GB2258839A - Lost core process - Google Patents

Lost core process Download PDF

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Publication number
GB2258839A
GB2258839A GB9214878A GB9214878A GB2258839A GB 2258839 A GB2258839 A GB 2258839A GB 9214878 A GB9214878 A GB 9214878A GB 9214878 A GB9214878 A GB 9214878A GB 2258839 A GB2258839 A GB 2258839A
Authority
GB
United Kingdom
Prior art keywords
layered structure
core process
fused core
coating
fused
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.)
Withdrawn
Application number
GB9214878A
Other versions
GB9214878D0 (en
Inventor
Martin John Fitzer
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.)
Individual
Original Assignee
Individual
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 Individual filed Critical Individual
Publication of GB9214878D0 publication Critical patent/GB9214878D0/en
Publication of GB2258839A publication Critical patent/GB2258839A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/34—Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/342—Moulds, cores, or mandrels of special material, e.g. destructible materials which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not
    • 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
    • B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/52—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles soluble or fusible
    • 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
    • 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
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
    • 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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/08—Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder
    • 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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/14—Dipping a core
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Electroplating Methods And Accessories (AREA)

Abstract

A fused core process for producing artifacts involves the production, from a low melting point alloy, of a core element; then forming, in contact with the surface of the core, layered material thereby to provide an internal shell form possessing properties desired in the article to be produced and thereafter forming, in contact with the surface of the layered material, an investment of plastic material; and, finally, melting out the core element. Neither the plastic material nor the layered material melting at a temperature lower than that of the alloy of which the core is composed. The layered material cladding the core may be in single or multiple layer configuration, at least one layer being a coating, sprayed or electrodeposited, dipped, painted, wound felted or of any other desired form. The layered structure may incorporate electrical and/or optical conductors or printed circuit systems.

Description

Lost Core Processes This invention relates to improvements in the fused core process and, in particular, is concerned with irproveeents to the said process enabling the production of structures possessing novel internal structural characteristics.
According to the invention a fused core process comprises: producing a core element composed of a low melting point alloy: forming, in intimate contact with the peripheral surface of the core, a layered structure of material such as to constitute a laminar internal shell portion possessing properties an/or characteristics desired in the article to be produced ; forming in intimate contact with the outer surface of the said layered structure an investment of plastic material, neither the said plastic material nor the said cladding material being susceptible to melting at a temperature l##r taah the melting point of the said alloy; and melting out the said core element,thereby to produce a hollow article having a plastic outer shell around the said layered structure.
The said layered structure may comprise a single layer or it may ccmprise a multiplicity of layers superimposed one upon another. At least one said layer may be formed by electroplating. at least one coating may be formed by electroless plating.
At least one coating may be formed by spray deposition. At least one coating may be formed by a dip coating process. At least one coating may be formed by winding filaeentary material around the said laminar structure; there may be a plurality of contiguous such windings laid up with different orientations such as to produce enhanced strength in the resulting composite winding arrangement. At least one coating may be formed by a vacuum deposition process.
The materials which may be employed as material for the said at least one coating include metals, paints, ceramics, semi-und#tors, or other materials or mixtures thereof whether in the form of continuous layers, sheets, weaves, filaments, powders, fibres, cloths, felts, mats, or other appropriate forms with or without internal or interlayer binding system.
The layered structure may incorporate material of different composition and exhibiting properties and characteristics differing fran that or those of the layered structure. without prejudice to the generality of the foregoing, the layered structure may incorporate conductors, whether electrical, optical, e.g. fibre optic cables, or of any other nature; it may incorporate printed cicuit systems.
By a knawn fused core process, an article is formed by moulding a plastic, a thersosetting or thermoplastic resin, article body part around a core carped of a low melting point alloy and, thereafter, melting cut the said core, the said body part being not suscptible to melting at the temFerature at which the core fuses. By the method referred to hollow components with complex internal characteristics, such, for example as threaded portions, may be achieved.
The method of the present invention offers an advance upon the above mentioned method enabling the production of hollow cspponents, particularly, though not exclusively of plastic materials as aforesaid, with differing or specialised internal configurations as eibodiments.
As mentioned above, the present invention proposes the provision, before investment of the plastic or other body part around the core, of a layered structure possessing characteristics, physical, chemical, or of other desired natures, calculated, in the finished article, properties not available in presently available artifacts. The categories of such properties are diverse; typically, however, one may cite the prospect of the production of articles, components, and other elements, which serve to electrically screen electrical components housed within the hollow article.
Again, the layered structure may be such as to enhance the structural strength of an otherwise insufficiently gecmetrically stable moulded part.
The layered structure may be formed on the low melting point alloy core element using any process step appropriate to the nature of the material being employed.
Thus the present invention contemplates the formation of the layered structurearound the said core element employing, depending upon the characteristcs of the layered structure to be achieved, an electroplating or electroless plating process step. It may be that the nature of the core element dictates employing an electroless plating step followed by an electroplating step.
Again, a layer or coating may be overlayed on the surface of the core element using a spray deposition process step. The production of the layered structure may involve a dip coating step; it may involve deposition of a layer or coating under vacuum. The production of the layered structure may involve the mechanical application of a distributed body of material.
So, filementary material may be wound over the core surface; moreover such fiementary material may be so wound laickp over the core surface with different orientations,e.g. as a braid, in order to impart desired mechanical strength the the finished article. Or the production of the layered structure may employ overlying the core surface with cloth or with a felted material. The foregoing are not exhaustive of the range of method steps which may be employed in the formation of the layered structure.
Additionally, the production of the structure may involve the deposition of ceramic, seei#roductor material, anchor paints possessing desirable physical properties or constituting simply a bland covering for the hollow interior of the article.
The layered structure formed over the core surface may comprise a single layer or coating; or the process may entail the deposition successively of a multiplicity of layers whether identical in character or performing different functions in the finished product.
To impart an enhanced geometrical stability to the layered structure, depending on the specific layered structure employed the layer or layers, perhaps a plurality of layers of different types as previously mentioned, may be irpregnated with internal or interlayer binding materials, e.g. thermosetting resins; and other material may be formed or moulded over the latter structure.
The layered structure of chosen form having been formed using a technique appropriate to the material utilized, the composite core and layered structure is postioned in a nuuid and an investment of plastic typically thermoplastic resin caused to overlay the layered structure in intimate contact therewith. After removal of the cored article from the mould, the article is subjected to heat treatment at a temperature such that the core is melted cut leaving, these having been appropriately chosen, the plastic body part and the layered structure therewithin in an unmelted and undistorted configuration.
The layered structure may incorporate material differing in properties and character from that of the said structure. Notably, the layered structure may incorporate conductors, electrical and/or optical, particularly fibre optic cables. It may constitute a matrix within which may be embedded printed circuit systems.

