Light weight thermoplastic flex foam and hybrid duct system

1. A duct comprising:

a thermoplastic foam sheet having flammability properties for use in an environmental control system of a vehicle;

a crenulated first edge of the thermoplastic foam sheet;

a second edge of the thermoplastic foam sheet;

a seam comprising the crenulated first edge compressed and bonded with the second edge;

at least one flaring attached to an inner face of the thermoplastic foam sheet, wherein the flaring is attached along the seam and extends radially inwardly; and

at least one flaring attached to an outer face of the thermoplastic foam sheet, wherein the flaring is attached along the seam and extends radially outward.

2. The duct of claim 1 wherein the crenulated first edge and the second edge are beveled.

3. The duct of claim 1 wherein the duct is formed by wrapping the thermoplastic foam sheet around a mandrel.

4. The duct of claim 3 wherein wrapping the thermoplastic foam sheet around a mandrel defines an internal shape of the thermoplastic foam sheet, wherein an outside tool is applied against at least overlapping edges of the thermoplastic foam sheet to compress the overlapping edges together, and wherein heat is applied to the duct.

5. The duct of claim 1 wherein the duct is post-formed to a different shape.

6. The duct of claim 5 wherein the duct is post-formed into a complex shape by heating the duct and pressing the duct into a mold, wherein the complex shape is defined as either a segmented duct or a “Y” duct fitting.

7. The duct of claim 6 wherein the duct is post-formed by blowing air inside the duct while applying heat.

8. A method of forming a duct, the method comprising:

skiving a sheet from a bun, the sheet having a closed cell structure;

cutting the sheet to create a first edge and a second edge;

crenulating the first edge of the sheet so as to form a crenulated edge;

cutting the crenulated edge so as to bevel the first edge along the crenulated edge;

thermally welding the first edge to the second edge creating a seam between the first edge and the second edge to form the duct;

adding at least one flaring to an inner face of the sheet, wherein the flaring is attached along the seam and extends radially inwardly; and

adding at least one flaring to an outer face of the sheet, wherein the flaring is attached along the seam and extends radially outwardly.

9. The method of claim 8 further comprising crenulating the second edge of the sheet.

10. The method of claim 9 , wherein the first edge comprises a first crenulation pattern characterized by a first radius and the second edge comprises a second crenulation pattern characterized by a second radius, the method comprising interlocking the first radius with the second radius.

11. The method of claim 10 further comprising cutting the second edge so as to bevel the second edge such that the first edge and the second edge have reciprocal bevels.

12. The method of claim 8 , wherein the step of thermally welding further comprises compressing the first edge and the second edge.

13. The method of claim 12 further comprising applying an adhesive between the first edge and the second edge.

14. The method of claim 8 , wherein crenulating a first edge comprises forming a foot pattern.

15. A method of forming a duct, the method comprising the steps of:

skiving a thermoplastic bun having a closed cell structure to form a sheet, the thermoplastic bun comprising an expanded foam polyvinylidene fluoride (PVDF) material;

cutting the sheet to create a first edge and a second edge of the sheet;

forming a crenulation pattern in the first edge of the sheet so as to form a first crenulated edge;

forming a crenulation pattern in the second edge of the sheet so as to form a second crenulated edge;

cutting the first crenulated edge so as to create a bevel along the first crenulated edge;

cutting the second crenulated edge so as to create a bevel along the second crenulated edge, the first crenulated edge reciprocally matching the second crenulated edge;

wrapping the sheet around a mandrel;

applying pressure and heat to thermally weld the first crenulated edge and the second crenulated edge together so as to form the duct, wherein an overlapping seam of the first edge and the second edge is formed;

attaching at least one flaring to an inner face of the sheet, wherein the flaring is attached along the seam and extends radially inwardly; and

attaching at least one flaring to an outer face of the sheet, wherein the flaring is attached along the seam and extends radially outwardly.

16. The method of claim 15 , wherein the step of applying pressure and heat further comprises pressing an outside tool against the overlapping seam of the first edge and the second edge.

17. The method of claim 15 further comprising molding the duct in a mold.

18. The method of claim 15 further comprising post forming the duct with injected gas and heat.