Field of the technology The present technology relates to associated methods, apparatuses and uses of foam for the manufacture of three dimensional components. In particular, the present technology relates to methods, apparatuses and uses of foam in the manufacturing of components or objects that are generally triangular-, ring-or donut-shaped. Such shapes may be particularly suitable for the formation of cushions for face masks, mask forehead support portions and mask cheek support portions and further particularly for such devices in medical and respiratory masks.

Background of the technology The use of elastics materials, such as foams has become widespread during recent years. Such elastic materials may, e.g., be used as cushioning materials in medical masks and respiratory masks. Such elastic materials are known in the prior art, for example in the field of face masks for delivering breathable air to a patient, particularly in sleep disordered breathing therapy, such as CPAP therapy. In such face masks cushions are used for providing contact zones for contacting the face of the user in order to improve wearing comfort of the user. Furthermore, such structures are used as a sealing structure for sealing the mask interior from the exterior in the contact region where the mask rests on a user's face. Depending on the exact application of the elastic material, it may be desirable to provide the elastic material, preferably foam, in different three dimensional shapes. Such shaping may be accomplished by different methods. For example, molding technologies may be used. Alternatively, block or layer-like foam sheets may be provided, from which a desired shape is cut. This may be accomplished, e.g., by distortion cutting processes including compression cutting or protrusion cutting.

Protrusion cutting may be understood to describe a process whereby an elastic material, such as foam 2, is forced under physical pressure through an aperture or cavity 8 which distorts the material's shape, as shown in the previously known arrangement shown in Fig. !a-b. In the figure, a block of foam 2 is provided and damped between a base plate 4 and an opposing plate 6. The opposing plat 6 is provided with an aperture 8, After foam 2 is placed between base plate 4 and opposing plate 6. physical pressure or force is applied, as indicated by arrows A. A portion 22 of foam 2 is pushed by the force and protmde¾ through the aperture 8. This portion is cut away by a knife 10 linearly along cutting plane 12. Thereby, a cut foam section 200 is separated from foam 2. This apparatus and method allows for formation of a solid foam portion 200. However, such protrusion cutting of foam 2 creates shapes that are without any holes or voids, ie. what may be termed solid shapes, and does not allow for the direct production of foam sections with holes, e.g., ring shape, torus or donut. shaped foam sections.

However, in some circumstances, it may also be desirable to cut a section of the foam 2 that is of non-solid shape. Such shapes may be suitable for medical and particularly respiratory masks, e.g. for the formation of mask cushions including nasal and/or mouth cushions, mask forehead support portions and mask cheek support portions

Apparatus and methods for the direct production of such ring shaped portions are known (WO 2010/028426). One is described with reference to Figures 2a-b. Again, this apparatus comprises a base plate 4 and an opposing plate 6. Opposing plate 6 comprises an aperture 8. When the foam 2 is compressed, a section 22 of the foam 2 protrudes through aperture 8. m contrast to the apparatus described in conjunction with Figures la-b, the apparatus of Figures 2a-b further comprises an opposing, center plate portion 14. This opposing ©enter piste portion 14 extends through foam 2 and is anchored through foam 2 to base plate 4, When the foam 2 is interposed between base plate 4 on the one side and opposing plate 6 and opposing center plate portioa 14 on the opposite side, again a pressure as indicated by arrows A may be applied. Due to the anchoring of opposing center plate section 14, a reverse compression force is- applied to a center section of the foam 2 extending through the aperture 8, As this area is palled back by the opposing center plate portion 14, the section of the foam 2 which is in the eross- sectional area of center plate portion J.4 does not protrude through the aperture! . The proeruding section of the foam 2 is indicated by reference numeral 22 in Figures 2a-b. Similar to the device of Figures la-b. a knife 10 may now be used to cut the protruding foam sections 22 to separate them from foam 2 by linear movement. In turn, a ring shaped cut foam section 202, with a hole 203, is generated. However, this prior art method has certain drawbacks. The need of the opposing center plate portion J 4 to be anchored to base plate 4 leads to a relatively complex. desigs with regards to both structure and usability. Further, this anchoring cuts through foam 2, thereby perforating it Another known method for the manufacture of foam sections with a hole, e.g., torus or donot shaped foam sections, is described in conjunction with Figures 3a-b. These Figures depict a compression cutting process. In such a compression cutting method, a block of foam 2 m placed between a base plate 4" and a template 16" comprising an opening or recess 18 being in the negative shape of the desired product, i .e. having a ring-like shape. Again, a pressure or compression force, as indicated by arrow A ^* is applied to the apparatus causing portions 22 of foam 2 to protrude and fill the ga s or recesses 18. A nife- .10 may then he used to linearly cut along cutting plane 12. Thereby, a cut-off foam section 202' is generated. This cut foam section 202' comprises an inner hole 203 and has the general shape of a ring, torus or domit. However, there are also considerable drawbacks with regard to such a compression cutting method. As an initial matter, the forces required to cut the foam 2 are high, since the foam is cut in a compressed (dense) state, Further, it is generally difficult to obtain a significant amount of height variation in the profile without also changing its width. It is desirable for a technology to overcome or at least alleviate shortcomings of the prior art and/or to propose alternative solutions.

Soaamary In a first aspect, the present technology relates to an apparatus for cutting of elastic material. The elastic material may be a block or a layer of elastic material and/or may be selected from die group consisting of foams, rubbers, gels and felted textiles. When foam is used, the foam may be an open-cell foam or a closed cell foam. The apparatus comprises two plates, which may be referred to as base plate and an opposing plate. The opposing plate typically comprises an aperture. The elastic material, such as the foam, may be placed between the base plate and the opposing, plate. Further, fe apparatus also comprises as opposing center plate portion, The opposing center plate portion Is typically located and/or placed on the side of the foam where the opposing plate is also placed. In other words, the base plate may be placed on one side of the foam and both the opposing plate and the opposing center plate portion may be placed on the opposite side of the foam. The apparatus further comprises separation means. The separation means is adapted to separate at least a portion of the elastic material from the remainder of the elastic material. Examples for the separation means include knives, blades, saws, circular saws, turkey cutters as well as a wire, particularly a hot or a heated wire.

Further, at least two of the base plates, the opposing plates, and the opposing center plate portions are adapted to move relative to one another in a first direction to change a distance therebetween. As an example, the opposing plate may be adapted to move relative to the base plate (that is, these two elements are adapted to move relative to one another). In such a configuration, e.g., the elastic material may be located on the base plate and the opposing plate may be moved closer to the base plate (or vice versa) to secure and squeeze the elastic material between the base plate and the opposing plate. Thus, a section or portion of the elastic material may protrude through the aperture of the opposing plate as it is not directly subject to the compressive forces. Further, the opposing center plate portion may also be adapted to move relative to the base plate and the opposing plate. As such, the opposing center plate portion may push at least a sector of the elastic material that protrudes through the aperture of the opposing plate and may, in fact, prevent this sector from protruding through said aperture. In the just described configuration, the base plate, the opposing plate and the opposing center plate portion would be adapted to move relative to one another. However, those of skill in the art will readily understand that even though it may be preferred that these three elements are movable relative to one another, other configurations are also possible. As a mere example, it may also be possible that the opposing plate and the opposing center plate portion are fixed relative to one another and may be moved together. In such a configuration, the elastic material may, e.g., be placed on the base plate and both the opposing plate and the opposing center plate portion may be moved closer to the base plate in parallel to squeeze the elastic material and force a portion of the elastic material to protrude through the aperture of the opposing plate, while, at the same time, preventing a sector of this portion from protruding. In such a configuration, the opposing plate and the opposing center plate portion would be adapted to move relative to the base plate.

Further, in the present technology, at least one of the separation means on the one hand and at least one of the base plate, the opposing plate and the opposing center plate portion on the other hand, are rotatable, preferably to one another and/or around one or more, more preferably the same, axes. As an example, the base plate, the opposing plate and the opposing center plate portion may be rotationally fixed. That is, they may only co-rotate, i.e. when one of the elements rotate, the other elements rotate as well. In such a configuration, the elastic material, e.g. the foam, which is fixed or jammed between the base plate, the opposing plate and the opposing center plate portion, is forced to co-rotate with the base plate, the opposing plateand the opposing center plate portion. That is, the foam is also rotationally fixed to the base plate, the opposing plate and the opposing center plate portion. In such a configuration, the base plate, the opposing plate, the opposing center plate portion and, in effect, also the elastic material, may be rotated relative to the separation means. This rotational movement may facilitate the separation of the protruding portion of the elastic material along the entire periphery of the opposing center plate portion. The term "being rotationally fixed to s.th." used in this description preferably denotes that two or more parts or portions are adapted and preferably fixed or connected to one another so that if one rotates (he other one rotates with it. That is. when the opposing plate portion is rotationally fixed to the base plate, they always undergo the same rotational movement at the same time and cannot rotate relative to each other. The elements may still be able to perform a linear movement or a rotational or curved movement with a linear component. Further, the term "rotationally fixed" without the specific mentioning of another entity preferably denotes a situation wherein something is incapable of rotating. The element in question, however, may still be capable of linear movement. For instance, if the separation means is said to be rotationally fixed, it indicates that the separation means does not rotate. However, the separation means may still be capable of linear movement with respect to the compression arrangement comprising the base plate, the opposing plate, the opposing center plate portion and the compressed elastic material.

