MX2007008705A - A tool having enhanced cooling characteristics and a method for producing a tool having enhanced cooling characteristics. - Google Patents

Abstract

A tool 10 which is made by a method which efficiently allows internal passageways, such as passageway 50,which are at least partially circumscribed by thermally conductive material 103, to be formed in the tool 10, thereby allowing for enhanced cooling characteristics and allowing decreased cycle time and a reduced likelihood of damage to the formed object.

Description

MOLDING TOOL OF COMPOUNDS BY THERMAL TRANSFER CONTROLLED BACKGROUND OF THE INVENTION 1. Field of the Invention The invention relates to tools for molding articles, more particularly to tools that incorporate cooling in the formation of articles. 2. Previous Technique A tool is used to selectively produce an article or object and, as used throughout this description, the term "tool" should be interpreted as broadly as possible and should not be limited to a configuration or type of exact configuration or to a certain installation of tools that suits to produce only a certain item / object or a certain class of items or objects.

Traditionally, a tool has been produced from a block of substantially solid material (i.e., by baking, cutting or otherwise "working" the material in a certain way). Although the above procedure allows a tool to be produced selectively, this traditional strategy or technique is highly inefficient and expensive.

To overcome these disadvantages, a lamination technique / strategy has been developed and is described, for example and without limitation, in US Pat. of E.U. No. 6, 587, 742 ("The 742 Patent") that was assigned to the applicant's assignee, issued on July 1, 2003, and that is fully and completely incorporated herein by reference, word by word and paragraph by paragraph .

In particular, the previous lamination strategy involves the creation of a "temporary tool design" (i.e., the tool is initially designed within a software environment). The temporary design is then used to create tangible physical sectional members that are coupled and thereafter cooperatively form the tool. Such a procedure is highly efficient and dramatically reduces the cost associated with prior tool production strategies and techniques.

Regardless of the technique or method for the production of a tool, often the article produced is damaged by the stress caused by the production operation of the tool (i.e., often referred to as "molding tension"). To relieve this tension, the "cycle time" or production time of the part / object is often undesirably increased, thus causing the production of the article / article or machining operation to be relatively inefficient.

Accordingly, there is a need for a new improved tool and method for producing a tool having improved cooling characteristics in order to overcome the above disadvantages associated with the above tools and methods, and the applicant has discovered that the production strategy of Rolling tools adapts very well in itself to the production of such tool and to the method of production of the tool.

The prior art provides various tools for forming articles by various training processes, such as injection molding, blow molding, reaction injection molding, die casting, stamping and the like. These tools frequently use a first mold half and a second mold half, each having opposing forming surfaces to collectively form an article therebetween. The mold halves are frequently formed separately and one half is translated relative to the other to close, form the article, open, remove the article and repeat these steps.

Frequently, the mold halves are each formed from a block of solid material capable of withstanding the stresses, pressures, impacts and other fatigue associated with the associated formation processes. Various forming processes involve heating the material of the article in order to mold the article on the forming surfaces of the mold halves. Frequently, one or more of the mold halves are cooled in order to increase the solidification rate of the article material and to reduce the cycle time of the molding process. A mold half is often cooled by fluid that is transported through a fluid line in the mold half. Fluid lines are often provided within the molds or mold halves by drilling a fluid line through the solid mold block.

SUMMARY OF THE INVENTION A first non-limiting objective of the present invention is to provide a tool that has improved cooling characteristics.

A second non-limiting objective of the present invention is to provide a method for producing a tool having improved cooling characteristics.

A third non-limiting objective of the present invention is to provide a tool and a method for producing a tool, which overcomes the various and previously outlined disadvantages of the above tools and methods for the production of tools.

According to a first non-limiting aspect of the present invention, a tool is provided and includes a forming surface formed from a first material; an internal cavity containing at least one passage; and a second material that at least partially circumscribes the at least one passage.

According to a second non-limiting aspect of the present invention, a sectional member is provided for use in a rolling type tool and includes a frame portion defining an internal area; and a gauge portion extending into the inner area, wherein the gauge portion includes an arm that terminates on the frame portion, and an open circular portion that resides within the internal area.

According to a third non-limiting aspect of the present invention, there is provided a method for producing a tool comprising the steps of creating a first sectional member with a first portion of passage formation; create a second sectional member with a second portion of passenger training; coupling the first sectional member with the second sectional member effectively to cause the first portion of the passage formation to align with the second portion of the passage formation, thereby forming a pre-tool having an internal passage; and causing the thermally conductive material to adhere to at least part of the internal passage formed, thus forming a tool from the pre-tool.

Another embodiment of the present invention provides a tool for forming an article in a molding operation with a tool body formed from a first material with a forming surface for forming the article. A heat transfer material is installed in the tool body, separated from the forming surface, and the thermal transfer material has a coefficient of thermal conductivity greater than that of the first material. The heat transfer material or the heat transfer material and the tool body collectively provide a conduit for transporting a fluid for heat transfer between the fluid and the forming surface through the tool body and the heat transfer material during a molding operation.

Yet another embodiment of the present invention provides a tool for forming an article in a molding operation with a tool body formed from a plurality of laminar sheets of a first material. The laminar sheets are configured to collectively form a forming surface to form the article, and at least one of the plurality of laminar sheets is configured to form a cavity in the tool body that is spaced apart from the forming surface. A thermal transfer material, having a coefficient of thermal conductivity greater than that of the first material, is placed within the cavity for thermal transfer from the forming surface to the heat transfer material through the tool body during an operation of molding.

Yet another embodiment of the present invention provides a method for forming a molding tool wherein the tool body is provided from a first material with a forming surface to form an article in a molding operation. A thermal transfer region is fused to the tool body for a thermal transfer between the forming surface and the thermal transfer region during a molding operation. The thermal transfer region is melted from a second material having a coefficient of thermal conductivity greater than that of the first material and a melting temperature lower than that of the first material.

Another embodiment of the present invention provides a method for forming a molding tool wherein a tool body is formed from a plurality of laminar sheets of a first material to collectively form a forming surface to form an article, and collectively form a cavity in the tool body that is separated from the forming surface. A thermal transfer material is placed within the cavity for thermal transfer between the forming surface and the heat transfer material through the tool body during a molding operation. The thermal transfer material has a coefficient of thermal conductivity greater than that of the first material.

