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WO1999039889A1 - Appareil de moulage thermiquement efficace et procede de fabrication associe - Google Patents

Appareil de moulage thermiquement efficace et procede de fabrication associe Download PDF

Info

Publication number
WO1999039889A1
WO1999039889A1 PCT/US1999/002565 US9902565W WO9939889A1 WO 1999039889 A1 WO1999039889 A1 WO 1999039889A1 US 9902565 W US9902565 W US 9902565W WO 9939889 A1 WO9939889 A1 WO 9939889A1
Authority
WO
WIPO (PCT)
Prior art keywords
mold
active surface
active
model
mold insert
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1999/002565
Other languages
English (en)
Inventor
Terrance Feeley
Paul Jacobs
Thomas Mcdonald
Mark Mello
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EXPRESS TOOL Inc
Original Assignee
EXPRESS TOOL Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by EXPRESS TOOL Inc filed Critical EXPRESS TOOL Inc
Priority to AU24966/99A priority Critical patent/AU2496699A/en
Publication of WO1999039889A1 publication Critical patent/WO1999039889A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3828—Moulds made of at least two different materials having different thermal conductivities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means
    • B29C33/04—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means using liquids, gas or steam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
    • B29C33/565—Consisting of shell-like structures supported by backing material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/38—Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • B29C33/3835—Designing moulds, e.g. using CAD-CAM

