said second section;
• stamping said first section into said second section;
• compressing, by pressurization of said diaphragm, said compliant member to urge said sheet material against said rigid mold base whereby said sheet material is uniformly dimensioned throughout its molded shape;
• and
• depressurizing said mold to release said molded shape.

A method of supporting and adjusting the movement of sheet material during a sheet molding operation, comprising:

• providing sheet material to be molded;
• providing a frame having a plurality of selectively movable clamp members;
• clamping said sheet material with said clamp member;
• effecting a molding operation during which said sheet material is exposed to irregular forces;
• and
• selectively operating said clamping members to allow movement and adjustment of said sheet material during exposure to said forces.

An apparatus for supporting and adjusting the movement of sheet material during a sheet molding operation, comprising:

• a frame
• a plurality of selectively movable clamp means for clamping said sheet material;
• means for effecting translational movement of said clamping members relative to said frame for adjustment of said sheet material relative to said frame during exposure to forces encountered in said molding operation;
• and
• means for effecting rotational movement of said clamping members about a vertical and a horizontal axis relative to said frame, whereby said sheet material is dynamically adjusted in a plurality of directions during molding.

An apparatus for molding a thermoformable sheet material having opposed sides, comprising:

• a mold having a first section and a second section, said first section including a compliant mold member, said second section including a rigid mold base configured to releasably receive said first section, said first section and said second section forming a mold volume when in contact;
• a selectively pressurizable diaphragm in said first section for coaction with said compliant mold member and operable within said mold volume;
• and
• means for pressurizing said mold volume to move said diaphragm whereby said sheet material is uniformly dimensioned throughout its molded shape.