Those of skill in the art will readily understand that configurations other than that described above are also possible. As a mere example, it is not mandatory that the opposing center plate portion is rotationally fixed to the base plate and/or to the opposing plate. It may, e.g., also be possible that the opposing center plate portion is not rotationally fixed to the other two just described elements, particularly when the opposing center plate portion is rotationally symmetric. As an example, if the opposing center plate portion is circular, it may push a sector of the protruding portion of the elastic material and prevent it from protruding. In such a case, a substantially round sector of the elastic material is prevented from protruding. It may then be possible to rotate only Hie base plate and the opposing plate (and, in effect, the elastic material), while not rotating the opposing center plate portion relative to the separation means. Alternatively, the entire compression arrangement comprising the base plate, the opposing plate, the opposing center plate portion and the compressed elastic material, may be rotationally fixed, whilst the cutting means are configured for rotation around the arrangement. The disclosed technology therefore provides a new and improved apparatus and method for the production of elastic materials in a non-solid shape. The disclosed technology further allows foam to be used as a preferred material since material changes to the surface or inner volume of the foam that are often observed with heat-associated processing have not been observed in the proposed method. In addition, the foam production is efficient (costs, time), fewer set up steps are required and satisfactory results are achieved. In particular, a cushion can be prepared in one operation and no secondary cutting process is required, e.g. to make the 'hole'.

In particular, the described apparatus may be adapted for automatic cutting, which may further improve the productivity of the described apparatus. Further still, an opposing supporting member, such as a rod or mandrel, may be provided. Typically, such an opposing supporting member may be connected to the opposing center plate portion on its side opposite the side or surface adapted for coming into contact with the elastic material. This may allow for a particularly simple and convenient way to apply the force to prevent a section of the elastic material from protruding through the aperture of the opposing plate, as well as to rotate the opposing center plate portion, if necessary.

Further still, it is preferred that the separation means is adapted to change its distance to the elastic material jammed in between the base plate and the opposing plate. That is, typically the apparatus is adapted to change a distance between the separation means and the remainder of the apparatus, e.g. the base plate, the opposing plate and the opposing center plate portion. Such a change of a distance brings the separation means in contact with the compressed elastic material to effect the cutting of the protruding section of the elastic material. The change of distance may be generally perpendicular to the first direction, i.e. the direction in which at least two of the base plate, the opposing plate and the opposing center plate portions are adapted to move relative to one another. The first direction in this embodiment happens to coincide with the direction of axes along which at least one of the base plate, the opposing plate and the opposing center plate portions rotates. More preferably, the apparatus is adapted to change the distance between the separation means and the opposing center plate portion to such an extent that the separation means may, in a view along the first direction, at least partially overly the opposing center plate portion or at least be flush with it. Such a configuration allows conveniently the direct and complete separation of the section of the elastic material protruding through said aperture.

In an embodiment, the aperture of the opposing plate may be referred to as a first aperture. The opposing plate may be movable relative to the base plate, e.g. to compress, squeeze or jam an elastic material. Further, the opposing center plate portion may also be movable relative to the base plate. In its move relative to the base plate, the opposing center plate portion may be either fixed to the opposing plate or may be independent therefrom. Alternatively, at least one of the opposing plate and the opposing center plate portion may be fixed and the base plate may be movable relative to the fixed componenl/s. The opposing center plate portion may be located in the first aperture or may be arranged to extend within the first aperture, so as to form a second aperture between an external periphery of the opposing center plate portion and an internal periphery of the first aperture. The elastic material may then be placed between at least two of the base plates, the opposing plates and the opposing center plate portion and protrude through the second aperture. The compression arrangement supporting the elastic material may then be rotated with respect to the separation means and the separation means may be moved towards the elastic material to effect separation of the elastic material along the entire periphery.

The disclosed technology also relates to a method of cutting of an elastic material. Preferably, the afore described apparatus may be used therefor. That is, in the method, a base plate, an opposing plate comprising an aperture and an opposing center plate portion are provided. Further, an elastic material is provided between the base plate and the opposing plate and the opposing center plate portion. A distance along a first direction between the opposing center plate portion and at least one of the base plate and the opposing plate is adjusted such that the foam can only protrude between an external periphery of the opposing center plate portion and an internal periphery of the aperture of the opposing plate. Further, separation means, e.g. as afore described, is provided which are adapted for separating at least a portion of the elastic material from the remainder of the elastic material. Further, a rotational movement is effected between the elastic material and the separation means and the distance between the separation means and the opposing center plate portion is changed such that the protruding elastic material is separated from the non-protruding elastic material.

Further, those of skill in the art will readily understand that the above-described rotational movement is not limited to pure mathematical rotational movements. Preferably, within the meaning of the technology presently disclosed, also combinations of movements including a roiation may be referred to as rotational movements. The disclosed technology in particular is adapted or allows the production of mask cushions, forehead support portions, cheek support portions for patient interfaces such as masks, particularly medical masks and more particularly breathing masks.

The disclosed technology, whether in the form of the above discussed apparatus or its associated method, allows production of non-solid foam cushions that are shaped to closely fit the shape of the face. The disclosed technology further allows foam to be used as a preferred material since the processing involved in the disclosed technology does not alter in any way the foam's properties. Particularly, no skin or property change due to, e.g. the use of heat to permanently form the material, has been observed. In addition, the foam production is more efficient (costs, time), less set up steps are required and satisfactory results are achieved. In particular, a cushion can be prepared in one operation and no secondary cutting process is required, e.g. to make the 'hole'.

Additionally or alternatively, the disclosed technology relates to the following aspects.

1. Apparatus for cutting of elastic material (2), the apparatus comprising

a base plate (4, 4'),

an opposing plate (6, 6') comprising an aperture (8, 8 ^" ),

an opposing center plate portion ( 14, 14') and

separation means (10) adapted to separate at least a portion of the elastic material (2), wherein at least two of the base plate (4, 4'), the opposing plate (6, 6'), and the opposing center plate portion (14, 14') are adapted to move relative to one another in a first direction to change a distance therebetween, and

at least one of the separation means (10) on the one hand and at least one of the base plate (4, 4') the opposing plate (6, 6'), and the opposing center plate portion ( 14, 14') on the other hand is/are rotatable, preferably relative to one another and/or around one or more, more preferably the same, axes. The apparatus according to aspect 1, wherein the elastic material (2) is a block or a layer of elastic material and/or selected from the group consisting of foams, particularly open celled foams, closed celled foams, rubbers, gels and felted textiles. The apparatus according to any of the preceding aspects, wherein the apparatus is adapted for forming mask cushions, forehead support portions and/or cheek support portions for patient interfaces such as masks, particularly medical masks and more preferably breathing masks. The apparatus according to any of the preceding aspects, wherein the base plate (4) is substantially planar. The apparatus according to any of the aspects 1 to 4. wherein the base plate (4') is not planar and/or comprises a cone shaped portion. The apparatus according to any of the preceding aspects, wherein the opposing plate (6) is substantially planar. The apparatus according to any of the aspects 1 to 5, wherein the opposing plate (6\) is not planar and/or is of a generally truncated cone shape. The apparatus according to any of the preceding aspects, expect aspect 6 when depending on aspect 4, wherein the base plate is of a generally circular shape and the distance between the opposing plate (6, 6') and the base plate (4, 4') can vary in radial direction. . The apparatus according to any of the preceding aspects, wherein a distance between the opposing plate (6, 6') and the base plate (4, 4') may be changed, preferably in the first direction 10. Tine apparatus according to any of the preceding aspects, wherein the opposing center plate section (14, 14') is substantially planar.

1 1. The apparatus according to any of the preceding aspects, wherein the opposing center plate section (14' ) is not planar and preferably is conical.

12. The apparatus according to any of the preceding aspects, wherein the aperture (8) in the opposing plate (6) has a generally triangular circumferential shape, preferably when seen in a direction substantially perpendicular to the opposing plate (14, 14'). 13. The apparatus according to any of the preceding aspects, wherein the separation means (10) are adapted to separate the elastic material (2) along a separation plane ( 12).

