Cross-Reference to Related Application

[0001] The present application claims the benefit of U.S. Provisional Application No. 63/330,838, filed April 14, 2022.

Background

[0002] The present invention generally relates to thermoforming, and, more particularly, to vacuum thermoforming.

[0003] Vacuum thermoforming is known to include heating an imperforate sheet of thermoplastic material so that it becomes pliable, using a vacuum to draw the pliable sheet against the face of a mold so that the pliable sheet “takes” the shape of the mold face, and then cooling and removing the molded sheet from the mold, so the molded sheet retains the shape of the mold face. After vacuum thermoforming, the molded sheet can be cut, and this cutting can include forming through holes in the molded sheet.

[0004] In some situations, it can be relatively challenging to accurately cut through holes in contoured surfaces of molded sheets after thermoforming.

Brief Description of the Drawings

[0005] The drawings are provided as examples. The present invention may be embodied in many different forms and should not be construed as limited to the examples depicted in the drawings.

[0006] Fig. l is a schematic exploded view of a thermoforming system, in accordance with a first embodiment of this disclosure.

[0007] Fig. 2 is a schematic, side cross-sectional view depicting selected components of Fig. 1 in an assembled, closed configuration, wherein the interior of a differential pressure chamber (e.g., vacuum chamber) of the system is at ambient pressure and positioned beneath heating elements, in accordance with an exemplary implementation of the first embodiment. [0008] Fig. 3 is an isolated, top pictorial view of a multi-cavity mold of the system of Fig. I- [0009] Fig. 4 is an isolated, top plan view of a flat, thermoform able precursor sheet of the system of Fig. 1.

[0010] Fig. 5 is an isolated, top plan view of a flat, thermoformable blank of the precursor sheet of Figs. 1 and 4.

[0011] Fig. 6 is an isolated, top plan view of an upwardly concave, multistable body that was thermoformed (e.g., vacuum thermoformed) from the blank of Fig. 5, in accordance with the first embodiment.

[0012] Fig. 7 is a schematic side view of a thermoforming machine (e.g., vacuum thermoforming machine) with its vacuum chamber open, in accordance with a second embodiment.

[0013] Fig. 8 schematically depicts the machine of Fig. 7 with its vacuum box beneath a heater.

[0014] Fig. 9 depicts the machine of Fig. 7 with a partial vacuum in its closed vacuum chamber.

[0015] Fig. 10 is a schematic side view of a thermoforming machine (e.g., vacuum thermoforming machine) with its vacuum chamber open, in accordance with a third embodiment.

[0016] Fig. 11 schematically depicts the machine of Fig. 10 with its vacuum box beneath a heater.

[0017] Fig. 12 depicts the machine of Fig. 10 with a partial vacuum in its closed vacuum chamber.

[0018] Fig. 13 is a schematic side view of a continuous-production vacuum thermoforming machine of a fourth embodiment.

[0019] Fig. 14 is a schematic side cross-sectional view of an example of a thermoforming system (e.g., vacuum thermoforming system), wherein the interior of the vacuum chamber of the system is at ambient pressure, in accordance with a fifth embodiment of this disclosure.

[0020] Fig. 15 is an isolated, schematic, top plan view of a flat, thermoformable blank of the precursor sheet of Fig. 14, in accordance with the fifth embodiment.

[0021] Fig. 16 is an isolated, schematic side view of a body that was vacuum thermoformed from the blank of Fig. 15, in accordance with the fifth embodiment. [0022] Fig. 17 is a schematic top plan view of a flat, thermoformable, multi-layer blank in accordance with a sixth embodiment of this disclosure.

[0023] Fig. 18 is a schematic cross-sectional view taken along line 18-18 of Fig. 17.

[0024] Fig. 19 is a schematic top perspective view of a multistable thermoformed laminate (e.g., tissue bridge) formed from the blank of Figs. 17-18, wherein the multistable thermoformed laminate is depicted in its extended stable equilibrium configuration, in accordance with the sixth embodiment.

[0025] Fig. 20 is a schematic exploded, top perspective view of the multistable thermoformed laminate of Fig. 19 in its extended stable equilibrium configuration. [0026] Fig. 21 is a schematic top perspective view of the multistable thermoformed laminate of Fig. 19 in its extended stable equilibrium configuration without release liner pieces, in accordance with the sixth embodiment.

[0027] Fig. 22 is a schematic top perspective view of the multistable thermoformed laminate of Fig. 21 in its retracted stable equilibrium configuration.

Detailed Description

[0028] Examples of embodiments are disclosed in the following. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. For example, features disclosed as part of one embodiment or example can be used in the context of another embodiment or example to yield a further embodiment or example. As another example of the breadth of this disclosure, it is within the scope of this disclosure for one or more of the terms “substantially,” “about,” “approximately,” and/or the like, to qualify each of the adjectives and adverbs of the Detailed Description section of disclosure, as discussed further below. [0029] A general discussion of at least a portion of a thermoforming system of a first embodiment of this disclosure is provided in the following with reference to Figs. 1 and 2, followed by more detailed discussions. Generally described, examples of the thermoforming systems of this disclosure are configured to use differential fluid pressure to facilitate the thermoforming, and this differential fluid pressure is not limited to requiring a partial vacuum. More specifically, the thermoforming system of the first embodiment is configured to use a partial vacuum in the thermoforming (e g., vacuum thermoforming). Stated differently, vacuum thermoforming may be more generally referred to as thermoforming using differential fluid pressure.

[00301 Referring to Fig. 1, the first embodiment system includes a vacuum container apparatus 12, at least one mold 14 (e.g., a multi-cavity mold apparatus or multi-mold apparatus) configured for use in vacuum thermoforming, a thermoformable precursor sheet 16, and a cover 18. Throughout the reminder of this Detailed Description section of this disclosure, the vacuum container apparatus 12 is referred to as a box apparatus 12 for ease of understanding, but not for the purpose of limiting the scope of this disclosure.

[0031] The precursor sheet 16 of the first embodiment comprises one more layers of material, at least one of which has properties (e.g., thermoplasticity) suitable for allowing the precursor sheet to be transformed by way of a vacuum thermoforming process (e.g., including using the cover 18). The precursor sheet 16 can be a single-layer sheet or a multilayer sheet that may be heated from one or both sides with the same or different heat rates or heat fluxes, as discussed further below. In the first embodiment, the box apparatus 12, precursor sheet 16, and mold 14 are cooperatively configured (e.g., at least the precursor sheet is configured) so that the precursor sheet is restricted from being (e.g., cannot be or substantially cannot be) vacuum thermoformed over the mold 14 on the box apparatus 12 without using, for example, the cover 18 or a portion thereof, or another suitable structure, as discussed further below.

[0032] In the example depicted in Fig. 1, the box apparatus 12 includes a container 20 defining an interior space 22 and an upper opening 24 to the interior space. The container 20 can be or include any suitable container, for example a container in the form of a box. Throughout the reminder of this Detailed Description section of this disclosure, the container 20 is referred to as a box 20 for ease of understanding, but not for the purpose of limiting the scope of this disclosure. The box apparatus 12 typically further includes at least one conventional vacuum pump 25, and one or more of any associated conventional vacuum tanks, passageways, holes, fittings, tubing, and/or piping, in fluid communication with the box interior space 22 for creating a partial vacuum therein, as discussed further below. Alternatively, the box 20 may be omitted and the partial vacuum can be supplied more directly to an interior space in the mold 14, as discussed further below. [0033] The first embodiment box apparatus 12 includes at least one support structure 26 proximate (e.g., obstructing without closing) the box upper opening 24. The support structure 26 is configured so that the box upper opening 24 is not sealed closed by the support structure. For example, the support structure 26 can define a plurality of openings 28 (e g., through holes) extending through the thickness of the support structure. A variety of differently configured support structures 26 are within the scope of this disclosure, as discussed further below. Also, the support structure 26 and/or the box 20 may be omitted, as discussed further below.

