Method to fabricate a seamless tube

1. A process for making a seamless tube from a liquid, comprising:

providing a mandrel having a longitudinal axis, an outer surface and a length;

providing a liquid material;

providing one or more doctor blades, wherein said one or more doctor blades are spaced from said mandrel outer surface and are inclined at an angle α with respect to said mandrel longitudinal axis;

applying said liquid to said outer surface and moving said one or more doctor blades along said longitudinal axis of said mandrel while rotating said mandrel around its longitudinal axis;

providing one or more fingers overlying said mandrel and positioned upstream of said one or more of blades, relative to the direction of movement of said blades along the longitudinal axis of said mandrel, and moving the fingers with the one or more doctor blades to assist feeding of said liquid thereto; and

converting said liquid material to form a seamless tube.

2. The process of claim 1 wherein said liquid material has a viscosity of between about 10,000 and 300,000 cps at a 10 sec −1 shear rate.

3. The process of claim 1 wherein the surface of said mandrel is coated with a material to aid in removal of said seamless tube from said mandrel.

4. The process of claim 1 wherein said liquid material includes one or more of the following polymers: polyimide, polysiloxane, thermosetting and thermoplastic urethanes, epoxies, polyethvlenes, polyamides, polyethylenes, polyphenylenesulfide, polyethersulfone, polysulfone, polyamideimide and fluororesins.

5. The process of claim 1 wherein each of said one or more doctor blades is spaced a different distance from said outer surface of said mandrel.

6. The process of claim 5 wherein said one or more doctor blades includes a leading blade and a trailing blade and the distance from said leading blade to said mandrel is less than the distance from said trailing blade to said mandrel, wherein less than 50% of said liquid material applied to said mandrel is applied by said trailing doctor blade.

7. The process of claim 1 wherein said angle α is 5-85 degrees relative to said longitudinal axis.

8. The process of claim 1 wherein said one or more fingers provide a pressure of 1-10 psi to said liquid material on said outer surface.

9. The process of claim 1 wherein said seamless tube has a thickness and said thickness does not vary by more than +/−10%.

10. The process of claim 1 wherein said tube has a thickness of 10-100microns.

11. The process of claim 1 wherein said mandrel is rotating at a surface speed of 10,000 mm/min to 50,000 mm/min.

12. The process of claim 1 wherein moving said one or more doctor blades along said longitudinal axis of said mandrel is at a speed of less than or equal to 2.5 mm/sec.

13. A process for making a seamless tube from a liquid, comprising:

providing a mandrel having a longitudinal axis, an outer surface and a length;

providing a liquid material;

providing a plurality of doctor blades, wherein said doctor blades are spaced from said mandrel outer surface and are inclined at an angle α with respect to said mandrel longitudinal axis, wherein said angle α is 5-85 degrees relative to said longitudinal axis;

applying said liquid to said outer surface and moving said doctor blades along said longitudinal axis of said mandrel while rotating said mandrel around its longitudinal axis;

providing a plurality of fingers overlying said mandrel and positioned upstream of said doctor blades, relative to the direction of movement of said blades along the longitudinal axis of said mandrel, and moving the fingers with the doctor blades along the longitudinal axis of the mandrel, wherein said one or more fingers provides a pressure of 1-10 psi to said liquid material on said outer surface; and

converting said liquid material to form a seamless tube.

14. The process of claim 13 wherein each of said doctor blades are spaced a different distance from said outer surface of said mandrel.

15. The process of claim 13 wherein said seamless tube has a thickness and said thickness does not vary by more than +/−10%.

16. The process of claim 1 wherein the one or a plurality of fingers move parallel to the longitudinal axis of the mandrel along with the doctor blades.

17. The process of claim 13 wherein the plurality of fingers move parallel to the longitudinal axis of the mandrel along with the doctor blades.

18. The process of claim 1 , wherein each finger includes a substantially planar surface for contacting said liquid, and the process further comprises orienting the one or more fingers relative to a surface of the one or more doctor blades so that the planar surface is positioned about 90 degrees relative to a surface of the one or more doctor blades which contacts said liquid.

19. A tube forming apparatus, comprising:

a mandrel having a longitudinal axis, an outer surface and a length, the mandrel being selectively rotated about the longitudinal axis;

one or more blades spaced from the outer surface of the mandrel and disposed at an angle with respect to the longitudinal axis of the mandrel, the one or more blades being selectively movable in a direction along the longitudinal axis of the mandrel so as to control a thickness of a formable material dispensed on the mandrel during tube forming operation; and

one or more fingers being upstream of the one or more blades and movable therewith so as to assist in feeding the formable material to the one or more blades, each finger including a substantially planar surface for contacting the formable material.

20. The apparatus of claim 19 , wherein the one or more fingers comprise a plurality of fingers, at least one finger being disposed forwardly of the one or more blades relative to a movable direction thereof.

21. The apparatus of claim 19 , wherein each finger includes a portion for attachment relative to the one or more blades.

22. The apparatus of claim 19 , wherein the planar surface of the finger is disposed at about 90 degrees relative to a surface of the one or more blades that is adjacent the mandrel.

23. The apparatus of claim 19 , wherein the one or more blades and the one or more fingers move in a substantially linear direction substantially parallel to the longitudinal axis of the mandrel.

24. The apparatus of claim 19 , wherein the one or more blades comprises a plurality of blades, each blade having a longitudinal axis that is substantially parallel to each other.