Reusable die shape for the manufacture of molded cushions

An apparatus for forming a contoured article, comprising:

• first means for forming a positive surface profile of a contoured surface from data for defining the positive surface profile;
• and
• second means for forming a negative surface profile of the contoured surface, said first means adapted to be maintained in contact with said second means,
• wherein said first means comprises a plurality of rods made of a magnetic material extending in a first longitudinal direction, each of said rods having a first end and a second end, a frame having a base and a rod guide plate attached to said base, said rod guide plate having a plurality of rod guide holes, each rod guide hole slidably receiving a respective rod, means for moving said first ends of said rods in a first longitudinal direction having a drive plate with an upper surface, said drive plate adapted to move in the first longitudinal direction, said rod second ends adapted to contact on said drive plate upper surface, and locking means for locking each of said rods in place having a plurality of magnetic members, each magnetic member being adapted to be positioned in close proximity to one of said respective rods whereby each of said magnetic members is adapted to be activated to magnetically attract said respective rod and prevent said rod from moving in the longitudinal direction.

An apparatus for forming a contoured article, comprising:

• first means for forming a positive surface profile of a contoured surface from data for defining the positive surface;
• and
• second means for forming a negative surface profile of the contoured surface, said first means adapted to be maintained in contact with said second means,
• wherein said second means comprises a plurality of rods extending in a first longitudinal direction, each of said rods having a slotted first end, a frame having a base, a rod guide plate attached to said base and a leg attached to said base, said rod guide plate having a plurality of rod guide holes, each rod guide hole slidably receiving a respective one of said rods, and a plurality of springs attached to said rods and adapted to coact with said rod guide plate and urge said rods in a first position, locking means for locking each of said rods in place including a mechanical locking member having a fixed plate having a plurality of second holes, wherein each of said second holes receives a respective rod and a moving plate having a plurality of third holes, whereby each of said third holes receives a respective rod, means for moving said moving plate in a second longitudinal direction so as to bind said rods and prevent said rods from moving in the first longitudinal direction, said leg attached to said rod guide plate and said fixed plate, said cam adapted to abut against said leg in a first position thereby binding said rods and preventing said rods from moving in the first longitudinal direction, a deformable member in contact with said rod first ends, said deformable member includes a plurality of deformable strands received by said slots, a spool attached to said frame, said spool adapted to receive said strands, and moving means for moving said first ends of said rods and said deformable member in the first longitudinal direction.

An apparatus for forming a positive surface profile used in forming a contoured article and used in combination with an apparatus for forming a negative surface profile of the contoured surface, which is to be maintained in contact with the apparatus for forming a positive profile, the positive surface profile forming apparatus comprising:

• a frame having a base;
• a plurality of rods made of magnetic material extending in a first longitudinal direction, each of said rods having a first end and a second end;
• a rod guide plate attached to said base, said rod guide plate having a plurality of rod guide holes, each rod guide hole slidably receiving a respective rod;
• a drive plate having an upper surface, said drive plate adapted to move in the first longitudinal direction, said rod second ends adapted to contact on said plate upper surface;
• and
• a plurality of magnetic members, each magnetic member being adapted to be positioned in close proximity to one of said respective rods whereby each of said magnetic members is adapted to be activated to magnetically attract said respective rod and prevent said rod from moving in the longitudinal direction.

An apparatus for forming a negative surface profile used in forming a contoured article and used in combination with an apparatus for forming a positive surface profile of the contoured surface, which is to be maintained in contact with the apparatus for forming the negative profile, comprising:

• a plurality of rods extending in a longitudinal direction, each of said rods having a first end;
• a frame having a base, a leg attached to said base, and a rod guide plate attached to said base, said rod guide plate having a plurality of rod guide holes, each rod guide hole slideably receiving a respective one of said rods;
• a plurality of springs attached to said rods and adapted to coact with said plate and urge said rods in a first position;
• a deformable member in contact with said first ends of said rods;
• a mechanical locking member including a fixed plate having a plurality of second holes, wherein each of said second holes receives a respective rod, and a moving plate having a plurality of third holes, whereby each of the third holes receives a respective rod;
• and
• a cam pivotally attached to said moving plate, wherein said cam is adapted to abut against said leg in a first position thereby binding said rods and preventing said rods from moving in the first longitudinal direction.