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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 performin

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.

대표청구항 ▼

1. 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 port

1. 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. 2. The process of claim 1 wherein said step of reshaping further comprises(a) transferring said extruded profile into a 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 first profile, a cavity temperature of said die being at a temperature which is sufficient to heat said first profile from said first temperature to said second temperature. 3. The process of claim 1 wherein(a) said step of cooling is to a temperature at least 50% below said extrusion temperature; and (b) said step of reheating is to a temperature at least within 50% of said melt processing temperature. 4. The process of claim 3 wherein(a) said step of cooling is to a temperature at least 75% below said extrusion temperature; and (b) said step of reheating is to a temperature at least within 50% of said melt processing temperature. 5. The process of claim 1 wherein(a) said step of cooling is to a temperature at least where said first profile has at least some rigidity to permit handling without imparting permanent deformation to said first profile; and (b) said step of reheating is to a temperature at least within 50% of said melt processing temperature. 6. The process of claim 1 wherein(a) said first temperature is greater than or equal to approximately 40° C. and less then or equal to approximately 95% of said second temperature. 7. The process of claim 6 wherein(a) said first temperature is greater than or equal to approximately 65° C. and less than or equal to approximately 95% of said second temperature. 8. The process of claim 1 wherein(a) a difference between said first and second temperatures is between approximately 5 and 30% inclusive of said second temperature. 9. The process of claim 8 wherein(a) the difference between said first and second temperatures is between approximately 8 and 15% inclusive of said second temperature. 10. The process of claim 2 wherein(a) said cavity in said die has at least two bends wherein each of the at least two bends defines an angle and an associated plane, such that a first bend and at least one other of the at least two bends lie in intersecting planes. 11. The process of claim 10 wherein(a) the die is a split mold die with no moving components within said die. 12. The process of claim 2 wherein prior to said step of reshaping,(a) said first profile is transferred from a profile heating means to said die with said first profile having at least one unheated end. 13. The process of claim 12 wherein prior to said stop of reshaping.(a) said first profile is transferred from a profile heating means to said die with said first profile having two unheated ends. 14. The process of claim 2 wherein prior to said step of reshaping,(a) said first profile is transferred from a profile heating means to said die wherein said first profile is completely heated. 15. The process of claim 2 wherein said step of reshaping further comprises(a) applying suction to said cavity. 16. The process of claim 1 which further comprises(a) a step of compression molding at least one end on said first or second profile. 17. The process of claim 16 wherein the step of compression molding comprisesmolding an end cap comprising the steps of: (a) inserting a first end of said profile through a female end cap die, the female end cap die surrounding and the first outer diameter of the profile and having a projection adapted to cooperate with a recess of a male end cap die; (b) heating a portion of the profile projecting from the female end cap die sufficiently to make such projecting portion pliable enough to form; and (c) forming the heated portion of the profile into a end cap by the cooperation of the projection of the female end cap die and recess of the male end cap die by closing the female and male end cap dies, the end cap die further comprising: (i) an end face and (ii) a sealing means with a centrally disposed aperture therethrough. 18. The process of claim 17 wherein the sealing means is selected from the group consisting of a radiused sealing means and a conical sealing means.19. The process of claim 17 which further comprises(a) insertion of a separate sealing means which is softer than the profile over the end face of the cap so as to form a nose cone. 20. The process of claim 16 wherein(a) said step of compression molding comprises a step of forming a belled end on one end of said profile. 21. The process of claim 20 wherein the step of forming a belled end comprising the steps of:(a) inserting an end of the profile through a female belling die, the female belling die surrounding a first outer diameter of the profile and having a projection adapted to cooperate with a recess of a male belling die; (b) heating a portion of the profile projecting from the female belling die sufficiently to make such projecting portion pliable enough to form; (c) forming the heated portion of the profile into the belled end by the cooperation of the recess of the male belling die and the projection of the female belling die by closing the male and female belling dies. 22. The process of claim 21 which further comprises a step of:(a) placing the projecting end of the profile partially on an elongated male belling die projection of the male belling die with the projection closely conforming to a first internal diameter of the projecting end of the profile, the male belling die including a recess which increases from the first internal diameter to a second internal diameter and correspondingly increased from a first outer diameter to a second outer diameter so as to maintain at least the same thickness, from which the male die projection projects axially and concentrically. 