[0034] The cover 18 can include or be in the form of at least one flexible (e.g., elastic) cover sheet 32 (e.g., an elastic multilayer laminate including silicone, elastic sheet of silicone, and/or other suitable structure(s)). In some configurations, the cover sheet 32 can be draped over the precursor sheet 16 on the mold 14. As another example, the peripheral edges or margins of the cover sheet 32 can optionally be mounted to an annular edging 34 (e.g., a centrally open frame, bezel and/or any other suitable structure) with suitable fasteners (e.g., staples, nails, and/or screws) and/or other suitable fastening techniques. The cover’s edging or centrally open frame 34 can include four sidepieces that are respectively joined to one another end to end, or the like, at miter joints and/or any other suitable joints with suitable fasteners and/or fastening techniques.

[0035] In some examples, the cover’s edging or frame 34 may be omitted, the frame may or may not be referred to as a portion of the cover 18, and/or a variety of differently configured frames are within the scope of this disclosure. In an example, the frame 34 may be omitted and the cover sheet 32 can be draped over the layered assembly including at least the mold 14 and the precursor sheet 16. As another example, the frame 34 can include one or more mullions (not depicted) and/or other suitable structures to which respective portions of the cover sheet 32 are mounted. As a further example, the cover sheet 32 can be replaced with multiple cover sheets having margins respectively mounted to the one or more mullions (e.g., structural mullions, structural crossmembers, and/or centrally located frame members). A wide variety of differently shaped boxes 20 and covers 18 are within the scope of this disclosure, as discussed further below.

[0036] For the example depicted in Fig. 2, when respective components of the system are in an assembled, closed configuration without a partial vacuum in the box interior space 22 (“closed non-vacuum configuration”): the box upper opening 24 is obstructed by, without being fully closed by, the support structure 26; a flat lower surface of the mold 14 is engaged against and supported by an upper flat surface of the support structure; and respective portions of the lower surface of the precursor sheet 16 are engaged against and supported by an upper surface 35 of the mold.

[0037] Referring in greater detail to Fig. 1, the box 20 can include an upwardly facing annular seating surface 36 that extends around the box upper opening 24. In the example of the closed non-vacuum configuration depicted in Fig. 2, a flat annular marginal portion 32M of the cover sheet 32 is engaged against the container’s seating surface 36, and some of a central portion 32C of the cover sheet 32 is engaged against and supported by the upper surface of the precursor sheet 16. In the example of Fig. 2, the cover sheet 32 includes an annular intermediate portion 321 between the cover sheet’s central and marginal portions 32C, 32M. In the closed non-vacuum configuration, the cover intermediate portion 321 can be in the form of multiple (e.g., four) inclined sheet portions that are respectively connected (e.g., end-to-end) to one another. Each of the inclined sheet portions can be in the shape of (e g., generally or substantially in the shape of), for example, a trapezoid, isosceles trapezoid, planar isosceles trapezoid, or other suitable shape(s), or the like.

[0038] In accordance with the first embodiment, the mold 14, precursor sheet 16, and support structure 26 are configured so that they do not fully close the box upper opening 24 (Fig. 1). Stated differently for the first embodiment, when the cover 18 is open, the box interior space 22 remains open to the ambient environment through openings in the mold 14, precursor sheet 16, and support structure 26, as discussed further below. Accordingly for the first embodiment, the precursor sheet 16 cannot be reasonably vacuum thermoformed when the cover 18 is open.

[0039] In contrast, the precursor sheet 16 can be reasonably vacuum thermoformed when the cover 18 is closed. More specifically, in the closed configuration depicted in Fig. 2, at least the first embodiment cover 18 forms an imperforate and non-porous (e.g., substantially non-porous) top covering that is sealed closed around the periphery of the box upper opening 24 and extends continuously over the entirety of the box upper opening, support structure 26, mold 14, and precursor sheet 16. In the example depicted in Fig. 2, a portion of the lower surface of the cover sheet 32 is engaged against the container seating surface 36. More specifically, the cover marginal portion 32M can be directly engaged (e g., hermetically sealed) against the box seating surface 36.

[00401 I ⁿ the first embodiment, the box 20 together with the closed cover 18 at least partially forms a vacuum chamber. The first embodiment vacuum chamber comprises the cover 18 together with the box 20 and/or the box apparatus 12. More specifically, the cover 18 in its closed configuration is cooperatively configured with the box apparatus 12 in a manner that allows the box interior space 22 together with the volume beneath the cover central and intermediate portions 32C, 321 to function as an interior space of the vacuum chamber.

[0041] In the configuration depicted in Fig. 2, the vacuum chamber is cooperative with respective components so that at least a portion of the sufficiently heated precursor sheet 16 can be vacuum thermoformed when the cover 18 is closed and the vacuum pump 25 (Fig. 1) is operated (“closed vacuum-thermoforming configuration”). More specifically, one or more portions 30 (e.g., blank portion(s)) of the precursor sheet 16 can be vacuum thermoformed during the closed vacuum-thermoforming configuration, as discussed further below. The precursor sheet 16 can be heated by one or more heaters 80 that are schematically depicted with dashed lines in Fig. 2 and/or the heating can be carried out in any other suitable manner, as discussed further below with reference to examples.

[0042] Referring to Fig. 1 in greater detail, the box 20 can include one or more upright sidewalls 40 extending upwardly from an outer periphery or outer margin of a lower base panel 42, so that the sidewalls 40 collectively extend around the box interior space 22. The upper edges or ends of the box sidewalls 40 can form the upwardly facing annular seating surface 36 that extends around the box upper opening 24. The upper, inner portions of the sidewalls 40 can define an annular mounting recess 46 with associated upward-facing shoulders or ledges for engaging and supporting the lower surface of the annular margin of the support structure 26, as discussed further below. The vacuum pump 25 and/or any other suitable features for creating a partial vacuum in the box interior space 22, can be in fluid communication with the box interior space by way of at least one passageway or hole 43 (Fig. 2) defined through any suitable portion of the box 20, base panel 42, sidewall(s) 40, and/or the like. [0043] As another example, the box 20 and support structure 26 can be omitted, in which case a variation of the interior space 22 can be defined, for example, within the body of the mold 14. In such an example, the vacuum pump 25 and/or any other suitable features for creating the partial vacuum in the interior space of the mold 14 can be in fluid communication with the mold interior space by way of at least one passageway or hole defined through any suitable portion of the mold 14.

[0044] Referring to Fig. 1, the support structure 26 can be a rigid panel or other suitable structure having a two-dimensional array of a multiplicity of support openings 28 (e.g., through holes) extending therethrough. Each support opening 28 can be in the form of a hole or passageway that is open at both of the upper and lower sides of the support structure 26, so that the support openings are open to the box interior space 22. The support structure 26 can be or include one or more of a grate, perforated sheet, a sheet of expanded metallic material, wire mesh, frame, and/or any other suitable structure(s) made or metallic material and/or any other suitable material.