The above embodiments and other embodiments, aspects, objectives, features and advantages of the present invention are readily apparent from the following detailed description of the embodiments of the invention when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of a tool made according to the teachings of the preferred embodiment of the invention; Figure 2 is a side view of one of the sectional members that can be used to create the tool shown in Figure 1 and that is made according to the teachings of a first embodiment of the invention; Figure 3 is a side view of a sectional member that can be used to create the tool shown in Figure 1 and which is made according to the teachings of a second embodiment of the invention; Figure 4 is a sectional view of a first embodiment of the tool that is shown in general in Figure 1 and taken along the line of sight 4-4 '; Figure 5 is a view similar to that shown in Figure 4 for the tool shown in general in Figure 1, but which is made according to the teachings of a second embodiment of the invention.

Figure 6 is a view similar to that shown in Figure 5, but illustrating the tool shown in Figure 1 in a preliminary completion stage; Figure 7 is a perspective view of a tool according to the present invention; Figure 8 is a sectional view of the tool of Figure 7 taken along section line 8-8; Figure 9 is a sectional view of another tool according to the present invention; Figure 10 is an exploded partial sectional view of a tool according to the present invention; Figure 11 is a sectional view of the tool of Figure 10, illustrated partially assembled; Figure 12 is a sectional view of the tool of Figure 10, illustrated after a manufacturing process; Figure 13 is an exploded partial sectional view of another tool according to the present invention; Figure 14 is a sectional view of the tool of Figure 13, illustrated partially assembled; Figure 15 is a sectional view of another tool according to the present invention; Figure 16 is a sectional view of the tool of Figure 15, illustrated after a manufacturing process; Figure 17 is a fragmentary perspective view of a portion of a tool according to the present invention; Figure 18 is another perspective view of the portion of the tool of Figure 17; Figure 19 is a perspective view of a sectioned tool according to the present invention; Figure 20 is an elevation view of another sectioned tool according to the present invention; Figure 21 is a perspective view of yet another sectioned tool according to the present invention; Figure 22 is a perspective view of another tool according to the present invention; Figure 23 is another perspective view of the tool of Figure 22; Figure 24 is a partial sectional view of the tool of Figure 22; Y Figure 25 is another partial section view of the tool of Figure 22.

DETAILED DESCRIPTION OF THE MODALITIES OF THE INVENTION As required, the detailed embodiments of the present invention are described herein; however, it is understood that the embodiments described are only exemplary of the invention that may be incorporated in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Accordingly, the specific and functional structural details described herein are not to be construed as limiting, but only as a representative basis for the claims and / or as a representative basis for teaching the skilled artisan to employ variously the present invention.

Referring now to Figure 1, a tool 10 made in accordance with the teachings of the various inventions is generally shown. Particularly, the tool 10 is a laminated type tool that is constructed by the sequential coupling of several sectional members, such as the sectional members 12, 14. In addition, the tool 10 formed includes a forming surface 16 that can be selectively used for form or create an object. A more detailed description of the technique or construction strategy of the laminated tool can be found in the "742 Patent. However, it should be understood that any type of lamination strategy can be used to selectively create the tool 10 and that nothing in this disclosure is intended to limit the various inventions to a particular type of laminating tool creation strategy.

Now, with reference to Figure 2, a sectional member 12 is shown which can be substantially similar to the sectional member 14 and the various other sectional members used to create the tool 10, according to the teachings of a first non-limiting mode of the invention. invention.

Particularly, the sectional member 12 includes a generally planar frame portion 20 which, in a non-limiting embodiment of the invention, generally forms a rectangular configuration. In a non-limiting embodiment of the invention, the frame portion 20 defines an internal area 23 and includes a gauge portion 22 having a portion of rod or arm 25 that terminates on or within (or emanates from) the frame portion. 20 and extending from the frame portion 20 to the defined internal area 23. The portion of rod 25 also terminates in or on (or forms) an open and generally circular portion 27. As shown, the generally circular portion 27 includes an orifice 29 and the generally circular portion 27 resides within the internal area 23 defined in general. In a non-limiting embodiment of the invention, the gauge portion 22 is formed integrally with the frame portion 20 and the generally circular portion 27 is formed integrally with the rod portion 25.

In addition, it should be appreciated that each sectional member, such as the sectional members 12, 14, may be formed of a substantially identical material, such as a carbon based one, or stainless steel or aluminum type, and each sectional member 12, 14 may be joined or selectively coupling in order to then cooperatively form the tool 10. Patent 742 discloses such a non-limiting coupling arrangement.

In a non-limiting embodiment of the invention, each sectional member, such as the sectional member 12, 14, has its respective holes 29 (ie, its respective "passage formation portions") aligned or level with respective holes 29 or portions thereof. of formation of passage of the sectional members to which they are coupled or clutched in an adjacent and spliced manner. In this manner, an internal passage, such as passage 50, can be selectively formed within the tool 10 selectively created by the selective engagement of the various sectional members, such as the sectional members 12, 14 cooperatively forming the tool 10. .

It should be appreciated that the holes 29 may be of any desired configuration and size and that the respective portions 22 may also be of any substantially identical configuration and size. Therefore, it should be further appreciated that only some of the sectional members, such as the sectional members 12, 14, can have holes 29 level allowing thus the internal passage formed to cross only a portion of the tool 10.