23. The process of claim 1 which further comprises a step of:(a) overmolding at least one second polymer onto said first or second profile. 24. The process of claim 23 wherein the step of overmolding comprises:(a) inserting a first end of a rigid core insert into a closely-fitting hollow profile having a first polymeric composition, said cylindrical core insert comprising a non-ribbed end for insertion into the profile; (b) molding a polymer having a second polymeric composition over at least a portion of the profile and over at least a portion of the core insert thereby forming a connector having an overmolded flexible segment; (c) removing the overmolded flexible segment from the core insert by application of a longitudinal axial force. 25. The process of claim 24 wherein(a) said core insert further comprises a ribbed portion and (b) said step of molding the polymer having the second polymeric composition also comprises molding said polymer over at least a portion of the ribbed portion of the core. 26. The process of claim 25 which further comprises:(a) sealing a second opposed end of the profile with a sealing means; (b) pressurizing the profile with a controllable pressurizing means to an internal pressure at which radial expansion of the ribbed segment will permit longitudinal movement of the ribbed segment over the ribbed portion of the core insert; and (c) removing the overmolded flexible ribbed segment by application of a longitudinal axial force. 27. The process of claim 26 wherein(a) the pressurizing means is a controllable supply of a compressible gas. 28. The process of claim 27 wherein(a) the step of pressurizing the profile is to a pressure from about 20 to about 100 psig. 29. The process of claim 26 wherein(a) the step of sealing the second opposed end of the profile with the sealing means is with a tapered plug inserted into the opposed end. 30. The process of claim 24 wherein(a) the step of overmolding occurs in a split die having a cavity therein. 31. The process of claim 23 wherein(a) the first polymeric composition is a thermoplastic and (b) the second polymeric composition is selected from the group consisting of thermoplastic elastomers and rubbers having a shore A durometer from approximately 45-85 inclusive. 32. The process of claim 31 wherein(a) the first and second polymeric compositions are selected independently from the group consisting of polyacetals, poly(meth)acrylics, polyarylether ketones, polyether ketones, polyacrylonitrile resins, polyamides, polyamide-imides, polyacrylates, polybutene resins, polycarbonates, polyalkylene terephthalates, polyetherimides, polyethylene homopolymers, polyethylene copolymers, polypropylene homopolymers, polypropylene copolymers, ethylene acid copolymers, ethylene-vinyl acetate copolymers, ethylene-vinyl alcohol copolymers, polyimides, polyphenylene oxides, polyphenylene sulfides, acrylonitrile butadiene styrene terpolymers, polystyrenes, styrene-acrylonitrile copolymers, styrene-butadiene copolymers, styrene maleic anhydride copolymers, polyarylsulfones, polyethersufones, polysulfones, thermoplastic styrenic block copolymers, thermoplastic polyolefin blends, thermoplastic elastomeric alloys, thermoplastic polyurethanes, thermoplastic copolyesters, thermoplastic polyamides, polyvinyl chlorides, chlorinated polyvinyl chlorides, polyvinylidene chlorides, allyl thermosets of allyl esters, bismaleimides, epoxy resins, phenolic resins, unsaturated thermoset polyesters, thermoset polyimides, polyurethanes, urea and melamine formaldehyde resins. 33. The process of claim 31 wherein(a) the first polymeric composition has a higher melt temperature than the second polymeric composition. 34. The process of claim 24 wherein(a) an exterior diameter of the core insert is in frictional engagement with an internal diameter of the core insert. 35. The process of claim 23 wherein(a) the second polymeric composition is in leak-proof engagement with the first polymeric composition by having at least a portion of the second polymeric composition which is melt fusible with at least a portion of the first polymeric composition at an interface of the first and second polymeric compositions. 36. The process of claim 35 wherein(a) the first polymeric composition is a polypropylene; and (b) the second polymeric composition is a thermoplastic elastomer. 37. The process of claim 35 wherein(a) the first and second polymeric compositions are different. 38. The process of claim 23 wherein the second polymeric composition is in leak-proof engagement with the first polymeric composition by having at least a portion of the second polymeric composition which is at least partially miscible with at least a portion of the first polymeric composition at an interface of the first and second polymeric compositions.39. The process of claim 23 wherein the second polymeric composition is in leak-proof engagement with the first polymeric composition, said leak-proof engagement being effected by a relaxation of internal stresses within the second polymeric composition thereby permitting a shrinking of the second polymeric composition about an exterior diameter of the first polymeric composition.40. The process of claim 23 which further comprises a step of:(a) overmolding a second polymeric composition onto a non-end region of the extruded profile. 