[0045] The support structure 26 can be supported by or mounted to the box 20, the box sidewalls 40, the upper ends or upper end portions of the box sidewalls, and/or any other suitable structures. More specifically referring to Figs. 1 and 2, the annular margin of the support structure 26 can fit into the box mounting recess 46 and be supported by the annular horizontal shoulder or ledge that defines the bottom of the mounting recess so that the upper surface of the support structure is flush with the box seating surface 36. As other examples, the box mounting recess 46 can extend relatively farther below the box seating surface 36 than is depicted in Figs. 1 and 2. As a result and for example, the upper surface(s) of the precursor sheet 16 and/or blank(s) 30 can be flush with, or recessed relative to, the box seating surface 36. Alternatively or additionally, the support structure 26 can be mounted to or operatively associated with the box 20 in any other suitable manner, for example using mounting brackets and/or fasteners. As a further example, the support structure 26 can be omitted and the mold 14 can be more directly supported by the box 20. As a more specific example, an annular margin of the lower surface of the mold 14 can fit into the box mounting recess 46 and be supported by the annular horizontal shoulder or ledge that defines the bottom of the mounting recess. [0046] Referring to Fig. 3, the depicted mold 14 is a block including one or more recesses configured such that the mold is a multi-cavity female mold. More specifically, the multicavity mold 14 of the first embodiment includes recessed (e.g., female) mold faces 50 extending downwardly from the upper surface 35 of the mold. The recessed mold faces 50 define mold cavities. In the example depicted in Fig. 3, the mold faces 50 are concave, partially spherical mold faces extending downwardly from the flat upper surface 35 of the mold. The mold upper surface 35 (e g., reference surface) can be a planar, relatively upper or uppermost surface of the mold 14. A wide variety of differently configured mold faces 50 are within the scope of this disclosure, depending, for example, on the desired shape or shapes of the one or more bodies being formed by the thermoforming, as discussed further below. For example, the thermoformed bodies can be relatively flat and/or in other configurations.

[0047] The first embodiment mold 14 includes through holes (e.g., passageways) having upper openings 54 (e.g., “mold upper openings”) and lower openings (not depicted in the drawings) defined in a lower surface of the mold. In the example depicted in Fig. 3, the mold upper openings 54 are respectively defined in the mold faces 50 and/or the mold upper surface 35. When respective components of the first embodiment of the thermoforming system are in the closed vacuum-thermoforming configuration, the partial vacuum provided in the box interior space 22 also extends into one or more passageways (e.g., numerous passageways) that comprise the mold upper openings 54, as discussed further below. Fig. 2 is schematic because, for example, the passageways and associated mold upper openings 54 (Fig. 3) are not depicted.

[0048] A wide variety of differently configured molds, mold faces, and mold upper surfaces are within the scope of this disclosure, for example depending upon the configuration of articles of manufacture to be thermoformed in the thermoforming system of this disclosure (see, e.g., thermoformed articles 82 (Figs. 6, 16, and 19-22). For example, the mold faces 50 (e.g., convex, partially spherical, and/or differently configured mold faces) can protrude upwardly from the mold reference surface 35 so that the mold is a male mold, or the like. In some examples, each or at least one of the mold faces 50, whether concave or convex, can at least partially define curved arcs that extend crosswise to one another. As a further example, the mold 14 can include registration features (not depicted), for example protrusions, holes for pins, and/or other suitable structures for aiding in relative positioning of the mold and precursor sheet 16, as discussed further below. As yet another example, the mold 14 may be cooled and/or other cooling features can be associated with the machines and systems of this disclosure, as discussed further below.

[0049] The thermoforming machine or system of the first embodiment can be reconfigured so that the mold 14 includes one or more interior spaces (e.g., chambers) that are closed except for being open at the mold upper openings 54 and also being open to the at least one conventional vacuum pump 25, or the like. In such an example, the box 20 and support structure 26 may be omitted. Additionally or alternatively, the mold 14 can include one or more internal chambers or passageways through which a cooling fluid is circulated for cooling the mold. Thus, the mold 14 can cool the thermoformed articles (see, e.g., thermoformed articles 82 (Figs. 6, 16, and 19-22)) by way of, for example, conductive heat transfer. In addition or alternatively, the thermoformed articles can be cooled downstream from the mold 14 by way of convective heat transfer facilitated by one or more air movers (e.g., fans) and/or cooling units (e.g., refrigeration units, thermoelectric coolers, and heat exchangers provided with a relatively cool fluid), as discussed further below.

[0050] Referring to the example of the precursor sheet 16 depicted in Fig. 4, the flat precursor sheet can include one or more precursor articles that may be referred to as blanks 30 (e.g., initially flat blanks) that are configured to be thermoformed, as discussed further below. The series of blanks 30 (e.g., precursor articles) can be respectively connected to one another by connectors, for example connector portions 60, 62 of the precursor sheet 16, as discussed further below. Alternatively, the precursor sheet can consist essentially of (e.g., can be or include only) a single blank.

[0051] It is believed that each blank 30 (e.g., article) or a variation thereof can be configured to be thermoformed into an article of manufacture configured, for example, for use as a tissue bridge or a portion thereof (e.g., a body, backbone, foot pad, spanning structure, multistable spanning structure, strut assembly, multistable struct assembly, strut, multistable strut, and/or the like). In this regard, the entire disclosure of each of U.S. Patent Nos. 10,327,774, 11,051,815, and 11,246,595 is incorporated herein by reference in its entirety. As a further or more specific example discussed in greater detail far below, it is believed that the precursor sheet 16 can be a multi-layer laminate (e.g., comprising pressure- sensitive adhesive fixedly mounted on a thermoform able substrate and covered by a removable release liner) and the blanks 30 can be configured to be thermoformed to create one or more respective articles of manufacture, for example thermoformed articles 82 (Figs. 6, 16, and 19-22) and respective suitable articles disclosed in the patents incorporated herein by reference. As compared to one another, when there are multiple layers within the precursor sheet 16, the different layers can be constructed of different materials, have different configurations, and/or have differently configured lines of disruption and/or openings 68 (e.g., cut slits, through holes, gaps, and/or the like).

[0052] Referring to the example depicted in Fig. 4, a representative blank 30 can have an elongated shape so as to include opposite end portions 64. One or more spanning portions 66 can extend between the end portions 64. Boundaries respectively between the spanning portions 66 can be at least partially defined by openings 68 defined in (e.g., formed by cutting) the blanks 30 (“blank openings 68”). In the first embodiment, the openings 68 are in the form of slits (e.g., substantially closed openings) that extend through the thickness of the precursor sheet 16. A slit can be a relatively narrow cut resulting in no removal of material so that opposite edges of the slit may be in opposing face-to-face contact with one another. More generally, the blank openings 68 can be disruptions in the form of slits or through holes wider than slits, disruptions in the form of perforations or kiss cuts configured to tear and form openings (see, e.g., through holes 84 in Figs. 6 and 16) during thermoforming, as discussed further below. For each blank 30 depicted in Fig. 4, structure of the blank extends completely around the blank openings 68. The blank openings 68 can be at least partially formed by, or completely formed by, cutting. Differently configured blanks 30, disruptions or openings 68, and the like, are within the scope of this disclosure, as discussed further below. During the thermoforming, the disruptions or openings 68 in the blanks 30 can be transformed (e.g., reconfigured) to form through holes 84 (Figs. 6 and 16). Similarly, disruptions or openings 68 in the blanks 30 can be reconfigured (e.g., enlarged) during the thermoforming, as discussed further below. Alternatively, the blanks 30 and molds 14 can be cooperatively configured so that one or more of the disruptions or openings 68 (e.g., through holes) in the blanks 30 are neither reconfigured nor enlarged during the thermoforming.

[0053] The one or more connector portions 60, 62 that are connected to the one or more blanks 30 can be in the form of tab portions 60 of the precursor sheet 16, strip portions 62 of the precursor sheet, and/or other suitable structures configured for connecting or mounting the blanks, or the like. The tabs 60 (e.g., arms) can respectively extend inwardly from the strips 62 (e.g., rails) and be connected to the blank end portions 64. One or more of the connector portions 60, 62 can include registration features, for example registration holes 70 for receiving pins, and/or other suitable structures, as discussed further below. In the first embodiment, the connector portions 60, 62 are typically eventually cut and removed from the articles of manufacture that are thermoformed from the blanks 30 (e.g., thermoformed articles 82 (Figs. 6, 1 , and 19-22) and respective suitable articles disclosed in the patents incorporated herein by reference), as discussed further below.