14. The apparatus according to any of the preceding aspects, wherein the opposing center plate portion (14, 14') comprises a first major surface ( 142) facing to the base plate

(4, 4') and a second major surface (144) facing to the opposite direction and/or wherein the opposing plate (6, 6') comprises a first surface (62) and a second surface (64) and wherein, in operation, the apparatus is adapted to position the opposing center plate portion (14, 14') such that the first major surface ( 142) and the second major surface (144) are on the same side of separation plane (12, 12') as the opposing plate (6, 6').

15. The apparatus according to any of the preceding aspects, wherein the opposing center plate portion (14, 14') comprises a first major surface ( 142) facing to the base plate (4, 4') and a second major surface (144) facing to the opposite direction and/or wherein the opposing plate (6, 6') comprises a first surface (62) and a second surface (64) and wherein the apparatus is adapted to position the opposing center plate portion (14, 14') such that the first major surface (142) is on the side of the separation plane (12, 12' ) of the opposing plate (6, 6') and such that the distance between the separation plane (12, 12') and the first major surface (142) of the opposing center plate portion (14, 14') is larger than the distance between the separation plane ( 12, 12') and the second major surface (64) of the opposing plate (6, 6').

16. The apparatus according to any of the preceding aspects, wherein the opposing center plate portion (14, 14') has a generally triangular shape, particularly with rounded corners, when viewed in a top view from the first direction. 17. The apparatus according to any of the preceding aspects, wherein the separation means (10) is selected from the group consisting of a knife, a blade, a saw, particularly a continuous saw, such as a band saw, a circular saw or a turkey cutter, a wire, particularly a hot or heated wire. 18. The apparatus according to any of the preceding aspects, wherein the apparatus is adapted to change a distance between the separation means (10) and the opposing center plate portion ( 14, 14'), particularly in a direction perpendicular to the first direction and/or parallel to the first surface (62) of opposing plate (6, 6'); wherein the apparatus is preferably adapted to change said distance to such an extent that the separation means (10) may, in a view along the first direction, effect at least one of the following:

at least partly overlie the opposing center plate portion (14, 14'); be flush with the opposing center plate portion (14, 14'); and come almost into contact with an opposing supporting member attached to the opposing center plate, such as a mandrel (30).

19. The apparatus according to any one of the preceding aspects, wherein the separation plane (12) is substantially perpendicular to the first direction. 20. The apparatus according to any of the preceding aspects, wherein the separation plane (12) is tilted with regard to a plane perpendicular to the first direction.

21. The apparatus according to any of the preceding aspects, wherein the base plate (4, 4') is connected to a base supporting member, such as a mandrel (18). 22, The apparatus according to any of the preceding aspects, wherein the apparatus is adapted to change a distance between the opposing center plate portion (14, 14') and both of the base plate (4, 4') and the opposing plate (6, 6').

23. The apparatus according to any of the preceding aspects, wherein an opposing supporting member, such as a mandrel (30) is connected to the opposing center plate portion (14, 14') at its second major surface ( 144) opposing its first major surface (142), the first major surface (142) facing the base plate (4. 4').

24. The apparatus according to any of the preceding aspects, wherein the opposing center plate portion (14, 14 ^" ) is adapted to be fixed to the base plate (4, 4'), preferably by means of bolts or screws. 25. The apparatus according to any of the preceding aspects, wherein the base plate (4, 4'), the opposing plate (6, 6') and the opposing center plate portion (14, 14')are rotattonally fixed and the separation means (10) is adapted to rotate or revolve with respect to the base plate (4, 4'), the opposing plate (6, 6') and the opposing center plate portion (14, 14').

26. The apparatus according to any of the preceding aspects, wherein the separation means (10) is rotationally fixed and the base plate (4, 4'), the opposing plate (6, 6') and the opposing center plate portion (14, 14')are adapted to rotate or revolve about a common axis of rotation, preferably parallel to the first direction.

27. The apparatus according to any of the preceding aspects, wherein the base plate (4, 4'), the opposing plate (6, 6') and the opposing center plate portion (14, 14')are adapted rotate to revolve in one direction about an axis of rotation, preferably a common axis of rotation, preferably parallel to the first direction and wherein the separation means (10) are preferably adapted to rotate or revolve in the opposite direction. 28. The apparatus according to any of the preceding aspects, wherein the opposing center plate portion (14, 14") is rotationally fixed to the base plate (4, 4' ) and the opposing plate (6, 6'). 29. Tine apparatus according to any of the preceding aspects, wherein the base plate (4, 4') is disposed substantially horizontally and wherein the opposing plate (6, 6') is preferably disposed parallel to the base plate (4, 4'), preferably above or below the base plate (4, 4'). 30. The apparatus according to any of the aspects 1 to 28, wherein the base plate (4, 4' ) is disposed substantially vertically, and wherein the opposing plate (6, 6') is preferably disposed parallel to the base plate (4, 4'), preferably left or right of the base plate (4, 4'). 1. The apparatus according to any of the preceding aspects 1 to 28, wherein the base plate (4, 4') is disposed inclined with respect to a horizontal plane, and wherein the opposing plate (6, 6') is preferably disposed parallel to the base plate (4, 4').

32. The apparatus according to any of the preceding aspects, the apparatus further comprising a spacer (34) adapted to be interposed between the base plate (4, 4') and the opposing plate (6, 6') to define a minimum distance between the base plate (4, 4' ) and the opposing plate (6, 6').

33. The apparatus according to aspect 32, wherein the spacer (34) is in the form of a ring and preferably flush with at least one of the base plate (4, 4') and the opposing plate

(6, 6').

34. The apparatus according to any one of aspects 32and 33, wherein the spacer (34) is formed of a rigid material, such as metal.

35. The apparatus according to any of the preceding aspects, wherein the apparatus is adapted for automated cutting. The apparatus according to any of the preceding aspects, wherein the opposing center plate portion (14, 14') comprises a supporting member, preferably a mandrel (30), which extends from its second surface 144, and wherein the opposing plate (6, 6') and/or the base plate (4, 4') comprise a supporting member extending into the opposite direction as the opposing center plate portion supporting member.

The apparatus according to any of the preceding aspects, wherein a supporting member of the opposing center plate portion (14, 14') does not extend through the elastic material.

The apparatus according to any of Ihe preceding aspects, wherein the apparatus is adapted for distortion cutting, particularly protrusion cutting.

Apparatus according to any of the preceding aspects, wherein

the aperture (8, 8') of the opposing plate is a first aperture ( 8, 8');

the opposing plate (6, 6') is movable relative to the base plate (8, 8'),

the opposing center plate portion (14, 14') is movable relative to the base plate (8, 8') and arranged to extend within the first aperture (8, 8'), so as to form a second aperture between an external periphery of the opposing center plate portion ( 14, 14') and an internal periphery of the first aperture (8, 8' );

at least two of the base plate (4, 4'), the opposing plate (6, 6') and the opposing center plate portion (14, 14') are arranged and/or adapted to receive the elastic material therebetween and cause a portion of the elastic material to protrude through the second aperture; and

at least one of: the separation means ( 10) on the one hand; and one or more of the base plate (4, 4'), the opposing plate (6, 6') and the opposing center plate portion (14, 14'), on the other hand; is arranged to be movable relative to the other to bring the separation means towards the elastic material and effect the separation of the elastic material.

The apparatus of aspect 39, wherein the arrangement is such that, in use:

the elastic material is positioned between at least two of the base plate (4, 4'), the opposing plate (6, 6') and the opposing center plate portion ( 14, 14') so that a move of the at least two of the base plate (4, 4'), the opposing plate (6, 6' ), and the opposing center plate portion (14, 14') relative to one another in the first direction changes the distance therebetween and causes a portion of the elastic material to protrude through the second aperture;

the elastic material and the separation means are rotated relative to one another; and the separation means and the elastic material are moved in contact with each other to effect the separation of the elastic material.

The apparatus of aspect 39or 40wherein: once the elastic material is positioned over the base plate (4, 4'), the opposing plate (6. 6') and the opposing center plate portion (14, 14') are moved towards the base plate so as to compress the elastic material and cause the portion of the elastic material to protrude through the second aperture;

The apparatus of any one of aspects 39to 41 , wherein, once the elastic material is compressed between the base plate (4, 4'), the opposing plate (6, 6' ) and the opposing center plate portion (14, 14'), the base plate (4, 4'), the opposing plate (6, 6'), the opposing center plate portion (14, 14') and the compressed elastic material are simultaneously rotated around the axis.

