Process for thermoforming a hollow plastic article using an extendible porous male mold assembly

Claim 1

In a process for thermoforming a hollow plastic article of uniform thickness over a male mold passed through a plane of a heated sheet of thermoplastic retained between a pressure box assembly including a chamber and a male mold assembly including said male mold and wherein said article is vacuum formed about said male mold, the improvement comprising: moving said male mold assembly towards said pressure box assembly and continuing such movement whereby said male mold is passed through said plane of said heated sheet of thermoplastic material and into said chamber of said pressure box assembly, said male mold formed in part of a porous metal and having a contoured surface corresponding to said article, said male mold being extendible from said male mold assembly; placing said male mold in fluid communication with the suction side of a pump means and controlling the pressure within said chamber whereby said thermoplastic material is caused to be drawn about said male mold; and causing said male mold to move further into said chamber of said pressure box assembly by extendible relative movement of said male mold with respect to said male mold assembly while maintaining said male mold in fluid communication with said suction side of said pump and said controlling of the pressure within said chamber, said extendible relative movement being effected to a point beyond further relative movement between said pressure box assembly and said male mold assembly.