Definitions

  • a mold insert generally consists of an active surface which contains the contours critical to accurate replication of the product, partings lines at which the mold inserts mate, and a body which provides structural integrity to the mold insert. These components are cast as a block and then machined. In order to achieve molds having active surfaces that provide accurate reproduction of the product with every manufacturing cycle, the active mold surface must have a hard detailed finish which in most processes requires complex and time consuming machining. Such molds or tools must be long lasting so that their cost can be amortized over as large a number of manufacturing cycles as possible.
  • Tool making has become the only low speed operation in the manufacturing process. For example, a typical tooling operation may require 12 to 18 weeks preparation time. Tooling is also recognized as one of the most expensive of the preproduction investments. It is the purpose of this invention to provide a high speed method of tool making at reduced cost. In addition, a tool is provided which minimizes the need for extensive finish machining by obtaining near net shape from a casting process.
  • the basic elements of the shape forming tools need to be identified.
  • the invention is described in the context of the casting of mold inserts used in the injection molding of plastic articles. Since the item being described is a mold which is itself cast from a mold, the clear designation of the parts is essential for understanding.
  • the mold inserts which are being cast in the method of this invention have active surfaces which mirror the contour of the article to be eventually formed.
  • the metal mold inserts are referred to as a core and a cavity which are assembled along mating parting surfaces. It should be understood that the mold inserts and process of this invention may be used for a wide variety of casting and molding applications.
  • One method of forming the core and cavity is investment casting.
  • Conventional investment casting involves a time consuming construction of a wax pattern mold. It is the purpose of this invention to use a simplified and more rapid process of investment casting.
  • the general sequence in the standard investment casting process consists of: making steel or aluminum molds from which a wax pattern of the final production article is formed; the wax pattern is coated with a ceramic slurry and hardened to form a ceramic shell enclosing the wax pattern; the wax pattern is then heated to remove the wax from the ceramic shell; the now hollow ceramic shell is then fired to obtain the necessary hardness and filled with molten metal to form a metal casting; and the ceramic shell is then broken to release the metal casting.
  • This positive element, thus formed, is then used to cast the molds for the article, i.e., negative forms of core and cavity.
  • the core and cavity formed in this manner generally consist of a solid block of hardened tool material. It is the purpose of this invention to utilize computer modeling to form an equivalent of the wax pattern directly, thereby eliminating the need for steel or aluminum wax pattern molds and accelerating the investment casting process. This will reduce the time required for the overall mold making process and allow a flexibility in mold design that was not heretofore available.
  • the present state of the art has sacrificed the thermal efficiency of the mold inserts through the use of tool steel as the primary construction material. Although having the required hardness, such steels exhibit poor thermal conductivity when compared to copper and even aluminum. This inhibits the thermal efficiency of the completed tool. It is desirable to remove the heat of the molten plastic as quickly as possible to obtain rapid and even solidification of the plastic part and to minimize lingering hot spots. This will improve the mold cycle time and the accuracy of the parts produced. It is the purpose of this invention, to conveniently employ materials of high thermal conductivity and to construct cooling channels which conform to the high thermal stress lines of the active surface of the mold. In this manner the thermal efficiency of the mold inserts of this invention will be superior to the tools of the prior art.
  • a mold insert or tool of this invention is constructed having; an active surface formed as a thin shell from a hardened tool material, cooling passages molded into the back of the active surface element in an arrangement which substantially conforms to the thermal stress lines generated by the shape of the active surface, a copper cooling layer to enclose the cooling passages, and to add structure to the mold insert.
  • the thin shell active surface element is formed from a computer generated positive model of the end article which is generated through state of the art CAD/CAM or similar computer modeling techniques. From this model, a stereolithography file (STL file) is constructed which represents an accurate depiction of the active surface shell.
  • the STL file allows the creation of a pattern of the active surface shell consisting of a thin skin supported internally by a honeycomb like structure. It is the pattern that is used to investment cast the active surface shell.
  • engagement channels such as dovetail slots
  • the active surface shell is mounted in an appropriate spray box for additional processing to complete the mold insert.
  • the active surface element is thermally analyzed to identify the optimum location for cooling channels.
  • Either bent copper tubing or an extruded wax mandrel of the cooling channel is constructed and arranged on the back of the active surface element to conform to the location of the maximum thermal stresses. In this manner the cooling efficiency of the channels is optimized.
  • a copper thermal layer is applied by spraying to encapsulate the cooling channels and provide structure to the active surface element.
  • the combination of conformal cooling channels in a copper matrix creates a very effective cooling layer.
  • the active surface shell and copper cooling layer is further supported by further application of sprayed copper behind the cooling layer.
  • the mold insert After the mold insert is removed from the spray box, it may be machined, as needed, to improve the accuracy of the active surface. In general a tolerance of ⁇ .020 inches is reasonably obtainable from the investment casting process. A further machining step is needed to bring the active surface to within a tolerance of ⁇ .005 inches as generally required for quality tooling. The end result is a durable mold insert which provides superior cooling properties in a more rapid time frame.
