Thermoforming machine and method of instituting a format change

1. A method of changing first upper and lower tools used in a station of a thermoforming machine, in a normal operation of the thermoforming machine a sheet is advanced in a forward movement direction along a horizontal plane through the station with the first upper tool residing above the sheet and the first lower tool residing below the sheet, one or both of the first upper and lower tools are capable of moving in a substantially vertical actuating direction to cause each of the first upper and lower tools to act on the sheet, the method comprising:

(a) removing all or a portion of the sheet located between the first upper and lower tools so that the first upper and lower tools may be moved together without contacting the sheet,

(b) from a starting position in which the first upper and lower tools are located in the station and spaced apart from one another, moving one or both of the first upper and lower tools in the vertical actuating direction so that the first upper tool is supported on the first lower tool and so that the entirety of each of the first upper and lower tools is vertically positioned below the horizontal plane; and

(c) moving the first upper and lower tools simultaneously and jointly out of the station to a first location in a replacement direction different from the actuating direction, the first location being located inside the thermoforming machine, below the horizontal plane.

2. A method according to claim 1 , further comprising:

(d) simultaneously and jointly moving the first upper and lower tools from the first location to a second location in a direction transverse to the replacement direction, the second location being located outside the thermoforming machine below the horizontal plane.

3. A method according to claim 1 , further comprising:

(d) obtaining second upper and lower tools to replace the first upper and lower tools,

(e) placing the second upper and lower tools at the first location with the second upper tool being supported on the second lower tool; and

(f) simultaneously and jointly moving the second upper and lower tools from the first location to the station in the replacement direction.

4. A method according to claim 2 , further comprising:

(e) obtaining second upper and lower tools to replace the first upper and lower tools,

(f) placing the second upper and lower tools at the second location with the second upper tool being supported on the second lower tool;

(g) simultaneously and jointly moving the second upper and lower tools from the second location to the first location in the transverse direction; and

(h) simultaneously and jointly moving the second upper and lower tools from the first location to the station in the replacement direction.

5. A method according to claim 1 , wherein the replacement direction is substantially horizontal.

6. A method according to claim 1 , wherein the replacement direction is substantially longitudinal in the forward movement direction.

7. A method according to claim 1 , wherein one of the first upper and lower tools comprises at least one cavity and the other of the first upper and lower tools comprises at least one protrusion corresponding with the at least one cavity, the at least one cavity and at least one protrusion configured to produce containers having a specific shape, at the same time as moving one or both of the first upper and lower tools in the vertical actuating direction so that the first upper tool is supported on the first lower tool, the first upper tool is centered with respect to the first lower tool as a result of the configuration of the at least one cavity and at least one protrusion.

8. A method according to claim 1 , further comprising situating a template between the first upper and lower tools, at the same time as moving one or both of the first upper and lower tools in the vertical actuating direction so that the first upper tool is supported on the first lower tool, the first upper tool is centered with respect to the first lower tool as a result of the template and first upper and lower tools having complimentary features that cause the first upper and lower tools to be centered with respect to one another.

9. A method according to claim 1 , wherein one or both of the first upper and lower tools are caused to move towards the other tool until the first upper tool is supported on the first lower tool, and the first upper tool is subsequently decoupled from a securing block arranged in the station over the first upper tool, the first upper tool being thus decoupled from the station to allow its subsequent removal in the replacement direction, and wherein, with the first upper tool being decoupled from the station, the first lower tool and the first upper tool are separated from the securing block at least a certain separation distance, and a box where the first lower tool is housed is decoupled from a table of the station being moved a distance equal to the separation distance in the actuating direction towards the securing block for being vertically positioned below the horizontal plane and decoupled from the station to allow its subsequent removal in the replacement direction.

10. A method according to claim 1 , wherein the thermoforming machine includes a structure that secures and moves the sheet in the forward movement direction, the step of removing all or a portion of the sheet located between the first upper and lower tools so that the first upper and lower tools may be moved together without contacting the sheet comprising a cutting of the sheet to form a window through which the first upper tool passes when moved to the first location without removing the sheet from the structure that secures and moves the sheet in the forward movement direction.

11. A method of changing first upper and lower tools used in a station of a thermoforming machine, in a normal operation of the thermoforming machine a sheet is advanced in a forward movement direction along a substantially horizontal plane through the station with the first upper tool residing above the sheet and the first lower tool residing below the sheet, one or both of the first upper and lower tools are capable of moving in a substantially vertical actuating direction to cause each of the first upper and lower tools to act on the sheet, the method comprising:

(a) removing all or a portion of the sheet located between the first upper and lower tools so that the first upper and lower tools may be moved together without contacting the sheet,

(b) from a starting position in which the first upper and lower tools are located in the station and spaced apart from one another, moving one or both of the first upper and lower tools in the vertical actuating direction so that the first upper tool is supported on the first lower tool and so that each of the first upper and lower tools is vertically positioned below the horizontal plane; and

(c) moving the first upper and lower tools simultaneously and jointly out of the station to a first location in a replacement direction different from the actuating direction, the first location being located inside the thermoforming machine, below the horizontal plane;

wherein the thermoforming machine includes a structure that secures and moves the sheet in the forward movement direction, the step of removing all or a portion of the sheet located between the first upper and lower tools so that the first upper and lower tools may be moved together without contacting the sheet comprising a cutting of the sheet to form a window through which the first upper tool passes when moved to the first location without removing the sheet from the structure that secures and moves the sheet in the forward movement direction.