The apparatus of any one of aspects39to 42, wherein the separation means and the elastic material are moved towards each other along a generally straight line to effect the separation of the elastic material.

The apparatus of any one of the preceding aspects, wherein the base plate (4, 4') and the opposing plate (6, 6') are fixedly attached to each other, or are replaced by a single monolithic base element comprising a cavity with an opening.

Apparatus for cutting of elastic material (2), the apparatus comprising

a single monolithic base element comprising a cavity with an opening, an opposing center plate portion (14, 14' ) and

separation means (10) adapted to separate at least a portion of the elastic material (2), wherein

the base element and the opposing center plate portion (14, 14') are adapted to move relative to one another in a first direction to change a distance therebetween, and at least one of the separation means (10) on the one hand and at least one of the base element, and the opposing center plate portion (14, 14 ^' ) on the other hand is/are rotatable, preferably relative to one another and/or around one or more, more preferably the same, axes.

46. Apparatus for cutting of elastic material (2) according to aspect 45 with any one of the individual features of the apparatus according to any individual of aspects 2 to 44.

Here, it is to be understood that aspect 45, may be considered to be an independent aspects with any one of aspects 2 to 44 being directly and/or independently dependent thereon. l . A method of cutting of an elastic material (2), preferably with an apparatus according to any of the preceding aspects, the method comprising the steps of:

providing a base plate (4, 4' ),

providing an opposing plate (6, 6'), the opposing plate (6, 6') comprising an aperture (8),

providing an opposing center plate portion (14, 14'),

providing an elastic material (2) between the base plate and the opposing plate (6, 6'),

providing separation means ( 10) adapted to separate at least a portion of the elastic material (2),

effecting a portion (22) of the elastic material (2) to protrude through the aperture (8),

adjusting a distance along a first direction between the opposing center plate portion ( 14, 14') and at least one of the base plate (4, 4') and the opposing plate (6, 6") such that a part of the elastic material (2) is prevented from protruding through the aperture (8),

effecting a rotational movement between the elastic material (2) and the separation means (10) such that the protruding elastic material is separated from the non- protruding elastic material.

Tt should be noted that the steps of the method are not necessarily listed in the order they are performed. In the above method, for instance, the skilled artisan will readily understand that the step effecting a portion of the elastic material to protrude through the aperture does not necessarily precede the step of adjusting a distance between the opposing center plate portion and at least one of the base plate and the opposing plate such that a section of the elastic material is prevented or hindered from protruding. Instead, it may, e.g., also be possible that these steps are performed simultaneously - i.e. that these two distances are adjusted at the same time. Further, the step listed second may also precede the step listed first - i.e. the opposing center plate section may first be adjusted to compress an inner portion of the elastic material before the opposing plate is brought towards the base plate and a portion of the elastic material is effected to protrude through the aperture.

M2. The method according to method aspect Ml, wherein the step of effecting a portion (22) of the elastic materia) (2) to protrude through the aperture comprises adjusting a distance between the base plate (4, 4') and the opposing plate (6, 6') such that a portion (22) of the elastic material (2) protrudes through the aperture (8).

M3. The method as according to any of the preceding method aspects, wherein the rotational movement is between the separation means (10) on the one hand and the elastic material (2), the base plate (4, 4'), the opposing plate (6. 6') and the opposing center plate portion (14, 14') on the other hand.

M4. The method according to any of the preceding method aspects, wherein the opposing center plate portion (14, 14') is rotationally fixed to at least one of the base plate (4, 4') and the opposing plate (6, 6').

M5. The method according to any of the preceding method aspects, wherein the rotational movement between the elastic material (2) and the separation means (10) and a linear movement between the separation means and the remaining elements effect at least partial separation of the protruding portion (22) of the elastic material (2) from the remainder of the elastic material (2).

M6. The method according to any of the preceding method aspects, wherein the rotational movement between the elastic material (2) and the separation means ( 10) effects complete separation of the protruding portion (22) of the elastic material (2) from the remainder of the elastic material (2) and wherein the separated elastic material (2) is preferably generally donut or torus shaped.

The method according to any of the preceding method aspects, wherein the separation means (10) separates the elastic material (2) along a separation plane ( 12).

The method according to any of the preceding method aspects, wherein the opposing center plate portion (14, 14') comprises a first major surface (142) facing to the direction of the base plate (4, 4') and a second major surface (144) facing to the opposite direction and wherein the opposite plate (6, 6') comprises a first surface(62), preferably facing in substantially the same direction as the second major surface (144) and a second surface (64), preferably facing in substantially the same direction as the first major surface (142). M9. The method according to method aspects M7 and M8 and further comprising the steps of locating the first major surface ( 142) of the center plate portion (14, 14') on the same side of separation plane (12, 12') as the opposing plate (6, 6'), while locating the second major surface (144) of the center plate portion (14. 14') in the separation plane (12, 12"), and fixing this position.

M10. The method according to method aspects M7 and M8 and further comprising the steps of locating the first major surface (142) and the second major surface (144) of the center plate portion ( 14, 14' ) on the same side of separation plane (12, 12') as the opposing plate (6, 6'), and fixing this position.

Mi l. The metliod according any of method aspects M8 to M10, wherein the first major surface (142) of the center plate portion (14, 14') is located on the same side of the separation plane (12, 12') as the opposing plate (6, 6') in such a manner that the distance between the separation plane ( 12, 12') and the first major surface (142) of the center plate portion (14, 14') is larger than the distance between the separation plane (12, 12') and the second major surface (64) of the opposing plate (6, 6').

M12. The method according to any of the preceding method aspects, further comprising the step of changing a distance between the separation means (10) and the elastic material (2), preferably in a direction perpendicular to the direction of adjusting the distance between the opposing center plate portion (14, 14'), and at least one of the base plate (4, 4') and the opposing plate (6, 6') and particularly to such an extent that the separation means (10) may, in a view along the first direction, overlie at least a part of the opposing center plate portion ( 14, 14') or be flush with it and most particularly to such an extent that the separation means (10) comes almost into contact with an opposing supporting member, such as a mandrel (30).

Ml 3. The method according to any of the preceding method aspects, wherein the distance between the opposing center plate section (14, 14') and both the base plate (4, 4' ) and the opposing plate (6, 6') is adjusted.

M l 4. The method according to any of the preceding method aspects and further comprising the step of fixing the opposing center plate portion ( 14, 14') to the base plate (4, 4'), preferably by means of screws or bolts.

Ml 5. The method according to any of the preceding method aspects, wherein the base plate (4, 4') and the opposing plate (6, 6') are rotationally fixed and the separation means ( 10) rotates or revolves with respect to the base plate (4, 4') and the opposing plate (6, 6').

Ml 6. The method according to any of the preceding method aspects, wherein the separation means (10) is rotationally fixed and the base plate (4, 4') and the opposing plate (6, 6') rotate or revolve about an axis of rotation parallel to the first direction.

M17. The method according to any of the preceding method aspects, wherein the base plate (4, 4') and the opposing plate (6, 6') rotate to revolve about an axis of rotation parallel to the first direction and the separation means ( 10) rotates or revolves in the opposite direction.

Ml 8. The method according to any of the preceding method aspects, wherein the opposing center plate portion ( 14, 14') rotates in the same manner as the base plate (4, 4') and the opposing plate (6, 6'). M19. The method according to any of the preceding method aspects, wherein an axis of rotation is disposed horizontal.

M20. The method according to any of the method aspects Ml to Ml 8, wherein an axis of rotation is disposed vertical.

M21. The method according to any of the method aspects Ml to Ml 8, wherein an axis of rotation is disposed tilted with respect to the vertical. M22. The method according to any of the preceding method aspects and further comprising the step of providing a spacer (34) between the base plate (4, 4') and the opposing plate (6, 6' ) defining a minimum distance between the base plate (4, 4') and the opposing plate (6, 6'). M23. The method according to arty of the preceding method aspects, wherein the method is an automated protrusion cutting method.

M24. The method according to any of the preceding method aspects, wherein the method is distortion cutting, particularly protrusion cutting.

M25. The method according to any of the preceding method aspects, wherein the method is adapted for automated cutting.

M26 The method, preferably according to any one of the preceding method aspects, the method comprising:

providing a base element,

providing an opposing center plate portion (14, 14'),

providing a pre-cut elastic material (2) adapted to fit in the cavity, providing separation means ( 10) adapted to separate at least a portion of the elastic material (2),

placing the elastic material (2) in the cavity,

adjusting a distance along a first direction between the opposing center plate portion ( 14, 14') and the base element such that a part of the elastic material (2) is prevented from protruding through the opening, effecting a rotational movement between the elastic material (2) and the separation means (10) such that the protruding elastic material is separated from the non-protruding elastic material. M27 Tine method according to aspect M26, wherein the base element is formed by a base plate (4, 4') and an opposing plate (6. 6') which are fixedly attached to each other or wherein the base element is a single monolithic base element comprising a cavity with an opening.