41. The process of claim 1 which further comprises a step of:(a) blow molding a check valve into said extruded profile. 42. The process of claim 41 which further comprises the steps of:(a) healing at least a portion of the extruded profile in a non-end region of the profile; (b) inserting a ball into said heated portion of the profile, said ball having a diameter which permits insertion into the extruded profile; (c) inserting the heated portion of the connector into a check valve mold having a check valve cavity, said check valve cavity having (i) a plurality of expanded ribs on one side of the check valve cavity and a corresponding number of valleys between said ribs, an internal diameter of the valleys being smaller than the diameter of the ball, and (ii) a restricted neck region at an opposed side of the check valve cavity, said restricted neck region having a smaller diameter than the diameter of the ball; (d) cooling said profile; and (e) removing said profile from said die. 43. The process of claim 42 wherein(a) said step of inserting the ball occurs subsequent to the cooling of said profile, but yet when said profile is still at a temperature which permits radial expansion of the restricted neck region by the application of a longitudinal force on the ball in that neck region, and (b) return of said restricted neck region to said smaller diameter than that of the diameter of the ball. 44. The process of claim 1 which further comprises a step of:(a) blow molding a ribbed segment into said extruded profile in a non-end region of the profile. 45. The process of claim 1 wherein(a) an initial degree of crosslinking of the profile prior to heating to said first temperature is less than or equal to 50%. 46. The process of claim 45 wherein(a) the initial degree of crosslinking of the profile prior to heating to said first temperature is less than or equal to 35%. 47. The process of claim 45 wherein(a) a final degree of crosslinking of the profile after heating said profile to said second temperature and after curing is greater than or equal to 60%. 48. The process of claim 47 wherein(a) said final degree of crosslinking of the profile after heating said profile to said second temperature and after curing is greater than or equal to 85%. 49. The process of claim 1 wherein(a) an initial degree of crosslinking of the profile prior to heating to said first temperature is less than or equal to 50% and a final degree of crosslinking of said profile after curing is greater than or equal to 60%. 50. The process of claim 49 wherein(a) said initial degree of crosslinking of the profile prior to heating to said first temperature is less then or equal to 35% and said final degree of crosslinking of said profile after curing is greater than or equal to 85%. 51. 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. 52. The process of claim 51 wherein said step of reshaping further comprises(a) transferring said profile into a 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 first profile, a cavity temperature of said die being at a temperature which is sufficient to heat said first profile from said first temperature to said second temperature. 53. The process of claim 51 wherein(a) said step of cooling is to a temperature at least 50% below said extrusion temperature; and (b) said step of reheating is to a temperature at least within 50% of said melt processing temperature. 54. The process of claim 53 wherein(a) said step of cooling is to a temperature at least 75% below said extrusion temperature; and (b) said step of reheating is to a temperature at least within 50% of said melt processing temperature. 55. The process of claim 51 wherein(a) said step of cooling is to a temperature at least where said first profile has at least some rigidity to permit handling without imparting permanent deformation to said first profile; and (b) said step of reheating is to a temperature at least within 50% of said melt processing temperature. 56. The process of claim 51 wherein(a) said first temperature is greater than or equal to approximately 40° C. and less than or equal to approximately 95% of said second temperature. 57. The process of claim 56 wherein(a) said first temperature is greater than or equal to approximately 65° C. and less than or equal to approximately 95% of said second temperature. 58. The process of claim 51 wherein(a) a difference between said first and second temperatures is between approximately 5 and 30% inclusive of said second temperature. 59. The process of claim 58 wherein(a) the difference between said first and second temperatures is between approximately 8 and 15% inclusive of said second temperature. 60. The process of claim 52 wherein(a) said cavity in said die has at least two bends wherein each of the at least two bends defines an angle and an associated plane, such that a first bend and at least one other of the at least two bonds lie in intersecting planes. 61. The process of claim 60 wherein(a) the die is a split mold die with no moving components within said die. 62. The process of claim 52 wherein prior to said step of reshaping,(a) said first profile is transferred from a profile heating means to said die with said first profile having at least one unheated end. 63. The process of claim 62 wherein prior to said step of reshaping,(a) said first profile is transferred from a profile heating means to said die with said first profile having two unheated ends. 64. The process of claim 52 wherein prior to said step of reshaping,(a) said first profile is transferred from a profile heating means to said die wherein said first profile is completely heated. 