Method for manufacturing heat-activatable articles

Claim 2

Method for manufacturing heat-activatable articles from a thermoplastic material comprising the steps of: forming a thermoplastic article into a first shape; impressing a shape memory on said thermoplastic article by introducing molecular orientations and molecular structures as a result of deformation of said first shape thereby producing a second shape, said article capable of back-deforming from said second shape to said first shape upon application of heat to said article; removing selected areas of thermoplastic material from said article after having impressed said shape memory to modify at least a portion of the molecular orientations and structures introduced in impressing said shape memory and thereby altering said second shape to form a final shape, said article being capable of deforming to a designated end use shape that differs from said first shape when said article is heated, the difference between said designated end use shape and said first shape resulting from said removal of said selected areas of material from said article; and, selecting said areas in which said thermoplastic material is removed dependent upon said designated end use shape.

Claim 3

A method as recited in claim 1, further comprising the step of applying heat to said thermoplastic article thereby causing said thermoplastic article to deform from said final shape to said designated end use shape, said designated end use shape differing from said first shape.

Claim 4

A method as recited in claim 1, wherein the step of removing selected areas of thermoplastic material is further defined by removing said areas of thermoplastic material by a mechanical process.

Claim 5

A method as recited in claim 2, wherein the step of removing selected areas of thermoplastic material is further defined by removing selected areas of said thermoplastic material by a mechanical process selected from the group consisting of milling, turning, boring and grinding processes.

Claim 6

A method as recited in claim 1, wherein the step of removing selected areas of thermoplastic material is further defined by removing said selected areas of thermoplastic material by a chemical process.

Claim 7

A method as recited in claim 5, wherein the step of removing selected areas of thermoplastic material is further defined by removing selected areas of thermoplastic material by a chemical process selected from the group consisting of etching and dissolving processes.

Claim 8

A method as recited in claim 1, wherein the step of removing selected areas of thermoplastic material is further defined by removing selected areas of said thermoplastic material at edge layers of said article.

Claim 9

A method as recited in claim 1, wherein the step of removing selected areas of thermoplastic material is further defined by removing selected areas of thermoplastic material to form a groove in said final shape of said article.

Claim 10

A method as recited in claim 1, wherein the step of removing selected areas of thermoplastic material is further defined by removing selected areas of thermoplastic material from said article to form a bore in said final shape of said article.

Claim 11

A method as recited in claim 1, further defined in that the steps of removing selected areas of thermoplastic material and impressing a shape memory on said thermoplastic material are integrated in a single process step.

Claim 12

A method as recited in claim 1, wherein the step of forming a thermoplastic article into said first shape is further defined by forming said thermoplastic article using a multi-component injection process to form said article into said first shape.

Claim 13

A method as recited in claim 1, wherein the step of removing selected areas of thermoplastic material is further defined by removing said selected areas of thermoplastic material by both a mechanical process and a chemical process.

Claim 14

A method as recited in claim 1, wherein the step of impressing said shape memory is further defined by impressing said shape memory on a thermoplastic article comprised of polyoxymethylene by said stretching process using a stretching temperature between 50° C. through 150° C.

Claim 15

A method as recited in claim 1, wherein the step of impressing said shape memory is further defined by impressing said shape memory on a thermoplastic article comprised of polyethylene by a stretching process using a stretching temperature between 50° C. through 130° C.

Claim 16

A method as recited in claim 1, wherein the step of forming said thermoplastic article into said first shape is further defined by forming said article from a thermoplastic selected from the group consisting of polyethylene, polypropylene, polyamide and polyoxymethylene.

Claim 17

Method for manufacturing heat-activatable articles of thermoplastic synthetic comprising the steps of: forming a thermoplastic article into a first shape; impressing a shape memory on said thermoplastic article by introducing molecular orientations and molecular structures as a result of deformation of said first shape thereby producing a second shape, said article capable of back-deforming from said second shape to said first shape upon application of heat to said article; removing selected areas of thermoplastic material from said article after having impressed said shape memory thereby altering said second shape to form a final shape and forming exposed surfaces where said thermoplastic material is removed, said final shape being capable of deforming to a designated end use shape that differs from said first shape when said article is heated, the difference between said designated end use shape and said first shape resulting from said removal of said selected areas of material from said article; and applying heat to said thermoplastic article thereby causing said thermoplastic article to deform from said final shape to said designated end use shape, said designated end use shape differing from said first shape, said difference particularly defined by molecular orientations in said exposed surfaces.

Claim 18

Method for manufacturing heat-activatable articles of thermoplastic synthetic comprising the steps of: forming a thermoplastic article into a first shape; impressing a shape memory on said thermoplastic article by introducing molecular orientations and molecular structures as a result of deformation of said first shape thereby producing a second shape, said article capable of back-deforming from said second shape to said first shape upon application of heat to said article; removing selected areas of thermoplastic material from said article after having impressed said shape memory thereby altering said second shape to form a final shape and forming exposed surfaces where said thermoplastic material is removed, said final shape being capable of deforming to a designated end use shape that differs from said first shape when said article is heated, the difference between said designated end use shape and said first shape resulting from said removal of said selected areas of material from said article; and applying heat to said thermoplastic article thereby causing said thermoplastic article to deform from said final shape to said designated end use shape, said designated end use shape differing from said first shape, said difference particularly defined by molecular orientations in said exposed surfaces.

Claim 19

Method for manufacturing heat-activatable articles from a thermoplastic material comprising the steps of: forming a thermoplastic article into a first shape; impressing a shape memory on said thermoplastic article by introducing molecular orientations and molecular structures as a result of deformation of said first shape thereby producing a second shape, said article capable of back-deforming from said second shape to said first shape upon application of heat to said article; dividing said article into a plurality of sub-articles after having impressed said shape memory, at least one of said sub-articles having a third shape, said at least one of said sub-articles being capable of back-deforming from said third shape to a shape corresponding to said first shape; removing selected areas of thermoplastic material from at least one of said articles having said third shape thereby altering said third shape to form a final shape and forming exposed surfaces where said thermoplastic material is removed; and applying heat to said thermoplastic article thereby causing said thermoplastic article to deform from said final shape to designated end use shape, said designated end use shape differing from said shape corresponding to said first shape.

Claim 20

Method for manufacturing heat-activatable articles from a thermoplastic material comprising the steps of: forming a thermoplastic article into a first shape; impressing a shape memory on said thermoplastic article by introducing molecular orientations and molecular structures as a result of deformation of said first shape thereby producing a second shape, said article capable of back-deforming from said second shape to said first shape upon application of heat to said article; dividing said article into a plurality of sub-articles after having impressed said shape memory, at least one of said sub-articles having a third shape, said at least one of said sub-articles being capable of back-deforming from said third shape to a shape corresponding to said first shape; removing selected areas of thermoplastic material from at least one of said articles having said third shape thereby altering said third shape to form a final shape and forming exposed surfaces where said thermoplastic material is removed; and applying heat to said thermoplastic article thereby causing said thermoplastic article to deform from said final shape to designated end use shape, said designated end use shape differing from said shape corresponding to said first shape.