Additionally, it should also be appreciated that each or some of the selectively coupled sectional members, such as the sectional members 12, 14, can have multiple portions 22, which can be used in the above manner to selectively create multiple internal passages within the tool formed 10. That is, each orifice 29 of each portion 22 can be used to create a single internal passage, such as passage 50, within tool 10 formed, selectively aligning or respectively with at least one other single hole 29 of at least one other member sectional As best shown in Figures 1 and 2, the respective internal areas 23 of each of the selectively coupled sectional members, such as the sectional members 12, 14, cooperatively form an internal cavity 70, within the tool 10 formed and these selectively formed internal passages, such as the internal passage 50, reside operatively within this internally formed tool cavity 70. In the most preferred embodiment of the invention, each selectively formed internal passage, such as the internal passageway 50, extends through one or both of the end sectional members, such as the sectional member 14 (ie, a sectional member of "end type", such as sectional member 14, means or refers to a sectional member that only fits a single sectional member). It should be appreciated that a first sectional member, such as sectional member 12, can be attached to a second sectional member, such as sectional member 14, by having its respective frame 20 aligned and coupled to the respective frame 20 of the second sectional member. In this way, access can be had to the internal passages formed, such as the internal passage 50, and receive and discharge water selectively (or some other means) effective to selectively cool the tool, thus reducing the total time of the production cycle and substantially reducing the likelihood of damage related to the stress to the tangible part or article produced. As discussed more fully below, the cooling, provided by these selectively formed cooling passages, such as passage 50, can be dramatically improved by the introduction of a thermally conductive material into the cavity 70 and / or purposely placed in relation to contact with the various operatively contained cooling passages, such as passage 50.

Now, with reference to Figure 3, as outlined above, it can be seen that in a non-limiting embodiment of the invention, each sectional member, such as the sectional members 12, 14, can have a substantially identical pair of gauge portions. which deploy to a defined area 23 formed respectively and which respectively include substantially circular portions 27 substantially identical, each having a respective one and only portion or portion 29 of passage formation. It should be understood that the pair of gauge portions 22 need not be substantially identical and that larger numbers of gauge portions 22 may be used, within or on a sectional member, such as sectional member 12, 14, in other non-limiting embodiments of the invention.

Further, in a non-limiting embodiment of the invention, each pair of generally circular portions 27, respectively and adjacently positioned, of each sectional member, such as the sectional members 12, 14, are engaged by the coupling member 73 for further structurally reinforcing the sectional members, such as the sectional members 12, 14. In an alternate embodiment, each portion 22 is formed integrally with the frame portion 20 from which they emanate or in which they terminate respectively.

In this "multiple gauge" mode, when the sectional members, such as the sectional members 12, 14, are selectively coupled to cooperatively form the tool 10, each portion of the passage formation 29 of a sectional member may be at the selective level and respectively with other single portions 29 of passage formation, in the above manner, to selectively produce multiple passages of various lengths within the cavity 70.

Regardless of the number used of gauge portions 22, the tool 10 created can selectively have improved cooling characteristics by the selective placement of a thermally conductive material within the internal cavity 70 in the following manner.

That is, in a first non-limiting embodiment of the invention, a first pair of sectional members, such as sectional members 12, 14, engage in spliced manner (ie, their respective frames 20 are aligned and engaged), so effective to overcome, and have their internal areas 23 respectively aligned aligned and level, thus causing their respective holes 29 to be communicatively level and aligned. A powdered metal 110 is then placed within the interior areas 23 defined superimposed, aligned and previously level, and the pair of spliced sectional members is joined in a spliced manner, such as the sectional members 12, 14, (ie, their respective frames 20 are joined together) by brazing, while copper is produced to infiltrate the powdered steel material, causing the pair of spliced sectional members, such as section members 12, 14, to join and cause the combination of powdered metal and copper adhere to at least a portion of the outer surface 101 of the pair of generally circular portions 22 previously aligned and level (ie, the combination of the powdered metal and the infiltrated copper (denoted as the material 103). As shown, the material 103 at least partially circumscribes this surface 101 (eg, at least partially circumscribes the formed passage that is formed ectively by the pair of holes 29 aligned and level), and the material 103 can reside substantially in all internal areas 23 aligned or just within a small portion. These first two coupled sectional members form a "pre-tool" installation (ie, a tool that is "under construction"), unless the tool 10 is actually comprised of this single pair of sectional members, such as sectional members 12, 14. In the latter case, the combined sectional members cooperatively form the final tool 10.

If additional sectional members are necessary to complete the creation of the tool 10, then these additional sectional members are selectively and sequentially coupled to the pre-tool, in a similar manner. That is, the internal area 23 of the newly added sectional member is made to overlap in the internal area 23 which is formed by the alignment of each of the previously coupled sectional members, such as the sectional members 12, 14. The orifice 29 of this newly added sectional member is also aligned with the pre-aligned holes 29 of each of the previously coupled sectional members and the frame 20 of the new sectional member engages and aligns with the frame 20 of one of the previously coupled sectional members. A powdered metal 110 is placed within the internally defined area 23 of the newly added sectional member and the new aggregate sectional member is welded on the pre-tool (eg, the frame 20 of the newly added sectional member is welded to the strong on the frame 20 of one of the section members previously coupled), while the copper infiltrates the defined internal area 23 of this newly added sectional member, thereby coupling the newly added sectional member to the pre-tool, extending or "growing" the internal passage formed by all the holes 29 aligned, and causing the thermally conductive material 103, formed from the combination of copper and powdered steel, to at least partially encircle the surface 101 of the portion 22 of the newly added sectional member. In this way, the pre-tool selectively "grows" in a manner of "sectional member per sectional member", the passage, such as passage 50 extends within the internal cavity 70 of the tool, and internal cavity 70 can filling substantially with this material 103 and / or the material 101, thus resulting in a substantially "solid" tool 10 with a strong copper / solder "structure" that clutches in a spliced manner and at least partially circumscribes the formed passages, as passage 50.It should be understood that while what has been discussed above involves the selective formation of a single passage within the tool 10, it is equally applicable to the selective formation of multiple passages formed from the various portions 22. It should be further appreciated that, in an alternative embodiment of In the invention, the respective rods of each coupled sectional member, such as the sectional members 12, 14, are broken in order to avoid interruption to the material 101 and / or 103, which can substantially fill the internal cavity 70.

The above process can be applied or used especially when sectional members, such as section members 12, 14, are formed from a "high temperature" material, such as carbon-based steel or stainless steel. When the sectional members, such as the sectional members 12, 14, are formed, from a relatively low temperature material, such as aluminum, then care must be taken to use a thermally conductive material within the cavity 70 having a temperature of fusion less than the melting temperature of the material used to form the sectional members 12, 14.

