Method for forming micro channels in molded components and an associated micro-channel forming tool

A micro-channel forming tool for attaching to a pressing device, the micro-channel forming tool comprising:

• a first end configured to removably couple to pressing device;
• and
• a second end including a press surface that extends along a plane, the second end comprises a micro-channel detail formed on the press end and extending beyond the plane of the press surface, wherein the micro-channel detail comprises,
• a non-critical portion coupled to the press surface and extending beyond the plane to an interface, and
• a critical portion extending from the interface and supported by the non-critical portion.

A method of forming micro-channels in a plastic surface using a pressing device, the method comprising:

• structuring a micro-channel forming tool for the pressing device to comprise,
• a press end including a press surface that extends along a plane,
• a micro-channel detail positioned on the press end and extending beyond the plane of the press surface;
• installing the micro-channel forming tool onto the pressing device;
• driving the press end of the micro-channel forming tool into the plastic surface at a predetermined force using a pressing device;
• applying ultrasonic vibrations to the micro-channel forming tool at a predetermine frequency for a predetermined amount of time;
• removing the ultrasonic vibrations after the predetermined amount of time has elapsed;
• and
• retracting the press end of the micro-channel forming tool from the plastic surface, wherein the ultrasonic vibrations melt portions of the plastic surface in contact with the pressing surface of the micro-channel forming tool.