Here, it is to be understood that aspect M26 or M27, may be considered to be an independent aspect with any one of aspects Ml to M25 being directly and/or independently dependent thereon.

M28. The method of aspects M26 or M27, further comprising changing a distance between the separation means (10) and the opposing center plate portion (14, 14'), particularly in a direction perpendicular to the first direction and/or parallel to the first surface (62) of opposing plate (6, 6'), to effect the separation of the elastic material.

M29 The method according to any one of aspects M26 to M29 with any one of the features according to aspects M l to M25.

M29. Use of the apparatus according to any of the preceding apparatus aspects or use of the method according to any of the preceding methods aspects for forming parts or portions of a mask, particularly a medical mask, wherein the parts or portions of the mask preferably include foam cushions, forehead supports and cheek supports for masks.

Al . An apparatus for carrying out the method of protrusion cutting according to any of the preceding method aspects, preferably according to one of the preceding apparatus aspects.

101. Apparatus for cutting of elastic material (2), the apparatus comprising:

a base plate (4, 4', 1 144, 1 144' ),

an opposing center plate portion (14, 14', 11 14, 1 114') and separation means (10) adapted to, in use, separate at least a portion of the elastic material (2),

wherein

at least one of the base plate (4, 4', 1 144, 1 144') and the opposing center plate portion ( 14, 14', 1 1 14, 1 1 14') is movable relative to the others to change a distance therebetween so as to compress the elastic material (2) and to define a protruding portion (22) of the elastic material (2),

at least one of the separation means ( 10), on the one hand, and the base plate (4, 4') and the opposing center plate portion (14, 14'), on the other hand, is/are rotatable; and

the apparatus is arranged to change a distance between the separation means (10) and the opposing center plate portion (14, 14', 1 ) 14, 1 1 14') to effect the cutting of the protruding portion (22).

102. The apparatus of aspect 101, the apparatus comprising an opposing plate (6, 6', 1 146) comprising an aperture (8, 8') arranged to, in use, receive the opposing center plate portion (14, 14') wherein

at least one of the base plate (4, 4'), the opposing plate (6, 6'), and the opposing center plate portion (14, 14') is movable relative to the others to change a distance therebetween,

at least one of the separation means ( 10), on the one hand, and the base plate (4, 4'), the opposing plate (6, 6') and the opposing center plate portion (14, 14'), on the other hand, is/are rotatable.

103. The apparatus of aspect 102, wherein:

the at least one of the base plate (4, 4"), the opposing plate (6, 6'), and the opposing center plate portion (14, 14') is movable in a first direction relative to the others to change a distance therebetween, and

to effect the cutting of the elastic material, the apparatus is arranged to change the distance between the separation means (10) and the opposing center plate portion (14, 14') in a direction perpendicular to the first direction and/or parallel to a first surface (62) of the opposing plate (6, 6'). 104. The apparatus according to any one of aspects 102 and 103, wherein the opposing center plate portion (14, 14") comprises a first major surface (142) facing to the base plate (4, 4') and a second major surface (144) facing in the opposite direction and/or wherein the opposing plate (6, 6') comprises a first surface (62) and a second surface (64) and wherein, in operation, the apparatus is adapted to position the opposing center plate portion (14, 14") such that the first major surface (142) and the second major surface (144) are on the same side of a separation plane (12, 12') as the opposing plate (6, 6').

105. The apparatus according to any one of the preceding aspects 102 to 104, wherein each of the opposing plate (6, 6' ) and the opposing center plate portion (14, 14') is adapted to be movable relative to the base plate (4, 4') to change a distance therebetween.

106. The apparatus according to any one of the preceding aspects 102 to 105, wherein the base plate (4, 4'), the opposing plate (6, 6') and the opposing center plate portion (14, 14') are adapted to rotate in one direction about an axis of rotation parallel to the first direction and wherein the separation means ( 10) are stationary.

107. The apparatus according to any one of the preceding aspects 102 to 106, the apparatus further comprising a spacer (34) adapted to be interposed between the base plate (4, 4') and the opposing plate (6, 6') to define a minimum distance between the base plate (4, 4') and the opposing plate (6, 6').

108. The apparatus according to any one of the preceding aspects 1 2 to 107, wherein the opposing center plate portion (14, 14') comprises a supporting member, preferably a mandrel (30), which extends from its second surface 144, and wherein the opposing plate (6, 6') and/or the base plate (4, 4') comprise a supporting member extending in the opposite direction to the opposing center plate portion supporting member.

109. The apparatus according to any one of the preceding aspects 101-108, wherein a supporting member (30) of the opposing center plate portion ( 14, 14') does not extend through the elastic material. 110. Apparatus according to any one of the preceding aspects 102 to 109, wherein the aperture (8, 8") of the opposing plate is a first aperture (8, 8'); the opposing plate (6, 6') is movable relative to the base plate (8, 8'), the opposing center plate portion (14, 14') is movable relative to the base plate (8, 8') and is arranged to extend within the first aperture (8, 8'), so as to form a second aperture between an external periphery of the opposing center plate portion (14, 14') and an internal periphery of the first aperture (8, 8');

at least two of the base plate (4, 4'), the opposing plate (6, 6') and the opposing center plate portion (14, 14') are arranged and/or adapted to receive the elastic material therebetween and cause a portion of the elastic material to protrude through the second aperture; and

at least one of: the separation means (10) on the one hand; and the base plate (4, 4'), the opposing plate (6, 6') and the opposing center plate portion (14, 14'), on the other hand; is arranged to be movable relative to the other to bring the separation means towards the elastic material and effect the separation of the elastic material.

11 1. The apparatus of any one of the preceding aspects 101-1 10, wherein the base plate (4, 4') and the opposing plate (6, 6') are fixedly attached to each other and/or together define a base element comprising a cavity with an opening arranged for receiving a pre-cut elastic material.

112. The apparatus of any one of the preceding aspects 101-1 1 1, wherein the apparatus is adapted for forming mask cushions, forehead support portions and/or cheek support portions for patient interfaces.

113. The apparatus according to any one of the preceding aspects 101-112, wherein the opposing center plate portion ( 14, 14') has a generally triangular shape, particularly with rounded corners, when viewed in a top view from the first direction.

114. A method of cutting of an elastic material (2), preferably with an apparatus according to any one of the preceding aspects 101-113, the method comprising the steps of: providing a base plate (4, 4'), providing an opposing plate (6, 6'), the opposing plate (6, 6') comprising an aperture (8),

providing an opposing center plate portion ( 14, 14'),

providing an elastic material (2) between the base plate and the opposing plate (6, 6'),

providing separation means (10) adapted to separate at least a portion of the elastic material (2),

adjusting a distance, along a first direction, between the opposing center plate portion (14, 14") and at least one of the base plate (4, 4') and the opposing plate (6, 6') such that a portion (22) of the elastic material (2) is caused to protrude through the aperture (8),

effecting a rotational movement between the elastic material (2) and the separation means ( 10), and

changing a distance between the separation means (10) and the opposing center plate portion (14, 14')to effect the cutting of the protruding portion (22). The method according to aspect 1 14, wherein the rotational movement is between the separation means ( 10) on the one hand, and the elastic material (2), the base plate (4, 4'), the opposing plate (6, 6') and the opposing center plate portion (14, 14'), on the other hand. The method according to any one of aspects 114 and 1 15, wherein the changing of the distance between the separation means (10) and the opposing center plate portion (14, 14') is affected in a direction perpendicular to the first direction and particularly to such an extent that the separation means (10) may, in a view along the first direction, overlie at least a part of the opposing center plate portion (14, 14'). The method of any one of aspects 114 to 1 16, wherein the base plate (4, 4') and the opposing plate (6, 6') are fixedly attached to each other to form a base element (1144') with an opening, the method comprising:

providing the base element,

providing an opposing center plate portion ( 14, 14', 1 1 14, 1 114'), providing a pre-cut elastic material (2) adapted to fit in the base element such that a portion of the elastic material protrudes through the opening, providing separation means (10) adapted to separate at least a portion of the elastic material (2),

placing the elastic material (2) in the base element,

adjusting a distance along a first direction between the opposing center plate portion and the base element uch that a portion of the protruding elastic material

