System and method for bulge forming a blank into an article including shaped portions

A system for bulge forming an unheated substantially flat blank which includes peripheral portions, by deforming the flat blank into an article which comprises a formed part, wherein the formed part includes a shaped portion, comprising:

• deforming-enabling means for enabling deforming of the unheated blank so as to enable the shaped portions of the article to be formed there against, including a complementary portion which is complementary in shape to the shape of the shaped portion of the article to be formed thereby;
• enclosing enabling means for enabling the deforming-enabling means to be enclosed therein, and for enabling the unheated blank to be positioned and enclosed therein without restricting deforming of the flat blank including the peripheral portions thereof;
• a flexible member, adapted to be enclosed within the enclosing enabling means, to bulge within the enclosing enabling means upon the application of pressure to the flexible member, to exert pressure on the unheated blank adapted to be positioned in the enclosing enabling means, and to deform the unheated blank relative to the deforming-enabling means complementary portion to form the shaped portion of the article;
• and
• expansion enabling means for enabling expansion of the flexible member so as to exert pressure on the unheated blank and deform the unheated blank to form the shaped portion of the article against the deforming-enabling means.

A method of bulge forming an unheated substantially flat blank which includes peripheral portions, by deforming the flat blank into an article which comprises a formed part, wherein the formed part includes a shaped portion, in a system which comprises a deforming-enabling element for enabling deforming of the unheated blank so as to enable the shaped portions of the article to be formed thereagainst, including a complementary portion which is complementary in shape to the shape of the shaped portion of the article to be formed thereby, an enclosing enabling element for enabling the deforming-enabling element to be enclosed therein, and for enabling the unheated blank to be positioned and enclosed therein without restricting deforming of the flat blank including the peripheral portions thereof, a flexible member, adapted to be enclosed within the enclosing enabling element, to bulge within the enclosing enabling element upon the application of pressure to the flexible member, to exert pressure on the unheated blank adapted to be positioned in the enclosing enabling element, and to deform the unheated blank relative to the form-shaping element complementary portions to form the shaped portion of the article, and an expansion enabling element for enabling expansion of the flexible member so as to exert pressure on the unheated blank and deform the unheated blank to form the shaped portion of the article against the deforming-enabling element, wherein the method comprises:

• opening the enclosing enabling element and positioning the unheated blank therein relative to the form-shaping element;
• closing the enclosing enabling element without restricting deforming of the flat blank including the peripheral portions thereof;
• and
• expanding the flexible member such that the flexible member bulges relative to the unheated blank and exerts pressure on the unheated blank against the deforming-enabling element so as to deform the unheated blank to form the shaped portion of the article.

A method of bulge forming an unheated substantially flat blank which includes peripheral portions, by deforming the flat blank into an article which comprises a formed part, wherein the formed part includes a shaped portion, in a system which comprises deforming-enabling means for enabling deforming of the unheated blank so as to enable the shaped portions of the article to be formed thereagainst, including a complementary portion which is complementary in shape to the shape of the shaped portion of the article to be formed thereby, enclosing enabling means for enabling the deforming-enabling means to be enclosed therein, and for enabling the unheated blank to be positioned and enclosed therein without restricting deforming of the flat blank including the perhipheral portions thereof, a flexible member, adapted to be enclosed within the enclosing enabling means, to bulge within the enclosing enabling means upon the application of pressure to the flexible member, to exert pressure on the unheated blank adapted to be positioned in the enclosing enabling means, and to deform the unheated blank relative to the form-shaping element complementary portions to form the shaped portion of the article, and expansion enabling means for enabling expansion of the flexible member so as to exert pressure on the unheated blank and deform the unheated blank to form the shaped portion of the article against the deforming-enabling means, wherein the method comprises:

• opening the enclosing enabling means and positioning the unheated blank therein relative to the form-shaping means;
• closing the enclosing enabling means without restricting deforming of the flat blank including the peripheral portions thereof;
• and
• expanding the flexible member such that the flexible member bulges relative to the unheated blank and exerts pressure on the unheated blank against the deforming-enabling means so as to deform the unheated blank to form the shaped portion of the article.

A system for bulge forming an unheated substantially flat blank into an article which comprises a formed part and which includes a shaped portion, comprising:

• a form-shaping element for enabling the shaped portions of the article to be formed thereagainst, including a complementary portion which is complementary in shape to the shape of the shaped portion of the article to be formed thereby;
• an enclosing enabling element for enabling the form-shaping element to be enclosed therein, and for enabling the unheated blank to be positioned and enclosed therein, comprising a plurality of inter-engagable cage sections, adapted to be secured together to enable the article shaped portion to be formed therein, and to be separated to enable the unheated blank to be inserted therein or to enable removal of the article formed therein;
• a flexible member, adapted to be enclosed within the enclosing enabling element, to bulge within the enclosing enabling element upon the application of pressure to the flexible member, to exert pressure on the unheated blank adapted to be positioned in the enclosing enabling element, and to bend the unheated blank relative to the form-shaping element complementary portion to form the shaped portion of the article;
• and
• an expansion enabling element for enabling expansion of the flexible member so as to exert pressure on the unheated blank and form the shaped portion of the article against the form-shaping element.

