Method and apparatus for folding the edges of a sheet of material

Claim 2

Apparatus for folding the edges of a sheet of material, which comprises: a die having walls on the sides; a compressible layer which rests on top of the die, over which the sheet of material is placed; a means for applying heat and force to the sheet of material to make the sheet of material pliable at margins along the edges thereof and to compress the compressible layer to cause the edges of the sheet of material to be bent upward against the inside of the walls of the die; and, a means for folding the erected edges of the sheet of material on top of the unfolded portion of the sheet of material.

Claim 3

Apparatus as claimed in claim 1 wherein: the die has a shelf around the inside of its walls for supporting the compressible layer and the unfolded portion of the sheet of material while the edges of the sheet of material are being folded; further comprising a template which rests upon the compressible layer and underneath the sheet of material to uniformly support the unfolded portion of the sheet of material when the means for applying heat and force to the sheet of material presses down on the sheet of material and causes the compressible layer to compress; wherein the means for applying heat and force to the sheet of material is a member which has dimensions less than those between the inside of the walls of the die so that the force applied to the sheet of material will cause the sheet of material to be pressed downward and the edges of the sheet of material to be bent upward between the inside of the walls of the die and the sides of the member; and, wherein the means for folding the edges of the sheet of material comprises a folding plate and a plurality of horizontally movable bars.

Claim 4

Apparatus as claimed in claim 2, which is used for folding the edges of a rigid sheet of material which has a concave portion and flanges around the perimeter of the concave portion, wherein; the die has a hollow section between its walls to receive the concave portion of the sheet of material; the shelf around the inside of the walls of the die is approximately the same width as the portion of the flanges around the perimeter of the sheet of material which are inside of the walls of the die, to evenly support this portion of the flanges when the means for applying heat and force is applied to the sheet of material so that the unfolded portion of the flanges are not bent; the compressible layer conforms to the shape of the shelf and also an opening to receive the concave portion of the sheet of material; the template conforms to the shape of the shelf and has an opening to receive the concave portion of the sheet of material; the member is a heating plate having outside dimensions which conform to, but are slightly less than the dimensions between the inside of the walls of the die; the folding plate has outside dimensions which are less than those between the erected edges of the sheet of material so it can be placed down upon the unfolded flanges without disturbing the erected edges of the sheet of material and which remains in place while the plurality of horizontally movable bars fold the erected edges of the sheet of material over the top of the unfolded flanges so a space is formed between the edges of the sheet of material and the unfolded portion of the flanges after the edges of the sheet have been folded.

Claim 5

Apparatus as claimed in claim 3 further comprising a cutter which cuts off the corners of the sheet of material prior to the application of the means for applying heat and force to the sheet of material so that the edges of the sheet of material will not overlap at the corners when they have been folded.

Claim 6

Apparatus as claimed in claim 3 further comprising an ejector means, which comprises a collar having an opening which generally conforms to the shape of the edge of the folding plate, and which slides along the folding plate to push the folded sheet of material off the folding plate.