Alternatively, after creating the tool 10, the thermally conductive material 160 can be inserted, as shown only as an example and without limitation in Figure 5, into the internal cavity 70, through one of the "end sectional members", such as the sectional member 14. That is, as best shown in Figure 6, the sectional rolling members, such as the sectional members 12, 14, are readily adapted to selectively "grow" the tool 10 while providing concomitantly a very accessible cavity 70 that can be used to deposit the thermally conductive material.

Particularly, in a non-limiting mode, after having glued or bonded the various sectional members, such as the sectional members 12, 14, the cavity 70 can be filled in a molten manner (eg, by a molding process) with copper, aluminum or any thermally conductive material having a melting temperature below the melting temperature of the material used to construct the sectional members, such as the sectional members 12, 14, which are used to form the tool 10. The thermally conductive materials that are used within the cavity 70 may alternatively comprise thermally conductive epoxy, graphite, a combination of epoxy and graphite, or some other composite material. Additionally and desirably, the heat of the casting process can be used to substantially or concurrently join and weld the sectional members, such as the section members 12, 14, thus reducing the total energy requirements of the tool forming process. In a non-limiting mode, the thermally conductive material may be fused to each surface 101 of each member 22 even within the cavity 70. Additionally, the applicant has found that the liquid copper material will naturally fill the spaces. Accordingly, copper or a strong solder type paste may be pre-applied between each pair of adjacently spliced and clutched section members, such as members 12, 14 (eg, in frame portions 20 respectively spliced), and when the heat is generated by the molten material placed within the cavity 70, as part of a casting process, the copper or pre-applied strong solder paste flows between the adjacently coupled sectional members, such as the sectional members 12, 14 , to fill any space that may exist between these selectively coupled sectional members (eg, between frame portions 20 respectively spliced).

It should be understood that the inventions are not limited to the exact construction and method illustrated and described above., but various modifications and changes can be made without departing from the spirit and scope of the inventions as outlined further in the following claims. It should be appreciated that the thermally conductive material increases the total cooling efficiency of the water (or other medium) that passes through the formed passages, such as passage 50, efficiently conveying the thermal type energy to the medium contained from the tool 10. Such improved cooling reduces cycle time and greatly reduces the likelihood of strain-type damage to the part or object formed. Furthermore, and importantly, the molding "around" the passages, such as the passage 50, (eg, causing the material 103 to at least partially circumscribe the formed passages, such as passage 50), or the substantial filling of the cavity 50 with material (eg, the material 101 and / or 103) greatly minimizes the probability of leakage of the passages to the tool surface (eg, to the forming portion 16). A non-limiting example of an acceptable copper infiltration process is described in the U.S. patent application. pending Series No. 10 / 000,910 which was filed on November 1, 2001, which is fully and completely incorporated herein by reference, word by word and paragraph by paragraph and which was invented by the present inventor.

Now, with reference to Figure 7, a tool according to the present invention is illustrated and is generally referred to by the number 220. The tool 220 is a tool for forming an article in a molding operation, such as injection molding. , blow molding, reaction injection molding, roto-molding, die-casting, stamping or the like. Alternatively, the tool may be a mandrel shaped similarly to the article to form a molding tool, a die-casting tool, a stamping tool or the like, which is then used to form the article. Although a tool 220 is illustrated, the invention contemplates that the tool 220 may be a molding member, which is used in combination with one or more molding members, such as an opposite mold half, for the formation of an article in a manner collective among them.

The tool 220 includes a tool body 222, which has a forming surface 224 for forming the article. The tool body 222 can be formed from a solid block that is machined in approximately an almost smooth configuration. Alternatively, the tool body 222 may be formed from a multi-layer process, for example, a rolling process such as that described in the U.S. Patent. No. 6,587, 742 B2, issued July 1, 2003 for Manuel et al.,; Patent of E.U. No. 5, 031, 483, issued July 16, 1991 to Weaver; and the Published Patent Application of E.U. 2005/0103427 Al, published on May 16, 2005 for Manuel et al., Whose descriptions are incorporated in their entirety by reference herein.

As illustrated, the tool body 222 can be provided by a series of laminated plates 226. The tool 220 can be equipped with a series of fluid lines 228 to convey fluid through the tool 220 to heat or cool the forming surface 224 For example, the tool body 222 can be formed of a material such as stainless steel, which has a limited conductivity. In order to control the heating and / or cooling of a part formed by the tool 220, the heat transfer rate of the work surface 224 can be increased and controlled by transporting fluid through the fluid lines 228. For example, it can be pumped. a hot fluid, such as a hot oil, through the fluid lines 228 to heat the work surface 224 to a predefined temperature to maintain a temperature of the material within the tool 220, such as a polymeric material in a molding process by injection. Similarly, coolant may be transported through the fluid lines 228 to cool the work surface 224, thereby solidifying the material of the article formed by the tool 220. Such controlled refrigerant is used to provide uniform heating and / or cooling of the product. Article formed within the tool 220. The controlled rates of heat transfer can be used to limit the internal stresses of a resulting product and limit the collapse, contraction and distortion of the product. Such control consequently improves the overall quality of the resulting product. Additionally, the cycle time can be reduced to improve the output volume of the components by the particular tool 220.

Now, with reference to Figure 8, the tool 220 is illustrated sectioned along the section line 8-8 to reveal the conduits 230 formed within the tool body 222. The conduits 230 are segments of the fluid lines 228. and are shaped to provide cooling in accordance with the forming surface 224 of the tool body 222. The conduits 230 can be cut into sheet sheets 226 individually to collectively provide fluid flow paths for the fluid within the cooling lines 228. The ends of the fluid lines 228 can be capped with an attachment for coupling to a source of fluid in the tool 220.

A conductive material 232 can be placed between the forming surface 224 and the conduits 230 through the tool body 220 to improve the rate of heat transfer between the forming surface 224 and the conduits 230. Since the tool 220 illustrated in the Figures 7 and 8 is formed by a multilayer sheet-layered process 226, the conductive material 232 can be provided in a shape that is profiled to match the contour of the forming surface 224 of the tool 220. The conductive material 232 can be a material such as copper having an improved coefficient of thermal conductivity relative to the structural material used for the tool body 222. The tool body 222 can be designed to withstand stresses, pressures and fatigue associated with the tool body forming process. 222, and the conductive material 230 can be designed to conduct the heat from the surface of the down 224 to the conduits 230, or from the conduits 230 to the forming surface 224.

