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US 6,838,041 B2Granted
Post formation profile processing
OwnerWilliam W. Rowleyinventor
Life of this patent
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Abstract
This invention relates to the post-formation processing of extruded or injection molded profiles in an economic manner without the need to purchase a blow molding machine, yet still effect post-formation radial expansion or contraction by the application of sufficient degree of heat or the performing of the operation sufficiently quickly to permit the utilization of the retained latent heat from the extrusion or injection molding process.
Claims146
A process for manufacturing a polymeric profile, comparing the steps of:
- (a) extruding a polymer having a first profile at an extrusion temperature;
- (b) cooling said polymetric profile;
- (c) cutting said profile to a predefined length, said length having a pair of ends;
- (d) rheating at least a portion of said extruded profile to at least a first temperature, said first temperature which is below a second temeperature at which the profile becomes melt processable;
- (e) sealing at least one end said profile,
- steps (d) and (e) being interchangeable;
- (f) reshaping said reheated portion of said first profile at said second temperature to a second profile by the application of internal pressure to an interior of said first profile or by the application of external vacuum to an exterior of said first profile or combinations thereof, said second profile having at least one middle internal cross-sectional dimension interior of said ends which is greater than a corresponding internal cross-sectional demension of said first profile, said second profile additionally having at least one of the following characteristics
- (i) at least two internal cross-sectional dimensions on opposed sides of said middle dimension which are smaller than said middle dimension, or
- (ii) at least two non-axially aligned segments, or
- (iii) at least two segments of different geometries in longitudinal cross-section;
- (iv) at least two non-planar aligned segments;
- and
- (g) cooling said second profile.
10 more elements
A process for manufacturing a polymeric profile, comprising the steps of:
- (a) injection molding a hollow polymer having a first profile at an injection molding temperature;
- (b) cooling said polymeric profile;
- (c) cutting said profile to a predefined length, said length having a pair of ends;
- (d) reheating at least a portion of said first profile to at least a first temperature, said first temperature which is below a second temperature at which the profile becomes melt processable;
- (e) sealing at least one end of said profile,
- steps (d) and (e) being interchangeable;
- (f) reshaping said reheated portion of said first profile at said second temperature to a second profile by the application of internal pressure to an interior of said first profile or by the application of external vacuum to an exterior of said first profile or combinations thereof, said second profile having at least one middle internal cross-sectional dimension interior of said ends which is greater than a corresponding internal cross-sectional dimension of said first profile, said second profile additionally having at least two internal cross-sectional dimensions on opposed sides of said middle dimension which are smaller than said middle dimension, said second profile additionally having at least one of the following characteristics
- (i) at least two internal cross-sectional dimensions on opposed sides of said middle dimension which are smaller than said middle dimension, or
- (ii) at least two non-axially aligned segments, or
- (iii) a least two segments of different geometries in longitudinal cross-section;
- (iv) at least two non-planar aligned segments;
- and
- (g) cooling said second profile.
10 more elements
A process comprising the steps of:
- (a) heating at least a portion of a first polymeric hollow profile to at least a first temperature, said first temperature which is below a second temperature at which the profile becomes melt processable, said first profile having a pair of ends;
- (b) sealing at least one end of said profile,
- steps (a) and (b) being interchangeable;
- (c) reshaping at least a portion of said heated portion of said first profile at said second temperature by using the application of internal pressure to an interior of said profile or by the application of external vacuum to an exterior of said profile or combinations thereof, said reshaped profile having least one middle internal cross-sectional dimension interior of said ends which is greater than a corresponding internal cross-sectional dimension of said first profile, said reshaped profile additionally having at least one of the following characteristics
- (i) at least two internal cross-sectional dimensions on opposed sides of said middle dimension which are smaller than said middle dimension, or
- (ii) at least two non-axially aligned segments, or
- (iii) at least two segments of different geometries in longitudinal cross-section;
- (iv) at least two non-planar aligned segments;
- and
- (d) cooling said reshaped profile.