65. The process of claim 52 wherein said step of reshaping further comprises(a) applying suction to said cavity. 66. The process of claim 51 which further comprises a step of compression molding at least one end on said first or second compression molded profile.67. The process of claim 66 wherein the step of compression molding comprises molding an end cap comprising the steps of:(a) inserting a first end of said profile through a female end cap die, the female end cap die surrounding and the first outer diameter of the profile and having a projection adapted to cooperate with a recess of a male end cap die; (b) heating a portion of the profile projecting from the female end cap die sufficiently to make such projecting portion pliable enough to form; and (c) forming the heated portion of the profile into an end cap by the cooperation of the projection of the female end cap die and recess of the male end cap die by closing the female and male end cap dies, the end cap die further comprising: (i) an end face and (ii) a sealing means with a centrally disposed aperture therethrough. 68. The process of claim 67 wherein the sealing means is selected from the group consisting of a radiused sealing means and a conical sealing means.69. The process of claim 67 which further comprises(a) insertion of a separate sealing means which is softer than the profile over the end face of the cap so as to form a nose cone. 70. The process of claim 66 wherein(a) said step of compression molding comprises forming a belled end on one end of said profile. 71. The process of claim 70 wherein the step of forming a belled end comprising the steps of:(a) inserting an end of the profile through a female belling die, the female belling die surrounding a first outer diameter of the profile and having a projection adapted to cooperate with a recess of a male belling die; (b) heating a portion of the profile projecting from the female belling die sufficiently to make such projecting portion pliable enough to form; (c) forming the heated portion of the profile into the belled end by the cooperation of the recess of the male belling die and the projection of the female belling die by closing the male and female belling dies. 72. The process of claim 71 which further comprises the step of:(a) placing the projecting end of the profile partially on an elongated male belling die projection of the male belling die with the projection closely conforming to a first internal diameter of the projecting end of the profile, the male belling die including a recess which increases from the first internal diameter to a second internal diameter and correspondingly increased from a first outer diameter to a second outer diameter so as to maintain at least the same thickness, from which the male die projection projections axially and concentrically. 73. The process of claim 51 which further comprises a step of:(a) overmolding at least one second polymer onto said molded profile. 74. The process of claim 73 wherein the step of overmolding comprises:(a) inserting a first end of a rigid core insert into a closely-fitting hollow profile having a first polymeric composition, said cylindrical core insert comprising a non-ribbed end for insertion into the profile; (b) molding a polymer having a second polymeric compositions over at least a portion of the profile and over at least a portion of the core insert thereby forming a connector having an overmolded flexible segment; (c) removing the overmolded flexible segment from the core insert by application of a longitudinal axial force. 75. The process of claim 74 wherein(a) said core insert further comprises a ribbed portion and (b) said step of molding the polymer having the second polymeric composition also comprises molding said polymer over at least a portion of the ribbed portion of the core. 76. The process of claim 75 which further comprises:(a) sealing a second opposed end of the profile with a sealing means; (b) pressurizing the profile with a controllable pressurizing means to an internal pressure at which radial expansion of the ribbed segment will permit longitudinal movement of the ribbed segment over the ribbed portion of the core insert; and (c) removing the overmolded flexible ribbed segment by application of a longitudinal axial force. 77. The process of claim 76 wherein(a) the pressurizing means is a controllable supply of a compressible gas. 78. The process of claim 77 wherein(a) the step of pressurizing the profile is to a pressure from about 20 to about 100 psig. 79. The process of claim 76 wherein(a) the step of sealing the second opposed end of the profile with the sealing means is with a tapered plug inserted into the opposed end. 80. The process of claim 74 wherein(a) the step of overmolding occurs in a split die having a cavity therein. 81. The process of claim 73 wherein(a) the first polymeric composition is a thermoplastic and (b) the second polymeric composition is selected from the group consisting of thermoplastic elastomers and rubbers having a shore A durometer from approximately 45-85 inclusive. 