Rotary high speed low compression thermoplastic molding method and apparatus

A molding apparatus comprising:

• a plurality of deep-draw compression molds, each of said molds including a mold cavity and an associated mold core, wherein said deep-draw compression molds have a depth to diameter ratio that is greater than one and at least a portion of the associated mold core fits into said mold cavity when said mold is closed;
• a rotating support structure operatively supporting said mold cavities and said mold cores relative to each other, said molds opening and closing as they travel around a closed path defined by said support structure;
• a mold material discharge mechanism operative to sequentially deposit a slug including a predetermined amount of mold material onto the mold core of each of said molds and/or into the mold cavity of each of said molds as said molds pass a first predetermined position along said closed path;
• a heat source physically coupled to the mold cavity and the mold core, the heat source preheating said molds to a temperature exceeding 212 degrees Fahrenheit before said molds are closed and continuing to heat said mold cavities and mold cores after said molds are closed as said molds travel between said first predetermined position and a second predetermined position along said closed path;
• a mold closing mechanism disposed to close said heated molds, compressing said mold material between said mold cavities and said mold cores to form a deep-draw component having the depth to diameter ratio that is greater than one, as said molds travel between said second predetermined position and a third predetermined position along said closed path, said heat source continuing to heat said mold cavities and said mold cores after said molds are closed;
• a coolant source coupled to cool said mold cavities and said mold cores while said molds are closed, wherein the coolant source cools said molds as said molds travel between said third predetermined position and a fourth predetermined position along said closed path;
• a mold opening mechanism disposed to open said cooled molds as said molds travel between said fourth predetermined position and a fifth predetermined position along said closed path;
• and
• an ejector disposed to eject said deep-draw components from said molds as said molds pass a sixth predetermined position along said closed path.