7 more elements
A process comprising the steps of:
- (a) forming a polymeric hollow first profile at a forming temperature;
- (b) cooling said first profile to a temperature where said profile has at least some rigidity to permit handling without imparting permanent deformation to said profile, said temperature still being sufficiently high for said profile to be melt reformable;
- (c) cutting said first profile to a predefined length, said length having a pair of ends;
- (d) sealing at least one end of said first profile;
- (a) reshaping said profile by heating and by the application of internal pressure to an interior of said first profile or by the application of external vacuum to an exterior of said first profile or combinations thereof and using a polymeric processing technique selected from the group consisting of blow molding, compression molding and injection overmolding, said reshaped second profile additionally having at least one of the following characteristics
- (i) at least two internal cross-sectional dimensions on opposed sides of said middle dimension which are smaller than said middle dimension, or
- (ii) at least two non-axially aligned segments, or
- (iii) at least two segments of different geometries in longitudinal cross-section;
- (iv) at least two non-planar aligned segments;
- and
- (f) cooling said reshaped profile.
8 more elements
A process for manufacturing a polymeric profile, comprising the steps of:
- (a) extruding a polymer having a first profile at an extrusion temperature;
- (b) cooling said first profile to a temperature where said first profile has at least some rigidity to permit handling without imparting permanent deformation to said first profile, said temperature still being sufficiently high for said first profile to be melt reformable;
- (c) cutting said profile to a predefined length, said length having a pair of ends;
- (d) sealing at least one end of said first profile;
- (e) reshaping said first profile at said temperature at which said first profile is melt reformable into a second profile by the application of internal pressure to an interior of said first profile or by the application of external vacuum to an exterior of said first profile or combinations thereof and having at least one middle internal cross-sectional dimension interior of said ends which is greater than a corresponding internal cross-sectional dimension of said first profile, said second profile additionally having at least one of the following characteristics
- (i) at least two internal cross-sectional dimensions on opposed sides of said middle dimension which are smaller than said middle dimension, or
- (ii) at least two non-axially aligned segments, or
- (iii) at least two segments of different geometries in longitudinal cross-section;
- (iv) at least two non-planer aligned segments;
- and
- (f) cooling said second profile.
8 more elements
A process for manufacturing a polymeric profile, comprising the steps of:
- (a) injection molding a polymer having a first profile at an injection molding temperature;
- (b) cooling said first profile to a temperature where said first profile has at least some rigidity to permit handling without imparting permanent deformation to said first profile, said temperature still being sufficiently high for said first profile to be melt reformable;
- (c) cutting said profile to a predefined length, said length having a pair of ends;
- (d) sealing at least one end of said first profile;
- (c) reshaping said first profile at said temperature at which said first profile is melt reformable into a second profile by the application of internal pressure to an interior of said first profile or by the application or external vacuum to an exterior of said first profile or combinations thereof and having at least one middle internal cross-sectional dimension interior of said ends which is larger than a corresponding internal cross-sectional dimension of said first profile, said second profile additionally having
- (i) at least two internal cross-sectional dimensions on opposed sides of said middle dimension which are smaller than said middle dimension, or
- (ii) at least two non-axially aligned segments, or
- (iii) at least two segments of different geometries in longitudinal cross-section;
- (iv) at least two non-planar aligned segments;
- and
- (f) cooling said second profile.
8 more elements
A process for manufacturing a polymeric profile, comprising the steps of:
- (a) extruding a polymer having a first profile at an extrusion temperature;
- (b) cooling said first polymeric profile to a temperature wherein said profile has sufficient structure to be physically moved, yet has sufficient retained heat to be formable;
- (c) moving said first profile into a forming mold;
- (d) sealing at least one end of said first profile;
- (e) reshaping said first profile into a second profile;
- and
- (f) cooling said second profile.
4 more elements
A process for manufacturing a polymeric profile, comprising the steps of:
- (a) injection molding a polymer having a first profile at an injection molding temperature;
- (b) cooling said first polymeric profile to a temperature wherein said first profile has sufficient structure to be physically moved, yet has sufficient retained heat to be formable;
- (c) moving said first profile into a forming mold;
- (d) sealing at least one end of said first profile;
- (e) reshaping said first profile into a second profile;
- and
- (f) cooling said second profile.
4 more elements
A process for manufacturing a polymeric profile, comprising the steps of:
- (a) extruding a polymer having a first profile at an extrusion temperature;
- (b) pinching off a first end or second first profile;
- (c) pinching off an opposed second end of said first profile;
- (d) moving said profile into a forming mold;
- (e) reshaping said first profile into a second profile;
- and
- (f) cooling said second profile.