(2) is prevented from protruding through the opening,

effecting a rotational movement between the elastic material (2) and the separation means (10) ; and

changing a distance between the separation means (10) and the opposing center plate portion (14, 14'), particularly in a direction perpendicular to the first direction and/or parallel to the first surface (62) of opposing plate (6, 6'), to effect the separation of the protruding elastic material from the non-protruding elastic material. The method of aspect 1 17, wherein the base element is a monolithic base element. Use of the apparatus according to any one of the aspects 101 to 1 13 or use of the method according to any of aspects 114 to 1 18, for forming parts or portions of a mask, particularly a medical mask, wherein the parts or portions of the mask preferably include foam cushions, forehead supports and cheek supports for masks. Apparatus for cutting of elastic material (2), the apparatus comprising:

a base plate (4, 4'),

an opposing center plate portion (14, 14')·

an opposing plate (6, 6') comprising an aperture (8, 8') arranged to, in use, receive the opposing center plate portion (14, 14', and

separation means (10) adapted to, in use, separate at least a portion of the elastic material (2),

wherein

at least one of the base plate (4, 4'), the opposing plate (6, 6') and the opposing center plate portion (14, 14') is movable relative to the others to change a distance therebetween, compress the elastic material inserted therebetween and define a protruding portion (22) of the elastic material (2), W

at least one of the separation means i 10), on the one. hand, and the base plate (4, 4'), the opposing plate (6, 6 ^s ) and the opposing center piate portion (14, 14% on the other hand, is/are rotatable with respect to the other, and

the apparatus is arranged to change a distance between the separation means ( 10) and the opposing cester piste portion (14. 14") to effect the cuttin of the protruding portion (22).

Brief descri tion of the drawings

The disclosed technology will become more fully understood from the detailed description given hereinafter and the accompanying drawings which are given by way of illustration only, and thus, are not .limitative of the disclosed technology, and wherein:

Figs. la~h and 2a-b are sectional schematic views of protrusion cutting devices according to the prior art;

Figs. ¾-b is a sectional schematic view of a compression cutting device according to the prior art;

Fig. 4a is a schematic perspective view of an apparatus for protrusion catting in accordance with an embodiment of the disclosed technology; Fig. 4b is a top view of the arrangement of Fig. 4a;

Figs. S¾--e are schematic cross-sectional views of an apparatus for protrusion cutting is accordance with an embodiment of the disclosed technology illustrating different configurations of such an apparatus;

Fig. 6&-e are schematic cross-sectional views of an apparatus for rofession cattin in accordance with an embodiment of the disclosed technology illustrating different configuration of such an apparatus;

Figs. 7a~7c are schematic cross-sectional views of an. apparatus for protrusion cutting in accordance with a first non-planar cutting embodiment of the disclosed technology;

Figs. 8a-b are schematic crons-sectionai views of as apparatus for protrusion cutting in accordance with a second non-planar cutting embodiment of the disclosed technology;

Fig, 9 is a schematic cross-sectional view of an apparatus for protrusion cutting in accordance with a further embodiment of the disclosed technology; and is a schematic cross-sectional view of an apparatus for protrusion cutting ^' accordance with yet another embodiment of the disclosed teclmologv.

List of reference numerals

2 elastic material

4 base plate

6 opposing plate

8 aperture of opposing plate

10 separation means

12 separation plane

14 opposing center plate portion

16 template

18 base mandrel

22 protruding portion of the elastic material

30 opposing mandrel

32 screw

34 spacer

62 first surface of the opposing plate

64 second surface of the opposing plate

142 first major surface of the opposing center plate portion

144 second major surface of the opposing center plate portion

200 cut foam section (solid)

202 cut foam section (donut or torus shaped)

203 opening or hole A arrow

Al , A3, A4 arrows indicating applied force

A2 arrow indicating direction of movement

OA opposing arrow

R circular arrow Detailed description of preferred embodiments

Reference is now made to embodiments according to the disclosed improved technology.

Turning to Figures 4a and 4b, an embodiment of the disclosed technology may provide a base plate 4 and an opposing plate 6 having an aperture 8. In particular. Figures 4a and 4b depict a respective perspective and planar view of an embodiment of the disclosed technology, whilst Figures 5a-5cdepict cross-sectional views or embodiments of the technology. As indicated in Figure 4a, the base plate 4 may be connected to opposing plate 6 by fasteners 32. In a simple embodiment, the fasteners 32 may include nuts and bolts. However, in more advanced configurations, such fasteners may be hydraulic, pneumatic or mechanical. The fasteners may be used to manually or automatically adjust the compression of an elastic material 2, e.g. foam, positioned between the base plate 4 and the opposing plate 6.The elastic material 2, such as a block of foam, may be placed between base plate 4 and opposing plate 6. The elastic material may comprise a variety of materials e.g. open or closed cells foams, rubbers, gels, felted textiles. One criterion is that the material can be defonned temporarily under pressure, cut or separated and then released to recover. As indicated by two-sided arrows A3 in Figure 5a and arrows A4 in Figure 5b, the distance between base plate 4 and opposing plate 6 may be altered and adjusted to effect the compression of the elastic material 2.

After the elastic material 2 (e.g. foam) is placed between base plate 4 and opposing plate 6, the distance between these two plates may be decreased. This can be achieved by the standard mechanical or pneumatic mechanisms that cause the driving force A3. In turn, the material 2 is compressed while a portion 22 of the foam and extends through opening 8 and protrudes beyond the surface of the opposing plate 6. The opposing center plate portion 14 may be supported on a mandrel 30 and comprise a first major surface facing the foam 2, the base plate 4 and/or the opposing plate 6, as well as an opposing second major surface facing away therefrom. The mandrel 30 extends, preferably from the opposing second major surface, into the direction away from the foam 2, (he base plate 4 and/or the opposing plate 6. Other supports may be possible. Base plate 4 may be positioned on mandrel 18 or other supporting means. In the present embodiment, mandrel 30 supporting opposing center plate portion 14 is disposed on the side of center plate portion 14 opposing the side facing base plate 4. As indicated by arrowAI in Figures 4 and 5a and as indicated by arrow A in Figure 5b, the opposing center plate portion 14 and mandrel 30 may have a non-constant or varying distance from base plate 4. As shown in Figure 5b. this may allow opposing center plate portion 14 to come into contact with foam 2 and to prevent a portion of foam 2 from protruding through the opening or aperture 8.

The shape of the opposing center plate portion 4 is such that the opposing center plate portion can be positioned in the aperture 8 of the opposing plate 6, preferably without touching the same, and further preferably while allowing a gap to be established at least along at least a major part of the circumferential sides of the opposing center plate portion 4 and circumference of the aperture 8 of the opposing plate 6. The gap is preferably such that elastic material 2 may extend therethrough.

The disclosed technology further provides a separation device or cutter 10. This separation device 10 may be realized as a blade, a knife, a saw, particularly a continuous saw, such as a band saw, a circular saw or a turkey cutter, or as a wire, particularly a hot wire. As indicated by arrow A2 in Figure 4, the location of separation device 10 with respect to the remainder of the apparatus may be varied. In particular, a distance between separation device 10 and an axis of mandrel 30 and/or an axis of mandrel 18 may be varied, effectively varying the distance between separation device 10 and the opposing centre plate portion 14, as well as the distance between separation device 10 and the elastic material 12. By varying the distance, the separation device 10 may cut into the protruding portion 22 of the elastic material or foam 2, as depicted, e.g., in Figure 5c. Further, the apparatus is adapted such that at least one of the combination of base plate 4, the opposing plate 6 and the opposing center plate portion 14 (and thus the elastic material 2 which is compressed between them), on the one hand, and the separation device 10, on the other hand, may rotate with respect to one another. In the embodiment shown, this is achieved by the base mandrel 18 being rotatable together with the base plate 4, the foam 2 and the opposing plate 6, whilst the separation device does not rotate. Further, it is also preferred that also the second mandrel 30 supporting the opposing center plate portion 14 may rotate, preferably synchronized with the base plate and the opposing plate. This is indicated by circular arrows R in Figures 4 and 5c.

However, it may also be possible that instead of these components, the separation device 10 may be the rotatable component. Tn such an embodiment, base mandrel 18, base plate 4, foam 2, opposing plate 6, opposing center plate portion 14 and second mandrel 30 supporting opposing center plate portion 14 may be rotational!y fixed or non-rotatable and separation device 10 may rotate with respect to these components. However, in another embodiment, all afore-mentioned components may be rotatable with the separation device being rotatable separately from and, e.g., in another direction, base plate 4, the opposing plate 6 as well as the opposing center plate portion 14 and thus the elastic material 2. In such an embodiment, separation device 10 and the components other than separation device 10 may, in particular, rotate in opposing directions. For example, the separation device 10 may rotate in a clockwise direction and the remaining components may rotate in counter clockwise direction, or vice versa.