The conductive material 232 can be provided by laminar or metallized sheets of a conductive material 232 which are located within the laminar sheets 226 of the tool body 222. Alternatively, the conductive material 232 can be fused within the tool body 222 in a cavity 234. formed within the tool body 222, or formed by multiple laminar sheets 226 of the tool body 222. Accordingly, a pouring channel 236 may be provided within the cavity 234 to allow infiltration of the conductive material 232 into the cavity 234. Alternatively , the conductive material 232 can be allowed to pass through tolerance spaces between the laminar sheets 226 by capillary action. In order to prevent the conductive material 232 from infiltrating the conduits 230, pipe may be placed in the conduits 230 during the installation of the tool body 222. Alternatively, a particulate material, such as sand, may be provided within the conduits 230 during the molding process to avoid infiltration of the conductive material 232 into the conduits. The particulate material can subsequently be removed by vibrating the tool 220, imparting fluid to the fluid lines 228, submerging the tool 220 within the fluid, or by any suitable particulate removal process.

Now, with reference to Figure 9, another tool 238 is illustrated in accordance with the present invention. The tool 238 includes an upper die 240 and a lower die 242 for forming an article within the dies 240, 242. Each of the dies 240, 242 includes cooperating forming surfaces 244, 246 for receiving a material such as plastic injection molding to mold a component. For example, if the tool 238 is for molding the plastic covers of the outlet, the sectional view is illustrated by bisecting the plate between the outlet openings. The sectional view of Figure 9 also illustrates outer side regions of the outlet cover with a conical profile, and a central configuration for providing a fastener opening centrally through the plate cover. Of course, various articles formed within the spirit and scope of the present invention are contemplated.

Similar to the previous embodiment of Figures 7 and 8, the dies 240, 242 may be formed of laminar sheets 248, 250, respectively. Similar to the previous embodiment, each die 240, 242 may include a series of fluid lines 252, 254, which extend through die 240, 242, to convey fluid through dies 240, 242. The lines of Fluid 252, 254 may be incorporated by tubing placed within a cavity 256, 258, within each die 240, 242. After assembling the dies 240, 242 with the laminar sheets 248, 250, and the corresponding fluid lines 252, 254, the heat sinks 260, 262 can be placed within each die 240, 242 by a conductive material that is separated from the forming surfaces 244, 246 corresponding. The heat sinks may also be in contact with the respective fluid lines 252, 254 as illustrated in Figure 9. The heat sinks 260, 262 may be used to conduct the heat to and / or from the forming surfaces 244, 246 toward the fluid within the fluid lines 252, 254.

Similar to the previous embodiment, the heat sinks 260, 262 can be melted in the dies 240, 242, and casting channels 264, 266 can be provided to allow infiltration of the conductive material into the cavities 256, 258.

Now, with reference to Figure 10, a tool according to the present invention is illustrated; the tool is illustrated exploded and is generally referred to by the number 320. The tool 320 is a tool for forming an article in a molding operation, such as infection molding, insufflation molding, reaction injection molding, die casting , stamping or the like. The tool 320 is illustrated exploded and oriented in relation to a support casting mold 322, which is used in forming the tool 320. Although a tool 320 is illustrated, the invention contemplates that the tool 320 may be a mold half. , which is used in combination with one or more mold components, such as an opposite mold half to form an article therebetween.

The tool 320 includes a tool body 324, which has a forming surface 326 for forming the article. The tool body 324 may be formed from a solid block that is machined in approximately an almost smooth configuration. Alternatively, the tool body 324 may be formed from a multilayer process, for example, a rolling process, such as that described in the U.S. Patent. No. 6, 587,742 B2; Patent of E.U. No. 5,031,483; and the Published Patent Application of E.U. 2005/0103427 Al.

The tool body 324 is provided with an open rear surface 328 that is suitably spaced from the forming surface 326 so that the tool body 324 can structurally support the forming surface 326, while providing access to the rear surface 328 for the fluid lines 330 for heating or cooling the forming surface 326. The rear surface 328 is shown notched within the tool body 324, however, the invention contemplates that the tool body 324 may have a rear surface 328 that it is not grooved within the tool body 324. The thickness between the back surface 328 and the forming surface 326 is determined by the necessary structural integrity of the tool body 324 and the desired heat transfer rate provided by the fluid lines 330 The structural integrity and the thermal transfer rate can They can be predetermined through conventional mechanics and thermal transfer calculations, finite element analysis, or the like, and these design criteria can be specific to each molding application.

If the back surface 328 of the tool body 324 is provided in a cavity as illustrated for the embodiment of Figure 10, the cavity can be formed in a solid block, which provides the tool body 324, or the cavity can be formed collectively to through laminar sheets.

The tool body 324 is provided by a material suitable for carrying out the forming or molding operation of the associated article. For example, the tool body 324 may be formed from a solid tool steel or stainless steel, or the tool body may be formed from sheet blades such as the designations of the American Iron and Steel Institute (AISI) 410 stainless steel , 4130 stainless steel, H13 stainless steel, S7 tool steel, P2 tool steel, various aluminum alloys, combinations thereof or the like.

The tool body 324 may include a tool body insert 332 for adding structural support through the tool body 324. The tool body insert 332 may be provided within the recess of the back surface 328 and may be engaged with the body of the tool body 324. tool 324 directly or may include a series of supports 334 extending from the insert 332 to engage with the rear surface 328 of the tool body 324. The tool body insert 332 may be unitarily formed from a solid block, or from multiple components such as laminar sheets.

Now, with reference to Figures 10 and 11, the fluid lines 330 are provided on the back surface 328 of the tool body 324. The fluid lines 330 can be increasingly spaced from the back surface 328 by spacing blocks 335. which can rest on the rear surface 328 or be fixed to the rear surface 328. The fluid lines 330 are arranged to conform to an outline of the forming surface 326 due to the arrangement of the fluid lines 330 in relation to the surface 326. The fluid lines 330 can include a single fluid line or multiple fluid lines 330 to cool and heat the forming surface. Unlike the prior art cooling methods, where the fluid lines are drilled in the tool body, the formed fluid lines 330 conform to the configuration of the forming surface 326 and can provide heating and / or uniform and controlled cooling of the forming surface 326 of the tool body 324.