4 more elements
A process for manufacturing a polymeric profile, comprising the steps of:
- (a) extruding a polymer having a first profile at an extrusion temperature;
- (b) cutting said profile to a predefined length, said length having a pair of ends;
- (c) sealing a first end of said first profile when said first profile has cooled to a temperature wherein said profile has sufficient structure to be physically moved, yet has sufficient retained heat to be formable;
- (d) moving said first profile into a forming mold;
- (e) reshaping said first profile into a second profile by the application of internal pressure to an interior of said first profile or by the application of external vacuum to an exterior of said first profile or combinations thereof, said second profile having at least one middle internal cross-sectional dimension interior of said ends which is greater than a corresponding internal cross-sectional dimension of said first profile, said second profile additionally having at least one of the following characteristics
- (i) at least two internal cross-sectional dimensions on opposed sides of said middle dimension which are smaller than said middle dimension, or
- (ii) at least two non-axially aligned segments, or
- (iii) at least two segments of different geometries in longitudinal cross-section;
- (iv) at least two non-planar aligned segments;
- and
- (f) cooling said second profile.
8 more elements
A process which comprises the steps of:
- (a) extruding an essentially horizontal first hollow polymeric profile at an extrusion temperature;
- (b) cutting said profile to a predefined length, said length having a pair of ends;
- (c) transferring said first profile into a reforming mold;
- and
- (d) reshaping said first profile into a second profile at a reforming temperature by the application of internal pressure to an interior of first said profile or by the application of external vacuum or combinations thereof to an exterior of said first profile, said second profile having at least one middle internal cross-section dimension interior of said ends which is greater than a corresponding internal cross-sectional dimension of said first profile, said second profile additionally having at least one of the following characteristics
- (i) at least two internal cross-sectional dimensions on opposed sides of said middle dimension which are smaller than said middle dimension, or
- (ii) at least two non-axially aligned segments, or
- (iii) at least two segments of different geometrics in longitudinal cross-section;
- (iv) at least two non-planar aligned segments;
- and
7 more elements
A process which comprises the steps of:
- (a) extruding a first hollow polymeric profile;
- (b) cutting said profile to a predefined length, said length having a pair of ends;
- (c) heating at least a portion of said first hollow polymeric profile in a heating means;
- (d) transferring said first profile into a reforming mold;
- and
- (e) reshaping said first profile into a second profile at a reforming temperature by the application of internal pressure to an interior of said first profile or by the application of external vacuum or combinations thereof to an exterior of said first profile, said second profile having at least one middle internal cross-sectional dimension interior of said ends which is greater than a corresponding internal cross-sectional dimension of said first profile, said second profile additionally having at least one of the following characteristics
- (i) at least two internal cross-sectional dimensions on opposed sides of said middle dimension which are smaller than said middle dimension, or
- (ii) at least two non-axially aligned segments, or
- (iii) at least two segments of different geometries in longitudinal cross-section, or
- (iv) at least two non-planar aligned segments.
7 more elements
A process which comprises the steps of:
- (a) extruding a first hollow polymeric profile;
- (b) cutting said profile to a predefined length, said length having a pair of ends;
- (c) heating at least a portion of said length of a plurality of said first hollow polymeric profiles in a heating means;
- (d) transferring at least one of said first profiles into a reforming mold;
- and
- (e) reshaping said at least one first profile into a second profile at a reforming temperature by the application of internal pressure to an interior of said first profile or by the application of external vacuum or combinations thereof to an exterior of said first profile, said second profile having at least one middle internal cross-sectional dimension interior of said ends which is greater than a corresponding cross-sectional dimension of said first profile, said second profile additionally having at least one of the following characteristics
- (i) at least two internal cross-sectional dimensions on opposed sides of said middle dimension which are smaller than said middle dimension, or
- (ii) at least two non-axially aligned segments, or
- (iii) at least two segments of different geometries in longitudinal cross-section, or
- (iv) at least two non-planar aligned segments.