82. The process of claim 81 wherein(a) the first and second polymeric compositions are selected independently from the group consisting of polyacetals, poly(meth)acrylics, polyarylether ketones, polyether ketones, polyacrylonitrile resins, polyamides, polyamide-imides, polyacrylates, polybutene resins, polycarbonates, polyalkylene terephthalates, polyetherimides, polyethylene homopolymers, polyethylene copolymers, polypropylene homopolymers, polypropylene copolymers, ethylene acid copolymers, ethylene-vinyl acetate copolymers, ethylene-vinyl alcohol copolymers, polyimides, polyphenylene oxides, polyphenylene sulfides, acrylonitrile butadiene styrene terpolymers, polystyrenes, styrene-acrylonitirile copolymers, styrene-butadiene copolymers, styrene maleic anhydride copolymers, polyarylsulfones, polyethersufones, polysulfones, thermoplastic styrenic block copolymers, thermoplastic polyolefin blends, thermoplastic elastomeric alloys, thermoplastic polyurethanes, thermoplastic copolyesters, thermoplastic polyamides, polyvinyl chlorides, chlorinated polyvinyl chlorides, polyvinylidene chlorides, allyl thermosets of allyl esters, bismaleimides, epoxy resins, phenolic rooms, unsaturated thermoset polyesters, thermoset polyimides, polyurethanes, urea and melamine formaldehyde resins. 83. The process of claim 81 wherein(a) the first polymeric composition has a higher melt temperature than the second polymeric composition. 84. The process of claim 74 wherein(a) an exterior diameter of the core insert is in frictional engagement with an internal diameter of the core insert. 85. The process of claim 73 wherein(a) the second polymeric composition is in leak-proof engagement with the first polymeric composition by having at least a portion of the second polymeric composition which is melt fusible with at least a portion of the first polymeric composition at an interface of the first and second polymeric compositions. 86. The process of claim 85 wherein(a) the first polymeric composition is a polypropylene; and (b) the second polymeric composition is a thermoplastic elastomer. 87. The process of claim 85 wherein(a) the first and second polymeric compositions are different. 88. The process of claim 73 wherein the second polymeric composition is in leak-proof engagement with the first polymeric composition by having at least a portion of the second polymeric composition which is at least partially miscible with at least a portion of the first polymeric composition at an interface of the first and second polymeric compositions.89. The process of claim 73 wherein the second polymeric composition is in leak-proof engagement with the first polymeric composition, said leak-proof engagement being effected by a relaxation of internal stresses within the second polymeric composition thereby permitting a shrinking of the second polymeric composition about an exterior diameter of the first polymeric composition.90. The process of claim 73 which further comprises overmolding a second polymeric composition onto a non-end region of the extruded profile.91. The process of claim 51 which further comprises blow molding a check valve into said extruded profile.92. The process of claim 91 which further comprises the steps of:(a) heating at least a portion of the extruded profile in a non-end region of the profile; (b) inserting a ball into said heated portion of the profile, said ball having a diameter which permits insertion into the extruded profile; (c) inserting the heated portion of the connector into a check valve mold having a check valve cavity, said check valve cavity having (i) a plurality of expanded ribs on one side of the check valve cavity and a corresponding number of valleys between said ribs, an internal diameter of the valleys being smaller than the diameter of the ball, and (ii) a restricted neck region at an opposed side of the check valve cavity, said restricted neck region having a smaller diameter than the diameter of the ball; (d) cooling said profile; and (e) removing said profile from said die. 93. The process of claim 92 wherein(a) said step of inserting the ball occurs subsequent to the cooling of said profile, but yet when said profile is still at a temperature which permits radial expansion of the restricted neck region by the application of a longitudinal force on the ball in that neck region, and (b) return of said restricted neck region to said smaller diameter than that of the diameter of the ball. 94. The process of claim 51 which further comprises blow molding a ribbed segment into said extruded profile in a non-end region of the profile.95. The process of claim 51 wherein(a) an initial degree of crosslinking of the profile prior to heating to said first temperature is less than or equal to 50%. 96. The process of claim 95 wherein(a) the initial degree of crosslinking of the profile prior to heating to said first temperature is less than or equal to 35%. 97. The process of claim 95 wherein(a) a final degree of crosslinking of the profile after heating said profile to said second temperature and after curing is greater than or equal to 60%. 98. The process of claim 97 wherein(a) said final degree of crosslinking of the profile after heating said profile to said second temperature and after curing is greater than or equal to 85%. 99. The process of claim 51 wherein(a) an initial degree of crosslinking of the profile prior to healing to said first temperature is less than or equal to 50% and a final degree of crosslinking of said profile after curing is greater than or equal to 60%. 100. The process of claim 99 wherein(a) said initial degree of crosslinking of the profile prior to heating to said first temperature is less than or equal to 35% and said final degree of crosslinking of said profile after curing is greater than or equal to 85%. 101. 