  • Figure 1 is a schematic view of the cooling configuration of the prior art
  • FIG. 2 is a schematic view of the cooling configuration of this invention
  • Figure 3 is a cross sectional view of the mold insert of this invention.
  • Figure 4 is a cross sectional view of the stereolithography pattern used in the casting process of this invention.
  • Figure 5a is a cross sectional view of the engagement slots of this invention.
  • Figure 5b is a plan view of the back of the active surface element of this invention showing the engagement slots
  • Figure 6 is a cross sectional view of the conformal cooling passages of this invention. Detailed Description of the Invention
  • the mold insert 1 of this invention consists of an active surface shell 2, cooling layer 3, and a structural backing 4.
  • Active surface shell 2 is constructed of hardened tool material, such as steel or beryllium-copper, having a uniform thickness (t) .
  • the active surface 5 forms the tool face.
  • the back face 6 of the active surface shell 2 is formed with slots 7 having a dove tail cross section to enhance bonding of the cooling layer 3.
  • the slots may be formed in a variety of cross sections and arrangements as shown in figures 5a and 5b.
  • Cooling layer 3 consists of cooling passages 8 which are arranged to substantially conform to the thermal stress lines of the active surface shell 2.
  • the passages are formed from bent copper tubing or extruded flexible mandrels which can follow the contours of the active surface shell 2, where necessary, to remove hot spots and promote efficient cooling. In the prior art, these passages generally must be formed in a solid block of steel which is the mold insert. The passages must be formed by drilling and are therefore limited to straight passages having a circular cross section, as shown in figures 1 and 6. These straight passages limit the positioning of the channels 8 and prevent access of cooling media to the most critical thermal zones.
  • a passage cross section can be constructed having an extended surface area such as the star shape shown in figures 3 and 6. This maximizes the cooling performance of the cooling passages 8.
  • the channels or passages 8 may be arranged to provide cooling media to the zones of the mold insert 1 that are at the highest thermal stress.
  • a material 9, having high thermal conductivity such as copper or aluminum, is sprayed to a thickness which encloses the cooling channels 8.
  • the application of the copper or aluminum will fill the engaging slots 7, thereby improving the integrity of the bond between the active surface element 2 and the cooling layer 3.
  • These channels under some conditions could be used for heating as well and may be appropriately referred to as thermal management channels.
  • a backing layer 4 is bonded to the cooling layer 3 and is constructed of additional sprayed copper or aluminum. It should be noted that although spraying is specified any appropriate deposition method may be employed.
  • the active surface shell 2 is investment cast as a thin shell using computer aided processes such as: QUICKCAST® or ACTUA- 2100 developed by 3D Systems, Inc. and MODELMAKER developed by Sanders Prototyping, Inc. Investment casting in general and the computer aided processes in particular works best when the sections to be cast are as close to uniform thickness as possible. Although, such methods have been used to cast mold inserts, it is a unique application of these processes to form only a thin shell active surface.
  • the investment casting process is generally time consuming and expensive because the wax patterns require the fabrication of wax injection tooling prior to the investment of the wax pattern in ceramic slurry.
  • the computer model is used to construct the equivalent of a wax model or pattern by stereolithography (STL) .
  • pattern 10 of the active surface shell 2 is generated which consists essentially of an exterior skin 11, which is less than 1 mm thick.
  • the skin 11 is supported internally by a quasi-hollow honeycomb-type structure 12, shown schematically in Figure 4.
  • the STL pattern 10 is then used to investment cast active surface shell 2, thereby entirely bypassing the expensive and time consuming step of fabricating steel or aluminum wax pattern injection tooling.
  • the active surface 5 must still be machined as a final finishing step to obtain the desired tolerance of ⁇ .005 inches.
  • the completed computer model of the active surface element may now be converted to a stereolithography file or STL file and the pattern 11 is constructed.
  • the pattern 11 is then used in the investment casting process, as described earlier.
  • a steel hardened tool or material embodiment of the active surface shell 2, including the dovetail channels, is thereby obtained.
  • the active surface shell 2 is then mounted in a spray box 14.
  • the spray box 14 is constructed such that the resulting mold element or insert 1 is compatible with standard mold bases.
  • an STL file is generated which forms the basis for a jig.
  • the jig is built through stereolithography and is then used to assure that the geometry of cooling passages 8 is indeed accurate in all dimensions within +/- 0.5 mm. Errors greater than +/- 0.5 mm become visible air gaps between the passage extrusions and the jig.
  • the resulting cooling passage configuration 15 is then positioned, within the spray box 14, on the back surface of the active surface element 2.
  • the back 6 of the active surface shell 2, including the adjacent cooling passage configuration 15 and tie-rods, are sprayed with molten, atomized, copper droplets. This spraying operation is continued until all portions of the conformal cooling passages 8 are completely encased within solidified copper cooling layer 3.
  • Any suitable material may be used that is an efficient thermal conductor.
  • a suitable deposition process can be employed other than spraying.
  • the copper spraying is continued to fill the remainder of the spray box 14 to form a backing layer 4 'for the mold insert 1.
  • the excess can be quickly machined away, providing a flat surface to mate with a standard tooling base.
  • Other backing materials may be used such as powdered aluminum in an epoxy matrix or similar composite materials having good thermal conductivity.
  • a mold is constructed having an active surface shell made from tool steel, Beryllium- copper, or • appropriate hardened tool material.
  • Tool performance is, therefore, at least comparable to conventional tool steel molds or potentially superior for the case of beryllium-copper.
  • the finish machining will be virtually identical to conventional tool making, resulting in ready acceptance by standard tool and die shops. Because the active surface 2 is very close to