[0054] With continued reference to Fig. 4, in addition to the blank openings 68, the precursor sheet 16 can define openings 72 (e.g., through holes, gaps, slits, and/or other suitable features). For example, adjacent edges of the blanks 30 and/or connector portions 60, 62 can be configured to at least partially define the additional openings 72 in the precursor sheet 16 (“precursor openings 72”). The precursor openings 72 can be defined between respective adjacent edges of the blanks 30, connector portions 60, 62, and/or other suitable features. More generally, the openings 68, 72 at least partially defined by or in the percussor sheet 16 can be defined in or between one or more blanks 30, connector portions 60, 62, and/or other suitable portions.

[0055] The precursor sheet 16 can, for example, be cut (e.g., die-cut and/or laser-cut) in a web of material and removed from remnant(s) of the web. The web and, thus, the precursor sheet 16, can comprise (e.g., can be or can include) a film of thermoformable thermoplastic material, for example a film formed of or including polycarbonate, acrylonitrile butadiene styrene, polyethylene terephthalate homopolymer, polyethylene terephthalate copolymer (e.g., polyethylene terephthalate glycol-modified (PETG or PET-G)), and/or any other suitable material (e.g., a multilayer laminate including a thermoformable thermoplastic substrate). For example, it is believed that the precursor sheet 16 can be a multi-layer laminate (e.g., comprising pressure-sensitive adhesive fixedly mounted on a thermoformable substrate and covered by a removable release liner) and the blanks 30 can be configured to be thermoformed to create one or more respective articles of manufacture (e.g., thermoformed articles 82 (Figs. 19-22) and respective suitable articles disclosed in the patents incorporated herein by reference), as discussed further below. Alternatively, the precursor sheet 16 can consist of, or consist essentially of, a single layer of thermoplastic polymeric material.

[00561 A variety of differently configured webs, precursor sheets 16, blanks 30, and connector portions 60, 62 are within the scope of this disclosure. For example, the blanks 30 and blank openings 68 can have round shapes, elliptical shapes, asymmetrical shapes, rectangular shapes, triangular shapes, and/or any other suitable shapes. As more specific examples, it is believed that the blanks 30 can be shaped like one or more of the blanks of U.S. Patent No. 11,246,595, and/or the blank openings 68 and/or other features can be shaped like one or more of the openings, holes, slots, slits, cuts, cutouts, perforations, kiss cuts, and/or gaps disclosed in any one or more of U.S. Patent Nos. 10,327,774, 11,051,815, and 11,246,595. As other examples, it is believed the blanks 30 (e.g., each having one or more openings 68) can be configured for being thermoformed to form thermoformed articles configured as structural panels and/or liners with through holes, for example interior panels and/or liners of refrigerators, shower pans, shower walls, sinks, tubs, wall panels (e.g., wall panels for being positioned above bathtubs), and/or the like. The through holes of such thermoformed articles can function as ventilation holes, access holes, and/or holes for having plumbing, electrical, optical and/or other suitable components extend therethrough or otherwise be associated therewith.

[0057] At least partially reiterating from above, the first embodiment precursor sheet 16 is restricted from being (e.g., cannot be or substantially cannot be) thermoformed over the mold 14 on the box apparatus 12 without using, for example, the cover 18 or a portion thereof, and/or other suitable covering features. In the example of the precursor sheet 16 depicted in Fig. 4, the precursor sheet 16 and/or blanks 30 include one or more through holes (e.g., the blank openings 68 and/or precursor sheet openings 72) that restrict the precursor sheet and/or blanks from being (e.g., cannot be or substantially cannot be) thermoformed over the mold 14 on the box apparatus 12 without using the cover 18 or a portion thereof. Stated differently, it is believed that through holes in the form of, or associated with, the blank openings 68 and/or precursor sheet openings 72 at least partially define vent pathways or passageways that inhibit (e.g., can prevent) conventional vacuum thermoforming of the precursor sheet 16, blanks 30, and/or portions thereof. [0058] An example of a method of thermoforming (e.g., at least thermoforming) using differential fluid pressure is described in the following, in accordance with the first embodiment. More specifically, an example of a method of vacuum thermoforming using the thermoforming system of the first embodiment is described in the following. Referring to Fig. 2, the closed non-vacuum configuration can be achieved by forming a layered assembly (e g., stack) including the mold 14 on the support structure 26, and the precursor sheet 16 on the mold (“the stack 14, 16, 26”). The blanks 30 can be respectively superposed with the mold faces 50. This superposition can be at least partially facilitated by mating registration features (see, e.g., Fig. 4, registration holes 70) of the precursor sheet 16 or blanks 30 with corresponding registration features (e.g., protrusions, pins, and/or other suitable features not depicted in the drawings) of the mold and/or other suitable registration features. As another example, the superposition between the blanks 30 and mold faces 50 can be at least partially facilitated by mating registration features (e.g., registration holes 70 and/or other openings 68, 72 (Fig. 4)) of the precursor sheet 16 or blanks 30 with corresponding registration features (e.g., protrusions, pins, and/or other suitable features not depicted in the drawings) of the frame 34 (e.g., frame sidepieces and/or mullions) and/or other suitable registration features. As a more specific example, the superposition between the blanks 30 and mold faces 50 can be at least partially facilitated by outwardly protruding (e.g., “male”) mold faces including one or more registration features (e.g., protrusions, pins, and/or other suitable features not depicted in the drawings) configured to extend into one or more respective blank openings 68.

[0059] The stack 14, 16, 26 can be covered with the cover sheet 32 so that the box upper opening 24 (Fig. 1) is closed or at least isolated from the ambient environment by the cover sheet. The closed cover sheet 32 can extend continuously over the entirety of the stack 14, 16, 26 and box upper opening 24. As an example for providing the closed configuration, the cover sheet marginal portion 32M can be hermetically sealed against the box seating surface 36 by, for example, pressing downwardly on the frame 34 and/or in any other suitable manner. In the example depicted in Fig. 2, in response to relative movement between the cover 18 and the stack 14, 16, 26 (e.g., the cover being pushed downwardly), the cover central portion 32C engages the precursor sheet 16 and optionally also portions of the mold 14, and at least the cover intermediate portion 321 stretches so that the cover sheet 32 is distended. As a contrasting example, when the box mounting recess 46 (Fig. 1) extends relatively farther below the box seating surface 36 so that the upper surface(s) of the precursor sheet 16 and/or blank(s) 30 are flush with, or recessed relative to, the box seating surface 36, closing the cover 18 typically will not cause stretching of the cover intermediate portion 321. The cover 18 can be releasably secured closed by one or more fasteners, for example as discussed further below.

[0060] In the closed configuration depicted in Fig. 2, the mold 14 and precursor sheet 16 (e g., at least one blank 30), are closed in an interior space of a vacuum chamber comprising the box 20 and cover 18 or cover sheet 32. Accordingly, the vacuum chamber may be designated by numerals 20, 32 and/or 18, 20.

[0061] The interior space of the vacuum chamber 20, 32 can include upper and lower chamber portions or subchambers. In the example depicted in Fig. 2, the boundary between the upper and lower portions of the interior space of the vacuum chamber 20, 32 is defined by the support structure 26. That is, the upper and lower portions of the interior space of the vacuum chamber 20, 32 can be divided by the support structure 26. The lower portion of the interior space of the vacuum chamber 20, 32 can be the box interior space 22. The upper portion of the interior space of the vacuum chamber 20, 32 can be the volume that is above the support structure 26 and beneath at least a portion of the cover 32. As another example, the upper portion of the interior space of the vacuum chamber 20, 32 can be the volume that is above the support structure 26 and beneath the cover central and intermediate portions 32M, 321.