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. 102. The process of claim 101 wherein(a) said step of cooling is to a temperature at least 50% below said forming temperature; and (b) said step of reheating is to a temperature at least within 50% of said melt processing temperature. 103. The process of claim 102 wherein(a) said step of cooling is to a temperature at least 75% below said forming temperature; and (b) said step of reheating is to a temperature at least within 50% of said melt processing temperature. 104. The process of claim 101 wherein(a) said step of cooling is to a temperature at least where said first profile has at least some rigidity to permit handling without imparting permanent deformation to said profile; and (b) said step of reheating is to a temperature at least within 50% of said melt processing temperature. 105. The process of claim 101 wherein(a) said first temperature is greater than or equal to approximately 40° C. and less than or equal to approximately 95% of said second temperature. 106. The process of claim 105 wherein(a) said first temperature is greater than or equal to approximately 65° C. and less than or equal to approximately 95% of said second temperature. 107. The process of claim 101 wherein(a) a difference between said first and second temperatures is between approximately 5 and 30% inclusive of said second temperature. 108. The process of claim 107 wherein(a) the difference between said first and second temperatures is between approximately 8 and 15% inclusive of said second temperature. 109. 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. 110. The process of claim 109 wherein(a) said polymeric profile is at least a partially crosslinked polymeric profile. 111. The process of claim 110 wherein(a) said at least partially crosslinked polymer profile is at least partially crosslinked polyethylene. 112. 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. 113. The process of claim 112 wherein(a) said polymeric profile is at least a partially crosslinked polymeric profile. 114. The process of claim 113 wherein(a) said at least partially crosslinked polymeric profile is at least partially crosslinked polyethylene. 115. 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. 116. The process of claim 115 wherein(a) said polymeric profile is at least a partially crosslinked polymeric profile. 117. The process of claim 116 wherein(a) said at least partially crosslinked polymeric profile is at least partially crosslinked polyethylene. 118. 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. 119. The process of claim 118 wherein(a) said polymeric profile is at least a partially crosslinked polymeric profile. 120. The process of claim 119 wherein(a) said at least partially crosslinked polymeric profile is at least partially crosslinked polyethylene. 121. The process of claim 118 wherein(a) said step of cooling said first polymeric profile is at least between about 2 to 5 seconds. 122. 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. 123. The process of claim 122 wherein(a) said polymeric profile is at least a partially crosslinked polymeric profile. 124. The process of claim 123 wherein(a) said at least partially crosslinked polymeric profile is at least partially crosslinked polyethylene. 125. The process of claim 122 wherein(a) said step of cooling said first polymeric profile is at least between about 2 to 5 seconds. 126. 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. 127. The process of claim 126 wherein(a) said polymeric profile is at least a partially crosslinked polymeric profile. 128. The process of claim 127 wherein(a) said at least partially crosslinked polymeric profile is at least partially crosslinked polyethylene. 129. The process of claim 126 wherein(a) said step of extruding further comprised an addition of air into said first profile inside an extrusion die to hold a cross-section of said profile open. 130. 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. 131. The process of claim 130 wherein(a) said polymeric profile is at least a partially crosslinked polymeric profile. 132. The process of claim 131 wherein(a) said at least partially crosslinked polymeric profile is at least partially crosslinked polyethylene. 133. 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 134. The process of claim 133 wherein(a) said polymeric profile is at least a partially crosslinked polymeric profile. 135. The process of claim 134 wherein(a) said at least partially crosslinked polymeric profile is at least partially crosslinked polyethylene. 136. The process of claim 133 wherein(a) said step of transferring is at a temperature which is lower than said extrusion temperature, yet higher than said reforming temperature. 137. The process of claim 136 wherein(a) said step of transferring is at a temperature which is lower than said reforming temperature; and (b) said step of reshaping further comprises a step of heating to at least said reforming temperature. 138. 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. 139. 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. 140. 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. 141. 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. 142. 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. 143. The process of claim 142 which further comprises(a) a step of sealing at least one end prior to said step of reshaping. 144. 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. 145. 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. 146. 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.