Claims (30)

1. A fused core process which comprises: producing a core element composed of a low melting point alloy: forming, in intimate contact with the peripheral surface of the core, a layered structure of material such as to constitute a laminar internal shell portion possessing properties and/or characteristics desired in the article to be produced ; forming in intimate contact with the outer surface of the said layered structure an investment of plastic material, neither the said plastic material nor the said cladding material being susceptible to melting at a temperature lower than the melting point of the said alloy; and melting out the said core element, thereby to produce a hollow article having a plastic outer shell around the said layered structure.
2. A fused core process as claimed in claim 1 in which the said layered structure is formed as a single layer.
3. A fused core process as claimed in claim 1 in which the said layered structure is produced by forming a multiplicity of layers superimposed one upon another.
4. A fused core process as claimed in claim 1 or 2 in which said layered structure is formed with at least one said electroplated layer.
5. A fused core process as claimed in claim 1, 2 or 3 in which the said layered structure is produced with at least one electroless plated coating.
6. A fused core process as claimed in any preceding claim in which the said layered structure is produced with at least one spray deposited coating.
7. A fused core process as claimed in any preceding claim in which the said layered structure is produced with at least one dip coating.
8. A fused core process as claimed in any preceding claim in which the said layered structure is produced with at least one winding of filementary material wound the said layered structure.
9. A fused core process as claimed in any preceding claim in which the said layered structure is produced with a plurality of contiguous such windings, laid up with different orientations such as to produce enhanced strength in the resulting composite winding arrangement.
10. A fused core process as claimed in any preceding claim in which the said layered structure is produced with at least one vacuum deposited coating.
11. A fused core process as claimed in any preceding claim in which the layered structure is formed with at least one metallic coating.
12. A fused core process as claimed in any preceding claim in which the layered structure is formed with at least one paint coating.
13. A fused core process as claimed in any preceding claim in which the layered structure is formed with at least one ceramic coating.
14. A fused core process as claimed in any preceding claim in which the layered structure is formed with at least one seni#roductine coating.
15. A fused core process as claimed in any preceding claim in which the layered structure is formed with at least one coating incorporating powdered matter.
16. A fused core process as claimed in any preceding claim in which the layered structure is formed with at least one coating comprising sheet material.
17. A fused core process as claimed in any preceding claim in which the said layered structure is formed with at least one coating comprising wDven material.
18. A fused core process as claimed in any preceding claim in which the said layered structure is formed with at least one coating comprising felted material.
19. A fused core process as claimed in any preceding claim in which the said layered structure is formed with at least one coating comprising mat material.
20. A fused core process as claimed in any preceding claim in internal and/or interlayer binding material contributes to the geometrical stability of the said layered structure.
21. A fused core process as claimed in any preceding claim in which the said article body material is of a thermc- tting plastic material.
22. A fused core process as claimed in any of claims 1 to 21 in which the said article body material is of a thermo-plastic material.
23. A fused core process as claimed in any preceding claim which includes the step of incorporating, within the material of which the layered structure is composed, material of differing composition.
24. A fused core process as claimed in claim 23 which includes the step of incorporating within the material of the layered structure conductor means.
25. A fused core process as claimed in claim 24 which includes the step of incorporating within the layered structure material electrical conductor means.
26. A fused core process as claimed in claim 25 which includes the step of incorporating within the layered structure material printed circuit means.
27. A fused core process as claimed in claim 24, 25, or 26, which includes the step of incorporating within the layered structure material, optical conductor means.
28. A fused core process as claimed in claim 27 which includes the step of incorporating within the layered structure material, fibre optic cable means.
29. An article produced using the process as claimed in any preceding claim.
30. An article produced using the method substantially as hereinbefore described.
GB9214878A 1991-07-20 1992-07-14 Lost core process Withdrawn GB2258839A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB919115711A GB9115711D0 (en) 1991-07-20 1991-07-20 The concept for the utilisation of the lost core process for specialised purposes