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

Selon l'invention, on fabrique une empreinte rapportée ou un outil (1) comprenant une surface active (5) formée sur une enveloppe mince (2) à partir d'un matériau d'outil trempé, des passages (8) de régulation thermique formés sur le dos de l'élément (2) comprenant une surface active, selon une agencement qui se conforme sensiblement aux lignes de contrainte thermique engendrées par la forme de la surface active (5), et une couche (4, 9) de régulation thermique en cuivre de manière à entourer les passages (8) de régulation thermique, et à renforcer la structure de l'empreinte rapportée (1).
PCT/US1999/002565 1998-02-06 1999-02-05 Appareil de moulage thermiquement efficace et procede de fabrication associe Ceased WO1999039889A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU24966/99A AU2496699A (en) 1998-02-06 1999-02-05 Thermally efficient mold apparatus and method

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US7388098P 1998-02-06 1998-02-06
US60/073,880 1998-02-06

Publications (1)

Publication Number Publication Date
WO1999039889A1 true WO1999039889A1 (fr) 1999-08-12

Family

ID=22116356

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1999/002565 Ceased WO1999039889A1 (fr) 1998-02-06 1999-02-05 Appareil de moulage thermiquement efficace et procede de fabrication associe

Country Status (2)

Country Link
AU (1) AU2496699A (fr)
WO (1) WO1999039889A1 (fr)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000050209A1 (fr) * 1999-02-25 2000-08-31 British Ceramic Research Limited Moules et procedes de fabrication associes
WO2001026498A1 (fr) * 1999-10-08 2001-04-19 Rapid Design Technologies (Pty) Limited Fabrication de coquilles metalliques
US7278197B2 (en) 2005-01-18 2007-10-09 Floodcooling Technologies, Llc Method for producing a tool
WO2008084006A1 (fr) * 2007-01-09 2008-07-17 Wiro Präzisions-Werkzeugbau Gmbh & Co. Kg Noyau de moule pour moules de moulage par injection
US8108982B2 (en) 2005-01-18 2012-02-07 Floodcooling Technologies, L.L.C. Compound mold tooling for controlled heat transfer
US8905739B2 (en) 2008-12-22 2014-12-09 Nederlandse Organisatie Voor Toegepast-Natuurwetenschappelijk Onderzoek Tno Method and apparatus for layerwise production of a 3D object
US20150064303A1 (en) * 2012-05-02 2015-03-05 iMFLUX Inc. Injection Mold Having a Simplified Evaporative Cooling System or a Simplified Cooling System with Exotic Cooling Fluids
US9399937B2 (en) 2009-03-12 2016-07-26 Volvo Lastvagnar Ab Operating method for an exhaust aftertreatment system and exhaust aftertreatment system
EP3657115A1 (fr) * 2018-11-23 2020-05-27 Commissariat à l'Energie Atomique et aux Energies Alternatives Procede de realisation d'un module d'echangeur de chaleur a au moins un circuit de circulation de fluide

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3723584A (en) * 1969-12-15 1973-03-27 Bischoff Chemical Corp Method of making an electroformed mold having heat transfer conduits and foam polyurethane foundation
US3811175A (en) * 1969-12-15 1974-05-21 Ici Ltd Method of making a split mold
US4844144A (en) * 1988-08-08 1989-07-04 Desoto, Inc. Investment casting utilizing patterns produced by stereolithography
US5169549A (en) * 1990-06-28 1992-12-08 Nickel Tooling Technology Inc. Method of producing nickel shell molds
US5189781A (en) * 1990-08-03 1993-03-02 Carnegie Mellon University Rapid tool manufacturing
US5437547A (en) * 1991-06-13 1995-08-01 Becker Group, Inc. Apparatus for injection molding
US5658506A (en) * 1995-12-27 1997-08-19 Ford Global Technologies, Inc. Methods of making spray formed rapid tools
US5775402A (en) * 1995-10-31 1998-07-07 Massachusetts Institute Of Technology Enhancement of thermal properties of tooling made by solid free form fabrication techniques
US5849238A (en) * 1997-06-26 1998-12-15 Ut Automotive Dearborn, Inc. Helical conformal channels for solid freeform fabrication and tooling applications

