Patent ID: 6988305

Claim:
A method for blow molding a large part, comprising the steps of: providing a reinforced plastic melt comprising at least one thermoplastic material and reinforcement particles dispersed within the at least one thermoplastic material, the reinforcement particles comprising less than 15% of a total volume of the plastic melt, at least 50% of the reinforcement particles having a thickness of less than about 20 nanometers, and at least 99% of the reinforcement particles having a thickness of less than about 30 nanometers; communicating a tubular formation of said plastic melt to a mold assembly having a mold cavity defined by mold surfaces, said mold surfaces corresponding to a configuration of the part to be molded, an amount of said plastic melt communicated to said mold assembly being sufficient to form a part having a weight of at least 2 pounds and a total surface area of at least 400 sq. inches; applying pressurized gas to an interior of said tubular formation to expand said tubular formation into conformity with said mold surfaces; solidifying said plastic melt to form said part; and removing said part from said mold assembly.