In other words, the separation device 10 and the remaining components may rotate with respect to one another. Thus, according to Figure 5c, the separation device 10 may cut into a protruding portion 22 of elastic material 2 and due to the relative rotational movement of the protruding portion 22 and the separation device 10 cut all along the protruding ring like portion 22 and thus finally sepai'ate or cut off the protruding portion 22 from the remainder of the elastic material 2.The separation means can either follow closely the top surface of the opposing plate or move at some distance above the surface. In some cases, the distance above the surface may be varied, e.g. to form a protrusion on the cushion's surface. With this arrangement the separation device 10 can cut and separate completely the protrusion portion 22 from the rest of the foam, without interfering with the axes of the second mandrel 30. The relative rotation of the separation device 10 with respect to the other component may be a full rotation of 360°. However, it may also be possible that this rotation is larger, i.e. more than 360° to allow for a more secure separation of the cut section 202 from the remaining elastic material 2. Further, depending on specific elastic material designs, the rotation may also be left incomplete, that is less than 360° and preferably less than 300° to leave at least a part of the protruding portion 22 of the elastic material 2 attached to the remaining elastic material. In other words, the disclosed technology generally utilizes a two-compression mechanism arrangement and. by allowing or providing circular cutting path that separates, e.g. cuts around the axes of the compression mechanism, provides an improved, easy to handle and operate manufacturing system.

In one embodiment of the technology, a body of a sample of an elastic material 2, e.g. soft foam is compressed at its periphery by a mechanism. The mechanism comprises and preferably consists of a base plate 4, on which the uncompressed body of foam 2 is placed and a first or opposing plate 6 that, in operation, is positioned above the foam 2 and pressed towards the base plate 4. The first or opposing plate 6 contains an aperture 8 through which the uncompressed portion of the foam 2 may extend such as to protrude above the first plate surface 62. A second mechanism, which in the illustrated drawing is in the form of a second plate or opposing center plate section 14, acts on the body of the foam 2 from above to compress a portion 22 of the foam 2 that would otherwise protrude above the level of the first plate 6, such that the upper level of the second plate 14 is below a second surface or cutting level of the first plate 6. This second mechanism is preferably driven by a mandrel 30. Once the first and the second opposing plates 6 and 14 are in operational position, both a peripheral and a central portion of the foam 2 are depressed below the cutting level of the first plate 6, whilst an annulus formed by an intermediate portion of the foam 2 protrudes above the first plate 6 and the second plate 14. A separation device 10, e.g. a cutter or knife, is then introduced across the foam 2, cutting it inwardly at one end until it reaches the mandrel 30. The plates with the foam 2 are rotated to complete the cutting process for the entire body of the foam 2 to produce the desired shape. Preferably, the upper mandrel 30 is rotated as well - that is, it is synchronously rotated. The rotation may be slow and extend only one or two cycles. Alternatively, the separation device, the remaining elements or both the separation device and the remaining elements may be rotated for a large number of C3'cles and at high speed during the entire cutting process. A minimal difference may be introduced between the rotational speed of the base plate 4 and the first opposing plate 6, and/or the speed of the mandrel rotating the second opposing plate 14. Such a difference will introduce a shear or twist in the elastic material. This would then change the compressed shape, which in turn would result in a slightly different cut shape. Furthermore, any of the plates could have a slightly different rotational speed relative to one another. In one example, the base plate may rotate at 1 rpm, the opposing plate at 1.1 rpm, and the centre opposing plate at 1.2 rpm. In the course of 1 rotation, the top of the elastic material will be rotated by 0.1 revolutions or 36 degrees relative to the bottom. The centre opposing plate would rotate by 0.2 revolutions or 72 degrees. If the aperture formed between the opposing plates were essentially circular (a doughnut) then this would only affect the sectional profile of the cut piece. However, if the aperture were not circular, then the size of the aperture would change also during rotation, which would affect the hole shape of the part.

In the above arrangement, the elastic material 2, such as the foam, is compressed between a base plate 4 and two or more top plates 6, 14.The outer top plate (first plate) 6 is pulled down from below. Alternative examples, where the plate is pressed from above are also envisaged, as long as they do not obstruct the top surface of the plate 6 that serves as a cutting plane 12 (to be discussed later re Fig. 6). The inner top plate (second plate or opposing center plate portion) 14 is pushed down from above using a mandrel. The two top plates 6, 14 leave a gap between them that creates a, preferably closed or ring shaped, aperture through which a portion of the elastic material 2, e.g. foam protrudes. The plates or a separation device 10, e.g. a knife, revolve around an axis and cut the protaiding foam in a circular motion. The method could also make an open "horseshoe"-type shapes. The circular path that cuts around and avoids interference with the axes of the compression mechanism or mandrel 30 may be achieved, as further described herein, by rotating movement of the apparatus including base plate 4,4', opposing plate 6, 6' and opposing center plate portion 14, 14' on the one hand and/or separation means 10 on the other hand. The movement does not have to be mathematically circular or rotating around a fixed axis. Rather, the combination of movements which include rotations allows the separation means to cut along the protruding material without interfering with the positioning or handling portions, such as mandrel 30.

Due to the action of the second plate 14 a hole or void is created in the body of the foam 2.Different first and/or second plate shapes would allow different protrusion aperture shapes to be created.

Further, in Figs. 5a, 5b and 5c, there is also depicted a spacer or stopper plate 34. This spacer or stopper plate 34 may be provided in different thicknesses to achieve and preset differing degrees of foam compression. Spacer 34 may in particular be rectangular, oval or other ring-like shapes. Further, it is preferred that spacer 34 is made of a rigid material, such as metal. Spacer 34 is adapted to determine to what degree the elastic material 2 may be compressed between the base plate 4, 4' and the opposing plate 6, 6 ^* . In other words, spacer 34 defines a minimum distance between base plate 4, 4' and opposing plate 6, 6'. The spacer 34 may be flush with the base plate 4, 4' and/or the opposing plate 6, 6'. In other words, the spacer 34 may have essentially the same outer diameter as at least one of the base plate 4, 4' and the opposing plate 6, 6\ Further, the base plate 4, 4' may also have the same outer diameter as the opposing plate 4, 4', i.e. may be flush with it. Further, it may be preferred that there are provided a plurality of spacers 34 which can be chosen by the skilled artisan, depending on the desired compression. Other spacer mechanisms or stoppers, such as cylinders around the supports 33, which limit the distance between the two plates, may be used. Additionally, the mechanism or drive A3 that provides the compressive force may also have its own method to limit the travel of one or more of the plates and hence the amount of compression of the elastic material.

As seen in, e.g., Figures 5a to 5c, the opposing plate 6 may be connected and/or moved relative to base plate 4 by posts or supports 33. There may be 3, 4, 5 or more supports 33. The supports are preferably arranged such that they do not pass through or interfere with material 2. In particular, they may be arranged to be distanced from material 2 as can be seen in Figures 5b and 5c, despite the fact that, as is apparent from the view according to Fig. 5a, in a certain view material 22 may still overlap supports 33. Supports 33 may be automatically driven, such as mechanical screws or hydraulic cylinders, to arrange appropriate compression and/or movement of the parts, as referred to above.

A further configuration of the cutting process is discussed in conjunction with Figures 6a- e. Similarly to some of the other figures, these figures also depict schematically only a specific section of the inventive apparatus, which is under consideration. For instance, the base plate 4 and the supports 33 have been omitted in Figs. 6a-e for succinctness. Opposing center plate portion 14 comprises two major surfaces. The first major surface 142 faces In the direction of base plate 4 and is adapted to come into contact with elastic material 2. The second surface 144 faces in the opposite direction and is typically supported by mandrel 30. However, other means of support may also be possible. According to Figure 6a, the cutting or separation plane 12on which separation device 10 operates, e.g., cuts the protruding portion 22 of the elastic material 2, generally is slightly "above" or at the same level as a first surface 62 of opposing plate 6. Preferably, it is provided by the first surface of opposing plate 6. However, with regard to the term "above", it is to be understood that this term is illustrative only to provide a clear and easy understanding of the respective Figures. This term should not be construed to limit the disclosed technology to certain configurations with regard to the gravitational direction. Even though using the term "above" may provide an easier and more intuitive understanding of the respective Figures, the skilled artisan will also understand that the disclosed technology is not limited to a certain configuration of the inventive apparatus in space. For example, the inventive apparatus may be rotated at an angle of 90° (or 180° etc.) so that the cutting plane 12 is not disposed horizontally, but vertically instead. Further, it is also possible to provide the inventive apparatus "upside down" with regard to the respective Figures. That is, base plate 4 may be provided "above" opposing plate 6. Further, the skilled artisan will also understand that the last paragraph not only applies to the term "above", but to any such term, such as "below", if not explicitly stated differently or if not principally clear that this term is meant in a limited manner.

