Patent ID: 7128558

Claim:
An apparatus for thermoplastically forming a contour in a thermoplastic duct defining a passage, the apparatus comprising: a collar extending longitudinally from a first end to a second end and having an inner surface extending at least partially between said first and second ends, said inner surface defining a cavity; an inner support structure extending longitudinally in said cavity of said collar and having an outer surface opposing said inner surface of said collar; a plurality of heaters extending at least partially through said inner support structure and configured to heat a formation portion of the duct to at least a formation temperature; and an expansion member disposed between said inner and outer surfaces and extending at least partially around said inner support structure, wherein said collar defines a mold contour, said expansion member is formed of an elastomeric material and said inner support structure defines a channel for receiving said expansion member, a width of said channel being adjustable in the longitudinal direction of said collar to compress said expansion member in the longitudinal direction and urge said expansion member radially toward said mold contour such that said expansion member is configured to urge a formation portion of the duct against said mold contour and thereby thermoplastically form the duct.