As illustrated in Figure 11, the fluid lines 330 and the separation blocks 335 are disposed on the rear surface 328 of the tool body 324. In order to improve heat transfer heat to and from the forming surface 326, a conductive material 336 is provided to cooperate with the back surface 328 of the tool body 324 and with the fluid lines 330. For the illustrated embodiment, the conductive material 336 is fused to the tool body 324 and the fluid lines 330. conductive material 336 can be any material having a coefficient of thermal conductivity greater than that of tool body 324. For example, conductive material 336 can be copper, which has a thermal conductivity coefficient of 390 W / mK (watts per meter * Kelvin), which is greater than that of aluminum having a conductivity of 360 W / mK, and a tool steel that has a thermal conductivity coefficient of 25 -35 W / m-K.

An exemplary method for melting the conductive material 336 in the tool body 324 involves placing the tool body 324 in the support casting mold 322. The support casting mold 322 can be a special or reusable mold for transporting the tool. tool 320 to a drying oven or oven to heat the tool 320 during the molding operation. The support casting mold 322 is configured to receive and support the tool body 324. In the illustrated embodiment, the support casting mold 322 is provided with a particulate material 338 having a melting temperature greater than that of the material conductive 336. The particulate material 338 may be any particulate material commonly used in molding operations such as sand, zincon (zirconium silicate), a ceramic fiber, (such as Fiberfrax® provided by Unifrax Corporation of Niagara Falls, New York) or the similar.

In addition to supporting the tool body 324 during the molding operation, the particulate material 338 joins an outer region of the tool body 324 such that the molten conductive material 336 can not flow past the tool body 324. For example, if the tool body 324 is formed of a plurality of laminar sheets with minimal gaps between them due to the tolerance of the sheets, the particulate material 338 provides an external barrier to the tool body 324 such that the conductive material 336 can not flow beyond the boundaries of the particulate material 338. Once the tool body 324 is inserted into the support casting mold 322, the support casting mold 322 can vibrate until the tool body 324 is substantially immersed within the particulate material 338.

The conductive material 336 can be placed on the back of the tool body 324 or the insert of the tool body 332. The conductive material 336 can be provided as blanks of the conductive material, such as bars or slabs. Depending on the amount of conductive material 336 required, the weight of the conductive material 336 may exceed a carrying capacity of the back surface 328 of the tool body 324 or the tool body insert 332. Accordingly, a support plate may be provided. 340 for uniform distribution of the weight of the conductive material 336 through the back of the tool body 324 and the tool body insert 332. Alternatively, the support plate 340 can be supported by the support casting mold 322 by fasteners Mechanical, or the support plate 340 can be welded directly to the support casting mold 322. Once the support plate 340 is installed to the support casting mold 322, the conductive material bars 336 can be placed on the support plate 340 within the support casting mold 322, as illustrated in Figure 11. Alternatively, the support plate 340 it can be attached to the tool body 324 for use as an installation plate in the associated molding machine.

Once the tool 320 is assembled within the support casting mold 322, as illustrated in Figure 11, the support casting mold 322 is placed inside a drying oven, oven or the like. The conductive material 336 has a melting temperature lower than that of the tool body 324 and the particulate material 338. The fluid lines 330 are formed either from a material having a melting temperature greater than that of the conductive material 336. , or are filled with a particulate material having a melting temperature greater than that of the conductive material 336 to maintain the fluid lines 330 after the molding process. For example, the fluid lines 330 may be formed from flexible stainless steel corrugated tubing and / or may be filled with sand to maintain the fluid lines 330 through the conductive material 336 after the molding operation.

During the molding operation, the tool 320 is heated to a temperature higher than the melting temperature of the conductive material 336. For example, if a copper conductive material 336 is used, the copper has a melting temperature of 1992 degrees Fahrenheit and consequently, the tool 320 must be heated to a temperature greater than 1992 degrees Fahrenheit, for example 2050 degrees Fahrenheit. The support plate 340, if used for the particular embodiment, can be provided with an opening 342 so that the conductive material 336 can melt and flow through the opening 342 towards the rear surface 328 of the tool body. If a tool body insert 332 is used for the particular mode, or if the conductive material 336 rests on the tool body 324, an opening 344 may also be formed through the tool body insert 332 or the tool body 324. so that the conductive material 336 can flow towards the back surface 328 of the tool body 324.

An ideal volume of conductive material 336 is placed within the support casting mold 322 to fill the volume provided adjacent the back surface 328 of the tool body 324. With reference to Figure 11, after the conductive material 336 has been melted and that the conductive material 336 has flowed towards the clutch with the back surface 328 of the tool body 324 and the fluid lines 330, the tool 320 is cooled so that the conductive material 336 can be solidified.

During various training operations, such as injection molding, the forming surface 326 of the tool body 324 is heated and cooled for each part formed by the particular tool. In order to uniformly control the heating and cooling of the tool body 324, the fluid lines 330 can be connected to a source of pressurized fluid, such as a coolant pump and a hot oil pump. In order to further facilitate the thermal transfer between the forming surface 326 and the fluid lines 330, the back surface 328 of the tool body 324 and the fluid lines 330 are in contact with the conductive material 336, which is melted at the back surface 328 of the tool body 324 and melts around the fluid lines 330. In this manner, the internal stresses of articles formed by the tool 320 can be controlled, reduced or eliminated.; the shrinkage, collapse and distortion of the molded article can be controlled; and the cycle time can be improved due to the improved heating and cooling adjustment of the fluid lines 330 and the forming surface 326 through the conductive material 336. Additionally, greater flexibility in the arrangement of the fluid lines 330 is provided. , allowing the fluid lines 330 to conform to the contour of the back surface 328 of the tool body 324 thereby equalizing the forming surface 326 for improved fluid cooling or fluid heating.

After forming the tool 320 with the conductive material 336 fused to the back surface 328 of the tool body 324, the tool 320 can be removed from the support casting mold 322 and can vibrate to remove the particulate material 338 from the forming surface 326 of the tool body 324. Additionally, the tool 320 may vibrate to remove the particulate material 338 from within the fluid lines 330, if used.