A system for bulge forming an unheated substantially flat blank into an article which comprises a formed part and which includes a shaped portion, comprising:

• a form-shaping element for enabling the shaped portions of the article to be formed thereagainst, including a complementary portion which is complementary in shape to the shape of the shaped portion of the article to be formed thereby;
• an enclosing enabling element for enabling the form-shaping element to be enclosed therein, and for enabling the unheated blank to be positioned and enclosed therein;
• a flexible member, adapted to be enclosed within the enclosing enabling element, to bulge within the enclosing enabling element upon the application of pressure to the flexible member, to exert pressure on the unheated blank adapted to be positioned in the enclosing enabling element, and to bend the unheated blank relative to the form-shaping element complementary portion to form the shaped portion of the article;
• an expansion enabling element for enabling expansion of the flexible member so as to exert pressure on the unheated blank and form the shaped portion of the article against the form-shaping element;
• a plurality of form-shaping elements;
• and
• a plurality of flexible members.

A system for bulge forming an unheated substantially flat blank into an article which comprises a formed part and which includes a shaped portion, comprising:

• form-shaping means for enabling the shaped portions of the article to be formed there against, including a complementary portion which is complementary in shape to the shape of the shaped portion of the article to be formed thereby;
• enclosing enabling means for enabling the form-shaping means to be enclosed therein, and for enabling the unheated blank to be positioned and enclosed therein, comprising a plurality of inter-engagable cage sections, adapted to be secured together to enable the article shaped portion to be formed therein, and to be separated to enable the unheated blank to be inserted therein or to enable removal of the article formed therein;
• a flexible member, adapted to be enclosed within the enclosing enabling means, to bulge within the enclosing enabling means upon the application of pressure to the flexible member, to exert pressure on the unheated blank adapted to be positioned in the enclosing enabling means, and to bend the unheated blank relative to the form-shaping element complementary portion to form the shaped portion of the article;
• and
• expansion enabling means for enabling expansion of the flexible member so as to exert pressure on the unheated blank and form the shaped portion of the article against the form-shaping element.

A system for bulge forming an unheated substantially flat blank into an article which comprises a formed part and which includes a shaped portion, comprising:

• form-shaping means for enabling the shaped portions of the article to be formed there against, including a complementary portion which is complementary in shape to the shape of the shaped portion of the article to be formed thereby;
• enclosing enabling means for enabling the form-shaping means to be enclosed therein, and for enabling the unheated blank to be positioned and enclosed therein;
• a flexible member, adapted to be enclosed within the enclosing enabling means, to bulge within the enclosing enabling means upon the application of pressure to the flexible member, to exert pressure on the unheated blank adapted to be positioned in the enclosing enabling means, and to bend the unheated blank relative to the form-shaping element complementary portion to form the shaped portion of the article;
• expansion enabling means for enabling expansion of the flexible member so as to exert pressure on the unheated blank and form the shaped portion of the article against the form-shaping element;
• a plurality of form-shaping elements;
• and
• a plurality of flexible members.

A method of bulge forming an unheated substantially flat blank into an article which comprises a formed part and which includes a shaped portion, in a system which comprises a form-shaping element for enabling the shaped portions of the article to be formed thereagainst, including a complementary portion which is complementary in shape to the shape of the shaped portion of the article to be formed thereby, an enclosing enabling element for enabling the form-shaping element to be enclosed therein, and for enabling the unheated blank to be positioned and enclosed therein, comprising a plurality of inter-engagable cage sections, adapted to be secured together to enable the article shaped portion to be formed therein, and to be separated to enable the unheated blank to be inserted therein or to enable removal formed therein, a flexible member, adapted to be enclosed within the enclosing enabling element, to bulge within the enclosing enabling means upon the application of pressure to the flexible member, to exert pressure on the unheated blank adapted to be positioned in the enclosing enabling element, and to bend the unheated blank relative to the form-shaping element complementary portions to form the shaped portion of the article, and an expansion enabling element for enabling expansion of the flexible member so as to exert pressure on the unheated blank and form the shaped portion of the article against the form-shaping element, wherein the method comprises:

• opening the enclosing enabling element and positioning the unheated blank therein relative to the form-shaping element;
• closing the enclosing enabling element, comprising engaging together the sections of the enclosing enabling element;
• and
• expanding the flexible member such that the flexible member bulges relative to the unheated blank and exerts pressure on the unheated blank against the form-shaped element to form the shaped portion of the article.