[0062] While the vacuum chamber 20, 32 is in the closed configuration depicted in Fig. 2, a partial vacuum can be provided in the interior space of the vacuum chamber 20, 32 by operating the vacuum pump 25 (Fig. 1) and/or in any other suitable manner. In the first embodiment, the partial vacuum in the interior space of the vacuum chamber 20, 32 exists simultaneously with at least one of the thermoplastic materials of the blanks 30 being at or above the thermoforming temperature of the thermoplastic material, as discussed further below. The vacuum thermoforming of the first embodiment affects at least the portions of the cover sheet 32 and precursor sheet 16 (e.g., blanks 30) that are superposed with the recessed mold faces 50. The respective portions of the cover sheet 32 and precursor sheet 16 together expand inwardly toward the recessed mold faces 50 so respective portions of the blanks 30 move into contact with the mold faces while at least portions of the blanks are at or above the thermoforming temperature. More specifically, the cover sheet 32 can be drawn inwardly by the differential pressure associated with the partial vacuum, so that respective portions of the cover sheet push the blanks 30 into contact with respective portions of the mold 14. After the blanks 30 are thermoformed and, thus, converted into thermoformed articles (e.g., thermoformed articles 82 (Figs. 6, 16, and 19-22) and respective suitable articles disclosed in the patents incorporated herein by reference), the cover 18 can be opened and thereafter the connector portions 60, 62 can be cut and removed from the thermoformed articles.

[0063] In the first embodiment, the providing of the partial vacuum in the interior space of the vacuum chamber 20, 32 is comprised of the cover sheet 32 obstructing (e.g., closing) openings at least partially defined by the precursor sheet 16 (e.g., one or more blank openings 68 and/or precursor openings 72) to restrict venting through the one or more openings at least partially defined by the precursor sheet 16. It is believed that a sufficient partial vacuum for vacuum thermoforming may not be reasonably achieved without the cover sheet 32 or another suitable feature obstructing (e.g., closing) the one or more openings 68 and/or 72 at least partially defined by the precursor sheet 16. At least one of the openings 68 and/or 72 can be at least partially defined by a one or more cut edges of the precursor sheet 16, as discussed further below.

[0064] Further regarding the one or more support structure openings 28 (Fig. 1), the one or more mold openings 54 (Fig. 3), the one or more blank openings 68 (Fig. 4), and/or the one or more precursory openings 72 (Fig. 4), during the vacuum thermoforming, the cover sheet 32 can obstruct (e.g., close) one or more openings 28, 54, 68, and/or 72. For example, the cover intermediate portion 321 can be stretched by the differential pressure to move into engagement with and obstruct the support openings 28 that are not covered by the mold 14. As another example, portions of the cover central portion 32C can be stretched by the differential pressure to move into engagement with and obstruct the mold openings 54 that are not covered by the precursor sheet 16. As a further example, portions of the cover central portion 32C can be against and obstruct the openings at least partially defined by the precursor sheet 16 (e.g., one or more blank openings 68 and/or precursor openings 72). After the thermoforming, fluid (e g , cooled fluid) can be supplied to the box interior space 22 and/or other locations for cooling purposes and/or ejection purposes.

[00651 For at least partially facilitating the thermoforming, in addition to or as an alternative to creating the partial vacuum in the vacuum chamber 20, 32, a relatively high fluid pressure can be applied to the side of the cover sheet 32 facing away from the chamber 20, 32. As a more specific example, it is believed that at least some components of the vacuum chamber 20, 32 may be omitted when a predetermined relatively high fluid pressure is applied (e.g., by way of a pressure chamber) to the side of the cover sheet 32 facing away from the vacuum chamber.

[0066] Reiterating from above, after the blanks 30 are thermoformed in the vacuum chamber 20, 32, or the like, to create the thermoformed articles (e g., thermoformed articles 82 (Figs. 6, 16, and 19-22) and respective suitable articles disclosed in the patents incorporated herein by reference), the cover 18 can be opened and thereafter the connector portions 60, 62 can be cut and removed from the thermoformed articles. For example, the thermoformed articles can be, but are not required to be multistable. As a specific example, when the mold 14 and precursor sheet 16 are configured as depicted in Figs. 3 and 4, a representative thermoformed article (see, e.g., thermoformed body 82 of Fig. 6) can be flexible and multistable so that the article is reconfigurable between first and second stable equilibrium configurations, and the article has an unstable equilibrium configuration between the first and second stable equilibrium configurations. The article can define a first concavity comprising curved arcs that extend crosswise to one another in the first stable equilibrium configuration. Similarly yet oppositely, the article can define a second concavity comprising curved arcs that extend crosswise to one another in the second stable equilibrium configuration.

[0067] During such vacuum thermoforming that is carried out to change the shape of the portion of a representative blank 30 that defines a blank opening 68 or a precursor thereof (e g., one or more perforations or kiss cuts), the configuration of the blank opening or precursor thereof can be changed during the thermoforming. For example, a blank opening 68 in the form of a slit (see, e.g., Fig. 4) can be transformed into a through hole during the thermoforming, so that a gap becomes defined between the opposite edges of the slit / through hole that may have originally been in opposing face-to-face contact with one another (e g., it is believed that a slit may be a substantially closed opening). The crosswise dimension (e.g., diameter) of the through hole can increase during the thermoforming. [00681 As a specific example for the first embodiment, Fig. 5 depicts a representative one of the blanks 30, and Fig. 6 depicts a multistable spanning structure or body 82 vacuum thermoformed from the blank of Fig. 5. In this depicted example, in response to the thermoforming of the blank 30, the resulting thermoformed body 82 is multistable and includes elongate through holes 84 that are relatively wide and may be referred to as slots. [0069] The multistable thermoformed body 82 of the first embodiment is reconfigurable between first and second stable equilibrium configurations, and the article has an unstable equilibrium configuration between the first and second stable equilibrium configurations. In the first stable equilibrium configuration, the thermoformed body 82 can define an upward concavity comprising curved arcs that extend crosswise to one another. In the second stable equilibrium configuration, the thermoformed body 82 can define a downward concavity comprising curved arcs that extend crosswise to one another.

[0070] Reiterating from above for the example depicted in Figs. 5 and 6, the blank’s slits 68 (e.g., cut openings that may be substantially closed) are transformed into (e g., enlarged to form) the slot-like through holes 84 in response to the thermoforming. In response to the thermoforming, the one or more slits 68 can become somewhat elliptical through holes 84 that are relatively wide (e.g., increased size of crosswise dimension). The resulting through holes 84 can advantageously function as ventilation and/or access holes. As a further example, it is believed that the resulting through holes 84 can advantageously function to help release the internal stress in the thermoformed body 82 during transitions between its stable equilibrium configurations (e.g., to reduce the energy required to manually transition the thermoformed body between the stable equilibrium configurations).