The particular molding application for the tool 320 may require such large heat transfer rates, that the thermal expansion rates of the tool body 324 and the conductive material 336 are in conflict. Thus, a series of spaces 346 is illustrated, in dotted lines in Figure 12, which can be provided through the conductive material 336 to allow varying rates of thermal expansion of the conductive material 336 relative to those of the tool body 324. The spaces 346 can be formed during the molding operation by inserts of sand blocks or can be machined in the conductive material.

Many conductive materials have a substantial shrinkage rate as they solidify. For example, copper has a contraction rate of approximately five percent. To prevent the contraction from affecting the final tool, an enhancement may be incorporated in the back surface 328 of the tool in an orientation that does not affect the heat transfer to allow shrinkage to occur away from any critical thermal transfer region.

Alternatively, the casting support mold 322 can be a temporary mold that can be made of wood. A meltable refractory material 338 such as a meltable ceramic that is thermally conductive, such as aluminum silicate carbide, can be used in place of sand or other particulate material. The refractory material 338 can be mixed with water and inserted into the support casting mold 322. Subsequently, the tool body 324 can be inserted into the refractory material 338 thereby melting the refractory material 338 around the tool body 324. The refractory material 338 it is allowed to dry and harden. To improve the curing of the refractory material 338, the support casting mold 322, the refractory material 338 and the tool body 324 can be placed in an oven and heated to a temperature greater than 250 degrees. Fahrenheit to accelerate the evaporation of water from the refractory material.

Once the refractory material 338 is cured and hardened, the support casting mold 322 can be removed from the molten refractory material 338 and the tool body 324 and placed in a drying oven or furnace to melt a conductive material 336 in the tool body. 324 as described above. For example, a refractory material 338 such as an aluminum-silicate carbide can withstand temperatures of up to 3,400 degrees Fahrenheit. The refractory material 338 provides a thermal conductivity rate that is approximately twenty percent of the thermal conductivity rate of the tool body 324, and that is greater than that of the sand. The relatively high heat transfer rate of the refractory material 338 ensures strong welding of the conductive material 336 through the tool body 324, particularly to the forming surface, without requiring a prolonged drying time. Accordingly, the time of the casting cycle within the furnace is reduced and an adequate strong weld is provided through the tool body 324. Once the conductive material 336 is fused in the tool body 324, the tool body 324 can to cool and the refractory material 338 can be removed from the tool body 324 by destroying the molten refractory material 338.

Now, with reference to Figures 13 and 14, another tool 348 is illustrated for forming an article in a molding operation in accordance with the present invention. Similar or equal elements are assigned the same reference numerals, in which the new elements are assigned new reference numerals.

The tool 348 includes a tool body 324 with a forming surface 326 and a rear surface 328. A plurality of fluid lines 330 are provided to abut the back surface 328 of the tool body 324 on spacing blocks 335. A plate 349 is installed directly on the tool body 324. Due to the varied rates of thermal expansion, the installation plate 349 is fixed to the tool body 324 only in one location to allow variable rates of thermal expansion of the plate. 349 and the tool body 324. Accordingly, a central support 350 is provided on the rear surface 328 of the tool body 324, which is fixed directly to the installation plate 349. For example, the installation plate 349 can be welded to the central support 350. In this way, the installation plate 349 is supported by the central support 350 of the tool body 324 and, for example, by the distal ends 352, 354 of the tool body 324. This arrangement of The support supports the installation plate 349 in relation to the tool body 324 and allows the linear translation of the distal ends 352, 354 in relation to the central support 350 due to the thermal expansion. Similarly, the tool body 324 can be supported by the installation plate 349 by means of the central support 350 and the distal ends 352, 354.

Now, with reference to Figure 14, the support plate 349 also includes an opening 356 formed therethrough, which is offset from the central support 350 to allow the conductive material 336 to pass through the installation plate 349 during the molding operation. Similar to the previous embodiment, the support casting mold 322 can be placed in an oven to melt the conductive material 336 and melt the conductive material 336 to the back surface 328 of the tool body 324.

With reference to Figure 15, another tool 358 is illustrated for forming an article in a molding operation, in accordance with the present invention. The tool 358 is formed from a plurality of laminar sheets 360, using one of the plurality of methods for the formation of mold tools from sheet sheets, such as those described in the U.S. Patent. No. 6,587,742 B2 of Manuel, Weaver's Patent No. 5,031,483, or Patent Application of Manuel et al., No. 2005/0103427 Al, or any other suitable laminated tooling process. The laminar sheets 360 may each be formed of a suitable material, such as stainless steel, to effect the forming operation. The laminar sheets 360 can collectively provide a conduit 362 formed through a plurality of sheets 360 for transporting fluid. A tube 364 may be inserted into the conduit 362 and may be filled with a particulate material such as sand. The distal ends of tube 364 can be sealed with a material having a high melting temperature, such as a Fiberfrax® plug to prevent conductive material from infiltrating tube 364.

The laminar sheets 360 collectively provide the shape of the tool 358 and can be assembled together by bolts, snap-fit projections, welds or the like. Projections for assembling adjacent laminar sheets are described in the U.S. Patent Application Publication. No. 2005/0196232 Al, published on September 8, 2005 for Manuel et al., Whose description is incorporated in its entirety by reference herein.

The laminar sheets 360 also provide an almost flat forming surface 366 on the tool 358. A plurality of cavities 368 are formed within the tool 358 by notches in selected laminar sheets 360. The cavities 368 can be formed by intersecting the conduit 362. The tool 358 can be assembled with a conductive material disposed within the cavities 368 of the laminar sheets 360. Alternatively, a conductive material 370, such as copper, may be melted in the cavities 368 of the tool 358. The conductive material 370 may be fused to the tool 358 in a manner similar to that described in the previous embodiments of Figures 10-14. Alternatively, the side walls 372 can be installed directly on the tool 358 around a periphery of a rear surface 374 of the tool to retain the slabs of the conductive material 370.

Although the cavities 368 are illustrated parallel with the laminar sheets 360, the invention contemplates that the laminar sheets 360 may be formed perpendicular to the laminar sheets 360.