7 more elements
A process which comprises the steps of:
- (a) heating at least a portion of a length of a plurality of hollow polymeric first profiles in a heating means, each of said profiles having a pair of ends;
- (b) transferring at least one of said first profiles into a reforming mold;
- and
- (c) reshaping said at least one first profile into a second profile at a reforming temperature by the application of internal pressure to an interior of said first profile or by the application of external vacuum or combinations thereof to an exterior of said first profile, said second profile having at least one middle internal cross-sectional dimension interior of said ends which is greater than a corresponding cross-sectional dimension of said first profile, said second profile additionally having at least one of the following characteristics
- (i) at least two internal cross-sectional dimensions on opposed sides of said middle dimension which are smaller than said middle dimension, or
- (ii) at least two non-axially aligned segments, or
- (iii) at least two segments of different geometries in longitudinal cross-section, or
- (iv) at least two non-planar aligned segments.
5 more elements
A process which comprises the steps of:
- (a) extruding a first hollow polymeric profile;
- (b) cutting said profile to a predefined length, said length having a pair of ends;
- (c) heating at least a portion of said length of a plurality of said first hollow polymeric profiles in a heating means;
- (d) transferring at least one of said first profiles into a reforming mold;
- and
- (e) reshaping at least one of said first profiles into a second profile at a reforming temperature by the application of internal pressure to an interior of said first profile or by the application of external vacuum or combinations thereof to an exterior of said first profile, at least a portion of said second profile having a curvilinear internal and external profile.
3 more elements
A process which comprises the steps of:
- (a) heating at least a portion of a length of at least one said first hollow polymeric profiles in a heating means, said at least one first profile having a pair of ends;
- (b) transferring at least one of said first profiles into a reforming mold;
- and
- (c) reshaping at least one of said first profiles in said reforming mold into a second profile at a second reforming temperature by the application of internal pressure to an interior of said first profile or by the application of external vacuum or combinations thereof to an exterior of said first profile, said second reforming temperature being greater than said first temperature, at least a portion of said second profile having a curvilinear internal and external profile.
1 more element
A process for manufacturing a polymeric profile, comprising the steps of:
- (a) heating at least a portion of a length of a plurality of extruded profiles in a preheated profile heating means to a first temperature, said first temperature being lower than a second temperature at which the profile becomes melt processable;
- (b) transferring at least one of said extruded profiles into a heated die having a cavity therein, said cavity having at least one region where an internal cross-sectional dimension of the cavity is larger than an external cross-sectional dimension of said profile, a cavity temperature of said die being at a temperature which is sufficient to heat the profile from said first temperature to said second temperature;
- (c) sealing at least one end of said profile;
- (d) injecting a pressurized medium into an open end of the profile to conform the heated portion of the profile to the internal diameter of the cavity, creating a modified profile;
- (e) cooling and depressurizing the modified profile;
- and
- (f) removing the cooled modified profile from the die.
4 more elements
A process for manufacturing a polymeric profile, comprising the steps of:
- (a) heating at least a portion of a length of a plurality of initial profiles having at least two ends in a heating means to a first temperature, said first temperature being lower than a second temperature at which the initial profile becomes melt processable;
- (b) transferring at least one of said initial profiles into a heated die having a cavity therein, said cavity having at least one region where an internal cross-sectional dimension of the cavity is larger than an external cross-sectional dimension of said profile, a cavity temperature of said die being at a temperature which is sufficient to heat the profile from said first temperature to said second temperature;
- (c) sealing at least one end of said initial profile;
- (d) injecting a pressurized medium into an open end of the initial profile to conform the heated portion of the initial profile to the internal diameter of the cavity, creating a modified profile;
- (e) cooling and depressurizing the modified profile;
- and
- (f) removing the cooled modified profile from the die.
4 more elements
A process which comprises the steps of:
- (a) heating at least a portion of a length of at least one hollow polymeric first profiles in a heating means, each of said profiles having a pair of ends;
- (b) transferring at least one of said first profiles into a reforming mold;
- and
- (c) reshaping said at least one first profile into a second profile at a reforming temperature by the application of internal pressure to an interior of said first profile or by the application of external vacuum or combinations thereof to an exterior of said first profile, said second profile having at least one middle internal cross-sectional dimension interior of said ends which is greater than a corresponding cross-sectional dimension of said first profile, said second profile additionally having at least one of the following characteristics
- (i) at least two internal cross-sectional dimensions on opposed sides of said middle dimension which are smaller than said middle dimension, or
- (ii) at least two non-axially aligned segments, or
- (iii) at least two segments of different geometries in longitudinal cross-section, or
- (iv) at least two non-planar aligned segments.
5 more elements
Dependencies are inferred from the claim text.