Figures6a and 6b show an intermediate configuration where the separation plane 12 is interposed between the major surfaces 142 and 144 of opposing center plate portion 14 or on level with the second major surface 144 of opposing center plate portion 14. While cutting the elastic material in these configurations is possible, special measures need to be taken to ensure smooth interaction between the separation device 10 and the peripheral wall of the opposing center plate 14. In the preferred embodiments shown in Figures 6c and 6d and 6e, the separation plane 12 extends "above" second major surface 144 of opposing center plate portion 14. The amount of how much these two surfaces may be separated from one another may be varied between minimal (shown in Figure 6c), intermediate (shown in Figure 6d) and substantial (shown in Figure 6e). In more general terms, in these configurations, first surface 62 of opposing plate 6 and second major surface 144 of opposing center plate portion 14 are disposed on the same side of cutting or separation plane 62. Such an embodiment may be particularly preferred as it allows for a particularly easy separation process without the risk of the separation device 10, particularly, e.g., a blade thereof, coming into contact with second major surface 144 of opposing center plate portion 14. It should be appreciated that opposing plate 6 does not necessarily have to be planar. Instead, it could also have other shapes. For example, it could have the shape of a generally truncated cone, as depicted in Figures 7a-7c. In such a configuration, opposing center plate portion 14' is preferably conically shaped. In the embodiment shown in Figures 7a-7c, base plate 4 is depicted to be generally planar. If the elastic material 2 is compressed in such a configuration, this may result in different levels of compression due to the varying distance between base plate 4 and opposing plate 6'. Generally speaking, according to certain embodiments of the disclosed technology, one of the base plate 4, 4 ^' and the opposing plate 6, 6' may be planar and the other may not be planar.

In Figures Sa and 8b, an embodiment is shown wherein both, the base plate 4' and the opposing plate 6' are non-planar and, in the particular embodiment, are conical. Again, it is then preferred that the opposing center plate portion 14' is also conical with a profile that matches that of opposing plate 6'. However, the person skilled in the art will readily understand that in this embodiment, as well as in the embodiment discussed in conjunction with Figures 7a-7c, the opposing center plate portion 14' may also be planar.

Similar to the embodiments shown in Figures 7a-7c, the embodiments of Figures 8a and 8b may define, depending on the radial distance and/or direction, varying distance between the base plate 4' and the opposing plate 6'. This may vary the compression of the elastic material (foam 2) and, therefore, the thickness and the shape of both the cutoff 22 and the remaining foam material 2. Exemplary for all the embodiments shown in Figures 7a-8b, the separation or cutting plane 12' will be discussed in conjunction with Figure 7b. In this regard, there appears to be a left-hand side separation plane 12' and a right hand side separation plane 12'. When the remaining components rotate or revolve with respect to the separation device 10, the two separation planes 12' may coincide by the rotational symmetry. However, the two separation planes 12' do not have to be rotationally symmetrical, if the cutting blade can accurately follow the change in height of the surface 12' as the mechanism rotates. That is, if the cutting device 10 can controllably move up and down as well as in and out of the shape formed by surface 12'. The technology also covers all further features shown in the figures individually although they may not have been described in the afore description. The disclosed technology covers further embodiments with any combination of features from different embodiments described above. For example, whilst the base plate. 4, the opposing plate 6 and the opposing center plate 14 are illustrated in specific shapes, other forms and configurations are also possible. For example, the base plate and the opposing plate 6 may not be circular, but square or rectangular. Similarly, the opposing center plate 14 may be not triangular, but have other shapes, such as square or rectangular, depending on the shape that needs to be cut. Reference signs in the claims are provided merely as a clarifying example and shall not be construed as limiting the scope of the claims in any way.

In another example schematically illustrated in Fig. 9, the system may comprise only a base plate 1 144 and an opposing center plate portion 1 114. In this arrangement the elastic material is placed on the base plate and at least one of the base plate and the opposing center plate portion is moved towards the other until the required foam compression and the associated protrusion (above the upper surface of the opposing center plate portion 1 114) is achieved. The two plates are then rotated and the knife is brought in contact with the protruding foam to effect the cutting along a plane on or above the upper surface of the opposing center plate portion. The compression in this example will only be achieved in the central portion of the foam, as there is no opposing plate to press the peripheral sections of the foam. In the general case where a square slab of foam is used, the arrangement will produce a foam cut-out with a straight line outer edge in the cross- sectional profile. However, cross-sectional profile edge of other shapes may be achieved by preforming the edge of the initial foam slab.

The apparatus and the method described in the previous examples comprise configurations where the distance between the base plate and the opposing plate is reduced to compress the periphery of the foam and effect its protrusion through a central opening. Alternatively, the base plate and the opposing plate may be attached together in a single base element. In one embodiment, such a base element may be a monolithic element, such as the box 1 144' shown in Fig. 10. The ceiling of the box includes a portion 1146 that extends above the periphery of the box cavity similarly to the way the opposing portion 6 does in Figs. 5a and 5b. An insertion opening 1 1 18 defined by the portion 1 146 enables a pre-cut elastic (e.g. foam) material to be placed on the base plate inside the box, as shown in Fig. 10. The height of the box is smaller than the thickness of the foam, when the foam is in its normal expanded configuration. However, the height of the box and the foam thickness are chosen so that when the foam is inserted in the box 1 144', its periphery is depressed and its thickness in the peripheral region, located under the peripheral top portion 1 146, is defined by the height of the box 1 144'. Thus, the base 1 1 0 of the box corresponds to the base plate 4 of Figs 4 and 5 and the peripheral top portion 1146 of the box corresponds to the opposing plate 6 of Figs 4 and 5. The insertion opening 1 1 18 enables the foam to be, manually or otherwise, inserted into the space between both. In another example (not shown), the foam insertion opening may be formed not in the top portion, as shown in the Fig. 10, but in a side wall of the box.

The opening 1 1.18 in Fig. 10, used for inserting the foam, can also be used for advancing the central portion plate 14 into the body of foam. As the height of the box is smaller than the thickness of the foam, foam within the central opening 1 1 18 will protrude above the box top. Either one of the box 1 144' or the opposing center plate portion 1 1 14 may then be moved to urge a region of the protruding elastic material engaged by the opposing center plate portion 11 14 to be compressed into the cavity to arrive at a state generally similar to that illustrated in Fig. 10. The rotation and the cutting can then be performed as described above, i.e. the monolithic base element (supported by a supporting element such as mandrel 18) and the opposing center plate portion 1 1 14' (supported by mandrel 30) are rotated to effect a rotation of the protruding elastic (e.g. foam) material. The separation means are then brought in contact with the protruding elastic material to effect the cutting.

In a further variation, the box 1144' may not include the top periphery portion 1 146 and may comprise only the base 1150 and the side walls 1 148. Such an arrangement will be equivalent to removal of the opposing plate, thus reducing the arrangement to the base plate 4 and the opposing center plate portion 14 only combination illustrated in Fig. 9.

It is clear from the above description that, as the base plate and the opposing plate in the above example are affixed with respect to each other within a single base element, the only relati ve movement will be between this base element and the central portion plate. In one example, this relative movement comprises moving the central portion plate towards the base element (comprising the base plate and the opposing plate). In another example, the opposing plate and the opposing central plate may be fixed (as far as vertical movement is concerned) and only the base plate is movable in a vertical direction. In this arrangement the elastic material is placed on the base plate and the base plate is moved towards the opposing plate and the opposing center plate portion, until the required foam compression and protrusion is achieved. The three plates are then rotated and the knife is brought in contact with the protruding foam to effect the cutting.

Also, whilst the above description described the separation (or cutting) means 10 as a part of the entire system, this is not necessarily the case, in another example, the system may comprise only the base plate, the opposing plate and the central opposing plate portion. The elastic material may be fastened between these elements and rotated. The system may also be arranged to move, e.g. in a linear fashion, towards stationary cutting means, it would be appreciated that such an arrangement will allow external cutting means to be used, such as a standard cutting blade affixed by way of any supporting means, as the cutting means need not rotate or move in any manner at all.

The disclosed technology also covers the exact terms, features, values and ranges etc. in case these terms, features, values and ranges etc. are used in conjunction with terms such as about, around, generally, substantially, essentially, at least etc. (i.e., "about 3" shall also cover exactly 3 or "substantially planar" shall also cover exactly planar). The terms "a", "an", "first", "second" etc. do not preclude a plurality.