Publications (2)

Publication Number Publication Date
GB9214878D0 GB9214878D0 (en) 1992-08-26
GB2258839A true GB2258839A (en) 1993-02-24

Family

ID=10698700

Family Applications (2)

Application Number Title Priority Date Filing Date
GB919115711A Pending GB9115711D0 (en) 1991-07-20 1991-07-20 The concept for the utilisation of the lost core process for specialised purposes
GB9214878A Withdrawn GB2258839A (en) 1991-07-20 1992-07-14 Lost core process

Family Applications Before (1)

Application Number Title Priority Date Filing Date
GB919115711A Pending GB9115711D0 (en) 1991-07-20 1991-07-20 The concept for the utilisation of the lost core process for specialised purposes

Country Status (1)

Country Link
GB (2) GB9115711D0 (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2269771A (en) * 1992-07-30 1994-02-23 Masaru Nemoto Method of moulding using a core of non-sand material
WO1998040195A1 (en) * 1997-03-13 1998-09-17 Filterwerk Mann+Hummel Gmbh Process for manufacturing hollow plastic objects
US5975189A (en) * 1992-07-30 1999-11-02 Suguru Nemoto Method of fabricating a metallic article using a non-sand core
GB2342886A (en) * 1998-10-22 2000-04-26 Aea Technology Plc A method of manufacturing a plastics composite artefact
AT6359U3 (en) * 2003-04-16 2004-03-25 Cool Structures Production And ELECTRICAL ASSEMBLY AND METHOD FOR THEIR PRODUCTION

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB696900A (en) * 1950-07-06 1953-09-09 Sydney Robson Improvements in waveguides and aerials
JPS592766A (en) * 1982-06-26 1984-01-09 ヤマハ株式会社 Production of wood club head or golf
JPH0257313A (en) * 1988-05-24 1990-02-27 Ebara Corp Plastic molding method using low melting point alloy core with heat-resistant film

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB696900A (en) * 1950-07-06 1953-09-09 Sydney Robson Improvements in waveguides and aerials
JPS592766A (en) * 1982-06-26 1984-01-09 ヤマハ株式会社 Production of wood club head or golf
JPH0257313A (en) * 1988-05-24 1990-02-27 Ebara Corp Plastic molding method using low melting point alloy core with heat-resistant film

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2269771A (en) * 1992-07-30 1994-02-23 Masaru Nemoto Method of moulding using a core of non-sand material
GB2269771B (en) * 1992-07-30 1996-05-22 Masaru Nemoto Method of moulding articles
US5975189A (en) * 1992-07-30 1999-11-02 Suguru Nemoto Method of fabricating a metallic article using a non-sand core
WO1998040195A1 (en) * 1997-03-13 1998-09-17 Filterwerk Mann+Hummel Gmbh Process for manufacturing hollow plastic objects
GB2342886A (en) * 1998-10-22 2000-04-26 Aea Technology Plc A method of manufacturing a plastics composite artefact
AT6359U3 (en) * 2003-04-16 2004-03-25 Cool Structures Production And ELECTRICAL ASSEMBLY AND METHOD FOR THEIR PRODUCTION

Also Published As

Publication number Publication date
GB9214878D0 (en) 1992-08-26
GB9115711D0 (en) 1991-09-04

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WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)