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3723584A (en) * 1969-12-15 1973-03-27 Bischoff Chemical Corp Method of making an electroformed mold having heat transfer conduits and foam polyurethane foundation
US3811175A (en) * 1969-12-15 1974-05-21 Ici Ltd Method of making a split mold
US4844144A (en) * 1988-08-08 1989-07-04 Desoto, Inc. Investment casting utilizing patterns produced by stereolithography
US5169549A (en) * 1990-06-28 1992-12-08 Nickel Tooling Technology Inc. Method of producing nickel shell molds
US5189781A (en) * 1990-08-03 1993-03-02 Carnegie Mellon University Rapid tool manufacturing
US5437547A (en) * 1991-06-13 1995-08-01 Becker Group, Inc. Apparatus for injection molding
US5775402A (en) * 1995-10-31 1998-07-07 Massachusetts Institute Of Technology Enhancement of thermal properties of tooling made by solid free form fabrication techniques
US5658506A (en) * 1995-12-27 1997-08-19 Ford Global Technologies, Inc. Methods of making spray formed rapid tools
US5849238A (en) * 1997-06-26 1998-12-15 Ut Automotive Dearborn, Inc. Helical conformal channels for solid freeform fabrication and tooling applications

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000050209A1 (fr) * 1999-02-25 2000-08-31 British Ceramic Research Limited Moules et procedes de fabrication associes
WO2001026498A1 (fr) * 1999-10-08 2001-04-19 Rapid Design Technologies (Pty) Limited Fabrication de coquilles metalliques
US6691763B1 (en) 1999-10-08 2004-02-17 Rapid Design Technologies (Pty) Limited Die manufacturing
AU771152B2 (en) * 1999-10-08 2004-03-18 Rapid Design Technologies (Pty) Limited Die manufacturing
AU771152C (en) * 1999-10-08 2005-04-14 Rapid Design Technologies (Pty) Limited Die manufacturing
US8108982B2 (en) 2005-01-18 2012-02-07 Floodcooling Technologies, L.L.C. Compound mold tooling for controlled heat transfer
US7278197B2 (en) 2005-01-18 2007-10-09 Floodcooling Technologies, Llc Method for producing a tool
WO2008084006A1 (fr) * 2007-01-09 2008-07-17 Wiro Präzisions-Werkzeugbau Gmbh & Co. Kg Noyau de moule pour moules de moulage par injection
US8905739B2 (en) 2008-12-22 2014-12-09 Nederlandse Organisatie Voor Toegepast-Natuurwetenschappelijk Onderzoek Tno Method and apparatus for layerwise production of a 3D object
US9399937B2 (en) 2009-03-12 2016-07-26 Volvo Lastvagnar Ab Operating method for an exhaust aftertreatment system and exhaust aftertreatment system
US20150064303A1 (en) * 2012-05-02 2015-03-05 iMFLUX Inc. Injection Mold Having a Simplified Evaporative Cooling System or a Simplified Cooling System with Exotic Cooling Fluids
US9682505B2 (en) * 2012-05-02 2017-06-20 Imflux Inc Injection mold having a simplified evaporative cooling system or a simplified cooling system with exotic cooling fluids
EP3657115A1 (fr) * 2018-11-23 2020-05-27 Commissariat à l'Energie Atomique et aux Energies Alternatives Procede de realisation d'un module d'echangeur de chaleur a au moins un circuit de circulation de fluide
FR3088997A1 (fr) * 2018-11-23 2020-05-29 Commissariat A L' Energie Atomique Et Aux Energies Alternatives Procédé de réalisation d’un module d’échangeur de chaleur à au moins un circuit de circulation de fluide

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Publication number Publication date
AU2496699A (en) 1999-08-23

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