[0071] The thermoforming system can include, or be associated with, at least one heater for heating at least the blanks 30, and at least one cooling mechanism for cooling the mold 14 and/or the thermoformed articles (e.g., thermoformed articles 82 (Figs. 6, 16, and 19-22) and respective suitable articles disclosed in the patents incorporated herein by reference), or the like. As schematically depicted in Fig. 2, it is believed that one or more heaters or heater elements (e.g., electric heating elements 80) can be cooperatively configured with the vacuum chamber 20, 32 for heating one or more respective portions of the precursor sheet 16 or blanks 30 to at least a thermoforming temperature. Tn the example depicted in Fig. 2, the heating can be performed while the vacuum chamber 20, 32 is closed, and the heating can be comprised of at least one of: conductive heat transfer from the cover sheet 32 to the one or more respective portions of the precursor sheet 16 or blanks 30; the one or more respective portions of the precursor sheet or blanks absorbing electromagnetic radiation emitted by cover sheet; and/or the one or more respective portions of the precursor sheet or blanks absorbing electromagnetic radiation transmitted through cover sheet. For example, one or more electric resistance heaters can be connected to, embedded in, and/or carried by the cover sheet 32. Alternatively the one or more respective portions of the precursor sheet 16 or blanks 30 can be heated while the vacuum chamber 20, 32 is open, as discussed further below. As another example, the precursor sheet 16 can be heated from above and/or below. [0072] The heating associated with the thermoforming can be controlled (e.g., tuned) for predetermined purposes. For example and reiterating from above, it is believed that the precursor sheet 16 can be a multi-layer laminate and the blanks 30 can be configured to be thermoformed to create respective articles of manufacture (e.g., thermoformed articles 82 (Figs. 19-22) and respective suitable articles disclosed in the patents incorporated herein by reference). For example, the precursor sheet 16 can be a multi-layer laminate comprising pressure-sensitive adhesive fixedly mounted on a thermoformable substrate and covered by a removable release liner, as discussed further below. As one example, it is believed that the method of heating can be carried out in a manner that seeks to allow the thermoformable substrate to be heated to at or above its thermoforming temperature without overheating the associated pressure-sensitive adhesive and release liner in a manner that degrades (e.g., substantially degrades) the intended operability of the pressure-sensitive adhesive and release liner. The thermoforming system can include sensors and/or actuators configured to monitor and/or control temperatures, heating, and/or cooling, as discussed further below.

[0073] Reiterating from above, the thermoforming system can include, or be associated with, at least one cooling mechanism. For example, the mold 14 can include one or more interior chambers through which a cooling fluid is circulated for cooling the mold and, thus, cooling the thermoformed articles (e g., thermoformed articles 82 (Figs. 6, 16, and 19-22) and respective suitable articles disclosed in the patents incorporated herein by reference) by way of, for example, conductive heat transfer. In addition or alternatively, the thermoformed articles can be cooled by way of convective heat transfer facilitated by one or more air movers (e.g., fans) and/or cooling units (e.g., refrigeration units, thermoelectric coolers, and heat exchangers provided with a relatively cool fluid), as discussed further below.

[0074] At least partially reiterating from above, in addition to or as an alternative to heating through the cover sheet 32, one or more respective portions of the precursor sheet 16 or blanks 30 can be heated while the vacuum chamber 20, 32 is open. More specifically, and as best understood with reference to second and third embodiments depicted in Figs. 7-12, one or more respective portions of the precursor sheet 16 or blanks 30 can be heated while the box 20, precursor sheet 16, and blanks 30 are not covered by the cover sheet 32. The first, second, and third embodiments can be alike except for variations noted and variations that will be apparent to those or ordinary skill in the art.

[0075] Fig. 7-12 are schematic because, for example, the support 14, precursor sheet 16, and mold 26 (Figs. 1 and 2) are not depicted. In Figs. 7-12, the box 20 is configured to be movable back and forth along (e.g., reciprocate along) at least one guideway supported by a suitable support, for example a platform or table 86. As a more specific example, the box 20 can be configured as a carriage, with wheels 90, that is movable back and forth along one or more tracks or rails 92, or the like. The box 20 can be automatically moved by way of a suitable apparatus and/or manually moved by way of at least one handle 93 directly or indirectly connected to the box. The cover 18 can be releasably secured in its open and closed configurations by one or more fasteners 94 (e.g., magnets, latches, and/or other suitable devices). A fluid communication device or apparatus 96 (e.g., one or more passageways, holes, fittings, tubes, and/or pipes) can provide fluid communication between the interior of the box 20 and the at least one vacuum pump 25 (Fig. 1) and/or the like. A respective portion of (e.g., at least one passageway of) the fluid communication device or apparatus 96 can extend through an elongate slot extending through the horizontal supporting surface of the platform or table 86. The heater (e.g., one or more heating elements 80) can be at least partially contained or shrouded in a shielding structure (e.g., downwardly open housing).

[0076] Fig. 7 depicts a second embodiment vacuum thermoforming machine or system with its movably mounted cover 18 held open by respective fasteners 94. More specifically, the cover 18 can be mounted (by way of one or more hinges) for pivoting relative to a frame of the machine and/or the box 20. Fig. 8 depicts the second embodiment machine with the box 20 proximate a heater (e.g., beneath one or more heating elements 80), so that one or more respective portions of the precursor sheet 16 or blanks 30 carried by the box can be relatively directly heated by the heating elements 80. Fig. 9 depicts the second embodiment machine with its cover 18 held closed by respective fasteners 94 and with a partial vacuum in the vacuum chamber 18, 20 for vacuum thermoforming the blanks 30.

[0077] Fig. 10 depicts a third embodiment vacuum thermoforming machine or system with the box 20 moved away from the cover 18. More specifically, the frame 32 (Figs. 1 and 2) of cover 18 can be fixedly mounted (e.g., by way of one or more fasteners 94) for remaining stationary relative to the frame of the machine. Fig. 11 depicts the third embodiment machine with the box 20 proximate a heater (e.g., beneath one or more heating elements 80), so that one or more respective portions of the precursor sheet 16 or blanks 30 carried by the box can be relatively directly heated by the heating elements 80. Fig. 12 depicts the third embodiment machine with the vacuum chamber 18, 20 closed by fasteners 94 and with a partial vacuum in the vacuum chamber for vacuum thermoforming the blanks 30.

[0078] In addition to, or as an alternative to, the one or more respective portions of the precursor sheet 16 or blanks 30 being positioned between the mold 14 and the heating elements 80, one or more heating elements can be embedded in or otherwise associated with the mold 14. More generally, the precursor sheet 16 or blanks 30 (e.g., one or more precursor articles) can be heated in any suitable manner.

[0079] Methods of the first through third embodiments may be described as comprising batch-type thermoforming processes. That said, continuous-production thermoforming processes are within the scope of this disclosure. For example, a fourth embodiment can be like the first through third embodiments, except, for example, that the fourth embodiment comprises a continuous-production vacuum thermoforming machine and associated processes.

[0080] Referring to the example depicted in Fig. 13, a continuous-production vacuum thermoforming machine can include a flexible endless sheet 32E (e.g., an endless elastic multilayer laminate including silicone, an endless elastic sheet of silicone, and/or other suitable structure(s)) that travels around pulleys, rollers, shafts and/or other suitable supporting structures, at least one of which is motor-driven for causing the endless sheet to travel along its path. It is believed that a series of boxes 20 respectively carrying molds 14 can travel along an endless pathway defined by a guideway, rails, and/or other suitable structures. As a more specific example, it is believed the series of boxes 20 can be mounted to, and carried by, an endless conveyor belt 100 that travels around pulleys, rollers, shafts and/or other suitable supporting structures, at least one of which is motor-driven for causing the conveyor belt to travel along its path. The paths of travel of the sheet 32E and boxes 20 can be arranged to at least partially define a nip area between a respectively portion of sheet 32E and a respective mold 14 that are closely adjacent one another. In Fig. 13, the nip area is above the central box 20 in the top row of boxes. One or more coolers 102 (e.g., at least one blower or fan optionally associated with one or more refrigeration units, thermoelectric coolers, and heat exchangers provided with a relatively cool fluid) can be positioned downstream from the nip area and/or in any other suitable locations. In one example, the cooler 102 can be configured to discharge onto or otherwise cool (e g., internally cool) the mold 14.

