Methods for forming complex-shaped components in a heated...

Plastic and nonmetallic article shaping or treating: processes – Direct application of fluid pressure differential to... – Differential temperature conditioning

Reexamination Certificate

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C264S554000, C264S294000, C264S296000, C264S332000, C264SDIG078, C425S388000, C425S393000

Reexamination Certificate

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07025923

ABSTRACT:
A thin-walled polymeric component that may have a selected complex shape, and a method of forming the component. The method includes heating a portion of a polymeric film to a selected malleable temperature, and forming a protrusion in the heated portion while it is malleable. The protrusion defines a protrusion having a first shape. The method also includes positioning a forming tool in the protrusion's interior and drawing a partial vacuum from within the protrusion so as to exert a force on the protrusion and move the protrusion's sidewalls inwardly into engagement with the forming tool. As the partial vacuum is drawn, the protrusion moves to a second shape that may be different than the first shape and that closely conforms to the selected shape of the forming tool. The protrusion is cooled below the malleable temperature and the forming tool is then removed. The distal portion of the protrusion having the selected shape forms the polymeric component, and that distal portion is separated from the remaining portion of the protrusion, thereby providing the thin-walled polymeric component.

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