[0081] A web 16W can comprise a series of precursors 16 and/or blanks (e.g., precursor articles or more specifically blanks 30) extending in a lengthwise direction of the web. The web 16W can be drawn through the nip area so that, for example, a first blank 30 of the web is nipped between a first portion of the endless sheet 32E and a first mold 14, and thereafter a second blank is nipped between a second portion of the endless sheet and a second mold, and so on for subsequent portions of the web. The blank 30 that is in the nip area can be thermoformed generally as discussed above for the first through third embodiments by providing a partial vacuum in the box 20 adjacent the nip area. The components for providing the partial vacuum in interior space 22 of the box 20 adjacent the nip area can include one or more of a vacuum pump 25 (Fig. 1), any associated vacuum tank(s), passageways, holes, fittings, tubing, and/or piping. The components for providing the partial vacuum in interior space 22 of the box 20 adjacent the nip area can further include manifold(s) and/or valves configured so that each time a respective box 20 is adjacent the nip area the partial vacuum is provided in the interior space 22 of the box 20 adjacent the nip area for facilitating the thermoforming. Alternatively, it is believed that only some of the box parts may be carried by and travel with the conveyor belt 100, and other stationary box parts may remain adjacent the nip area, so that respective portions become cooperatively arranged to create a temporary moving structure that defines the box interior space 22. As another example, it is believed that the vacuum may be omitted by applying sufficient fluid pressure to a respective area of the endless cover sheet 32 to facilitate the thermoforming, so that the boxes 20 may be omitted.

[0082] In the fourth embodiment, for facilitating the vacuum thermoforming, the blanks can be temporarily heated to at least their thermoforming temperature. An exterior surface of the blanks can be defined by thermoplastic material that becomes tacky (e.g., sticky) when heated, and becomes relatively less tacky or not tacky when subsequently cooled (e.g., after being thermoformed). As a result, the heated blanks and/or resultant vacuum-thermoformed articles of manufacture (e g., thermoformed articles 82 (Figs. 6, 16, and 19-22) and respective suitable articles disclosed in the patents incorporated herein by reference) can serially become temporarily adhered (via the temporary tackiness) to the rotating endless sheet for temporarily traveling therewith (e.g., so that the web 16W is drawn by the rotating endless sheet 32E, the blanks are held in predetermined positions by the endless sheet, the resultant articles of manufacture are separated from and carried away from the respective mold by the endless sheet, and/or the like).

[0083] Figs. 14-16 schematically depict examples in accordance with a fifth embodiment of this disclosure. The fifth embodiment (see, e.g.,) can be like the first through fourth embodiments, except for variations noted and variations that will be apparent to the skilled artisan.

[0084] In the example depicted in Fig. 14, the mold 14 is a male mold, at least partially a male mold, and/or one or more of its faces 50 are male mold faces. In the example depicted in Fig. 15, the blank 30 includes numerous openings 68 that are slits. The blank 30 can be elastic so that the resulting thermoformed body 82 can be configured as depicted in Fig. 16. [0085] As more specific examples, in Fig. 14, the lower, relatively small upwardly protruding members of the mold 14 can be define helically grooved surfaces. As a result, in Fig. 16, the lower, relatively small upwardly protruding members of the body 82 can include internally threaded through holes 84 for respectively receiving externally threaded fasteners (e g., screws and/or bolts). Referring to Fig. 16, it is believed that the upper, relatively large upwardly protruding member of the body 82 can function as a spray nozzle, or the like, with its relatively large through hole 84. As another example, it is believed that the upper, relatively large upwardly protruding member of the body 82 can function as the male and/or female part of an interference-fit type of fastener (e.g., snap fastener), or the like. Generally reiterating from above and as best understood with reference to Figs. 15 and 16, in response to the vacuum thermoforming, or the like, the blank’s openings 68 are enlarged and, thus, respectively transformed into the through holes 84.

[0086] A sixth embodiment can be like the first through fifth embodiments, except for variations noted and variations that will be apparent to the skilled artisan. Figs. 17-18 depict an example of a multilayer (e.g., laminate) flat blank 30 in accordance with the sixth embodiment. Figs. 19-22 depict an example of a multilayer article 82 that can be thermoformed from the blank 30 of Figs. 17-18 using a method and thermoforming system of a sixth embodiment of this disclosure, as discussed further below. At least a portion of each of the sixth embodiment blank 30 and the sixth embodiment thermoformed article 82 can be a multi-layer laminate. Accordingly, for ease of understanding in the Detailed Description section of this disclosure, the sixth embodiment blank 30 may be referred to as “laminate blank 30,” and the sixth embodiment thermoformed article 82 may be referred to as “thermoformed laminate 82.”

[0087] As best understood with reference to Figs. 17-18 and 20, each of the depicted examples of the laminate blank 30 and thermoformed laminate 82 can include the upper layer 114 and one or more lower layers of material connected to the underside of the upper layer 114. In the example depicted in Figs. 17-18, at least the upper layer 114 of the blank 30 includes opposite end portions 118; and lines of disruption and/or openings 68 (e.g., cut slits, through holes, gaps, and/or the like) in the upper layer are configured so that the upper layer includes opposite arms 144 extending between the end portions, and strut portions 120 respectively extending inwardly from the end portions. In the sixth embodiment, each of the strut portion 120 includes a proximal end connected to the respective end portion 118, and a distal end opposite from the proximal end. The upper layer 114 can be a piece of thermoformable polymeric film (e.g., polycarbonate, acrylonitrile butadiene styrene, polyethylene terephthalate homopolymer, polyethylene terephthalate copolymer, and/or any other suitable material (e.g., a multilayer laminate including a thermoplastic substrate that is thermoformable)). [0088] As alluded to above, and discussed further below and in respective documents incorporated herein by reference, the thermoformed laminate 82 can be used as a tissue bridge. In this regard and as best understood mainly with reference to Fig. 20, the lower layers of the laminate blank 30 and thermoformed laminate 82 can include, for example, carrier sheets 126, adhesive layers 128, 130, and outer release sheets or liners 132 (e.g., removable backings). In the sixth embodiment, patient-contact structures comprise, consist essentially of, or consist of the carrier sheets 126 and the lower or outer adhesive 130 being cooperatively configured so that the patient-contact structures can be used to attach the thermoformed laminate 82 to tissue (e.g., skin tissue) after removal of the one or more release liners 132. Accordingly and for ease of understanding, the carrier sheets 126 may be referred to as patient-contact carriers, and the outer or lower adhesive 130 may be referred to as patient-contact adhesive 130. More specifically regarding layers of the thermoformed laminate 82, the inner adhesive 128 can be between and fixedly connect the patient-contact carriers 126 to the upper layer 114, and the patient-contact adhesive 130 can be on the outer sides of the patient-contact carriers 126 for attaching the thermoformed laminate 82 to tissue (e.g., a patient’s skin) after removal of the release liner(s) 132.

[0089] For example, the patient-contact carriers 126 can be made of suitable fabric materials, cast materials, cast microporous polymeric sheet, polymeric films (e.g., polyurethane), padding, and/or other suitable materials (e.g., of the type from which skincontact layers of bandages or other wound dressings are formed). The one or more release liners 132 can be, for example, a paper or plastic-based film sheet coated with a release agent that is engaged against the patient-contact adhesive 130 so that a main body or portion of the thermoformed laminate 82 is releasably mounted on the release liner. The inner adhesive 128 can comprise adhesive materials that are compatible with the materials being connected thereby. Alternatively, the patient-contact carriers 126 can be connected to the respective portions of the upper layer 114 way of heat fusion and/or other suitable techniques. The patient-contact adhesive 130 can be, for example, a pressure-sensitive adhesive material of the type that is typically used as an adhesive backing for wearable medical devices, bandages, or other wound dressings. The patient-contact adhesive 130 can have a lower adhesive strength than the inner adhesive 128, such as when the thermoformed laminate 82 is to be removably mounted to tissue (e g., a patient’s skin). [0090] One or more of the adhesive layers 128, 130 or sheets 126, 132, or portions thereof, can be omitted. For example, the patient-contact carriers 126 and the inner adhesive 128 can be omitted, so that the patient-contact adhesive 130 is mounted directly on (e.g., is in opposing face-to-face contact with) the upper layer 114. As another example, the connection to tissue provided by the patient-contact adhesive 130 can be supplemented with or replaced by one or more suitable non-adhesive attachment mechanisms (e.g., pins, needles, sutures, staples, and/or the like). As further examples, the upper layer 114 can itself be a laminate and/or layer(s) can be attached to the upper side of the upper layer 114.

In the example depicted in Figs. 19-22, the lower layers 126, 128, 130, 132 are configured, including lines of disruption and/or openings (e.g., cut slits, through holes, gaps, and/or the like) in the lower layers 126, 128, 130, 132 being configured, so that each of a pair of strut assemblies 142 can be described as including an upper layer strut portion 120 and respective adhesive layers 128, 130 and sheet 126. The laminate blank 30 can be configured so that the lines of disruption and/or openings 68 (e.g., cut slits, through holes, gaps, and/or the like) in the upper layer 114 extend into one or more of the lower layers 126, 128, 130, 132 and/or one or more of the lower layers 126, 128, 130, 132 includes one or more lines of disruption and/or openings 68 (e.g., cut slits, through holes, gaps, and/or the like) that vary from any of those of the upper layer. In this regard and for the example of the flat laminate blank depicted in Figs. 17-18, the at least one release liner 132 includes an opening 68 (e.g., a cut in the form of a slit) narrower than the opening 68 (e.g., gap) defined between inner ends of the strut assemblies 142. Accordingly for the example of the resulting thermoformed laminate 82 depicted in Figs. 19-22, the through hole 84 defined between the inner ends of the release liners 132 is narrower than the through hole 84 defined between the inner ends of the strut assemblies 142. Generally reiterating from above and as best understood with reference to Figs. 17-22, in response to the vacuum thermoforming, or the like, the openings 68 of the laminate blank 30 are enlarged and, thus, respectively transformed into the through holes 84 of the thermoformed laminate 82.

[0091] For the sixth embodiment thermoforming system, it is believed the mold face (see, e.g., Fig. 3, mold face 50) can be configured (e.g., contoured) so that the vacuum thermoforming of the laminate blank 30 forms the thermoformed laminate 82 into the configuration depicted in Fig. 19, and the thermoformed laminate is multistable. In this regard, the thermoformed laminate 82 can be flexible and multi stable so that the thermoformed laminate is reconfigurable between first and second stable equilibrium configurations, and the thermoformed laminate has an unstable equilibrium configuration between the first and second stable equilibrium configurations. The thermoformed laminate 82 can define a first concavity comprising curved arcs that extend crosswise to one another in the first stable equilibrium configuration (see, e.g., Figs. 19-21). Similarly yet oppositely, thermoformed laminate 82 can define a second concavity comprising curved arcs that extend crosswise to one another in the second stable equilibrium configuration (see, e.g., Fig. 22). [0092] As an example, the thermoformed laminate 82 may be used as a multistable tissue bridge (“multistable tissue bridge 82”). In this regard, Fig. 19 may be referred to as a top perspective view of the multistable tissue bridge 82 (thermoformed from the laminate blank 30 of Figs. 17-18) in its extended stable equilibrium configuration; Fig. 20 may be referred to as an exploded, top perspective view of the multistable tissue bridge 82 in its extended stable equilibrium configuration; Fig. 21 may be referred to as a top perspective view of the multistable tissue bridge 82 in its extended stable equilibrium configuration without release liner pieces 132; and Fig. 22 may be referred to as a top perspective view of the multistable tissue bridge 82, without release liner pieces 132, in its retracted stable equilibrium configuration. A variety of differently configured laminate blanks 30 and thermoformed laminates 82 (e.g., multistable tissue bridges) are within the scope of this disclosure.

[0093] During the thermoforming of the laminate blank 30, it is believed that temperatures can be controlled so that any thermal degradation of the layers 114, 126, 128, 130, 132 can be avoided or limited. As one example, it is believed that the laminate blank 30 can be configured and/or heating and/or cooling can be controlled so that only the upper layer 114 reaches it thermoforming temperature, and it is the thermoformed upper layer that provides the multistable functionality of the multistable tissue bridge 82. For example, it is believed that one or more layers of a laminate blank 30 may not be thermoformable or may not be heated to their thermoforming temperature during the thermoforming. More generally, it is believed that one or more of the multiple layers of a laminate blank 30 can be heated to their thermoforming temperature(s) and, thus, be thermoformed. As another example, one or more of the above-discussed heating and cooling techniques can be used in various combinations to tune how the temperature varies across the thickness of the laminate blank 30. Tn this regard, it is believed that the upper layer 1 14 can be a thermoformable carrier substrate that is thermoformed while the lower layers 126, 128, 130, 132 remain attached to the upper layer 114; one or more or each of the lower layers 126, 128, 130, 132 may not be thermoformed (substantially not thermoformed) during the thermoforming of the upper layer 114; one or more or each of the lower layers 126, 128, 130, 132 may not be thermoformable (substantially not thermoformable); and/or one or more or each of the lower layers 126, 128, 130, 132 may be flexible enough to conform to (substantially confirm to) the final thermoformed shape of the upper layer 114.

[0094] In other embodiments like those discussed above, except for variations noted and variations that will be apparent to the skilled artisan, during the thermoforming, the one or more disruptions or openings 68 in the blanks 30 can be transformed (e.g., reconfigured) by male and/or female mold parts to form a series and/or two dimensional array of the through holes 84 in the thermoformed article. As examples, such thermoformed articles may be used as for filtering, sorting, spraying, creating a pressure drop, etc.

[0095] The thermoforming machines of the embodiments of this disclosure can include suitable sensor(s), actuators(s), and controller(s) for use in at least partially controlling operation of the thermoforming machine. The at least one controller can be operatively associated with, for example, numerous electrical components of the system. The at least one controller can include one or more computers, computer data storage devices, programmable logic devices (PLDs) and/or application-specific integrated circuits (ASIC). A suitable computer can include one or more of each of a central processing unit or processor, computer hardware integrated circuits or memory, user interface, peripheral or equipment interface for interfacing with other electrical components of the system, and/or any other suitable features. The controlled s) can respectively communicate with electrical components of the machine by way of suitable signal communication paths. Respective processes of this disclosure can be controlled (e.g., at least partially controlled) in response to the execution of computer-based algorithms operatively associated with the at least one controller. For example, in suitably configured respective systems of this disclosure, respective components can be automatically turned on, actuated, and/or turned off in response to the cover 18 being opened and/or closed. As a more specific example, in suitably configured respective systems of this disclosure, the heater(s) 80 and/or vacuum pump(s) 25 can be automatically turned on / actuated in response to the cover 18 being closed, and/or the heater(s) 80 and/or vacuum pump(s) 25 can be automatically turned off in response to the cover 18 being opened. As another example, the heater(s) 80 and/or vacuum pump(s) 25 can be automatically turned off after one or more predetermined periods of time, for example by one or more timers.

[0096] The entire disclosure of U.S. Provisional Application No. 63/330,838, filed April 14, 2022, is incorporated herein by reference.

[0097] Reiterating from above, it is within the scope of this disclosure for one or more of the terms “substantially,” “about,” “approximately,” and/or the like, to qualify each of the adjectives and adverbs of the foregoing disclosure, for the purpose of providing a broad disclosure. As an example, it is believed that those of ordinary skill in the art will readily understand that, in different implementations of the features of this disclosure, reasonably different engineering tolerances, precision, and/or accuracy may be applicable and suitable for obtaining the desired result. Accordingly, it is believed that those of ordinary skill will readily understand usage herein of the terms such as “substantially,” “about,” “approximately,” and the like.

[0098] In the specification and drawings, examples of embodiments have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.