The tool 358 can be placed within a particulate material 376 within a reusable support casting 378 mold. The support casting mold 378, the particulate material 376 and the tool 358 can vibrate until the tool 358 is partially submerged within the particulate material 376. The conductive material 370 can be placed on the back surface 374 of the tool 358. Selected conductive material 370 has a melting temperature lower than that of particulate material 376, laminate sheet 360 of tool 358 and any particulate material disposed within conduit 362 or tube 364 within conduit 362 so that the conductive material 370 is the first and only thing that melts during the molding process.

Once assembled, the support casting mold 378 is placed in a drying oven, oven or the like and heated to a temperature higher than the melting temperature of the conductive material 370. An opening can be formed within the tool 358 of so that the conductive material 370 can flow through the opening in the conduit 362 and the cavity 368. Due to the tolerance variations in the laminar sheets 360, the conductive material 370 can infiltrate between the spaces provided between the adjacent laminate sheets 360. of the tool 358 through capillary action. Accordingly, the conductive material 370 can infiltrate between the adjacent laminar sheets 360 and fill the cavities 368, and fill the conduit 362 around the tube 364. Upon cooling the tool 358, the conductive material 370 is placed within the cavities 368 and surrounds the tube 364 within the conduit 362. Additionally, the conductive material 370 welds the laminar sheets 360 of the tool 358 strong together. The particulate material 376 provides a limit to the molding process so that the conductive material 370 does not flow externally from the tool 358 beyond the particulate material 376.

As discussed above, with reference to Figures 11 and 12, the support casting mold 378 of Figure 15 may be temporary for the melting of a refractory material 376 around the tool 358. Then, the casting support mold 378 can be removed and the conductive material 370 can be melted in the tool 358. After the tool 358 is cooled, the refractory material 376 can be broken and removed from the tool 358.

Now, with reference to Figure 16, the tool 358 is illustrated with each of the cavities 368 filled with the conductive material 370. Additionally, the conductive material 370 has surrounded the tube 364 and the conduit 362. Still further, the conductive material 370 has soldered the individual 360 laminar sheets of the tool 358 to each other. The forming surface 366 of the tool 358 is illustrated after a machining process. During a molding operation, the conductive material 370 and the cavities 368 conduct the heat from the forming surface 366 to the tube 364 to heat the fluid therein while the fluid passes through the tube 364. Similarly, when the forming surface 366 requires an increase in heat, a hot fluid can be pumped through the tube 364 so as to conduct the heat through the conductive material 370 towards the forming surface 366.

Now, with reference to Figures 17 and 18, a portion of a tool 380 according to the present invention is illustrated. The tool 380 is formed from a series of laminar sheets 382 secured together by a series of press fit projections 384 for joining the plates adjacent laminae. A plurality of the laminar sheets 382 include each notch formed therein to collectively provide a conduit 386 for the passage of coolant or hot fluid to cool or heat a tool forming surface 380. The conduit 386 is illustrated separately from a forming surface 387 (illustrated in dotted lines) that can be cut into sheets 382 collectively with conduit 386 or subsequently in a machining operation.

A flexible tube 388 positioned within the conduit 386 is illustrated to adequately cool or adequately heat the tool 380. The flexible tube 388 may be a corrugated stainless steel tube with a wall thickness of 0.02 inches. The flexible tube 388 can be oxidized to prevent the molten conductive material from being calcined through the tube 388. Alternatively, the tube 388 can be filled with a separator such as sand. The corrugated tube 388 provides flexibility to the tube and also causes turbulence to the fluid forced therethrough for improved heat transfer from the tube 388 to the fluid passing therethrough. Of course, the flexible tube 388 can be formed from any suitable material, such as brass that can be fused with the conductive material and formed integrally thereon around a limiter provided within the tube 388, such as sand.

Various arrangements and configurations of conduits, arrangements of the conductive material, such as heat sinks, and their combinations are contemplated within the spirit and scope of the present invention.

Now, with reference to Figure 19, a perspective view of a sectioned tool 390 according to the present invention is illustrated. The tool 390 is illustrated as a tool formed from a series of laminar sheets 392 that are joined together. The tool 390 is illustrated sectioned after the molding process. The tool 390 includes a conduit 394 that is collectively formed by notches formed through the laminar sheets 390. The conduit 394 includes a first segment 396 formed generally perpendicular to the blades 392 of the tool 390. The conduit 394 also includes a profiled segment. 398 formed generally parallel with the laminar sheets 392, thus illustrating various conforming arrangements of conduits that may be provided within the spirit and scope of the present invention. The tube is not illustrated in the embodiment of tool 390 of Figure 19. A particulate material such as sand can be provided in conduit 394 during the molding operation to maintain the integrity of conduit 394.

The invention also contemplates heat dissipators of various complexities. Now, with reference to Figure 20, another tool 400 sectioned in accordance with the present invention is illustrated. Heat sinks 402, 404 of variable geometry are provided throughout the tool body to provide controlled heating or cooling of the tool 400 specific to the molding operation of the tool 400.

Referring now to Figure 21, there is illustrated another sectioned or segmented tool 406 formed from a plurality of sheet sheets 408, illustrating the complexity of the heat sinks and conduits that may be provided in accordance with the present invention. A conduit 410 is formed through the tool 406 and is collectively provided by the plurality of laminar sheets 408. A corrugated pipe 412 is provided within the conduit for conveying fluid through the tool 406 to heat and cool the tool 406. conduit 410 is filled with conductive material 414 to provide a heat sink for tool 406 for transferring heat between fluid and tube 412 and a tool forming surface 406.

In Figure 22, another tool 416 is illustrated in accordance with the present invention. The tool 416 shown in Figure 22 can be used in a mode with a corresponding mold half to collectively form an inner door panel by a molding operation within an injection molding machine. The tool 416 can also be used alone to mold the door panel. The tool 416 can be formed from a rolling process or can be formed from a machined solid block. The tool 416 is illustrated with a forming surface 418 that is provided in a tool body 420 with appropriate profiles to form the article in the desired configuration. For example, the forming surface 418 provides a mating surface for a finished door panel with door panel components such as a support arm 422 and an acoustic housing 424. The forming surface 418 can be of an almost smooth configuration in the illustrated manufacturing step, for a subsequent machining for a final forming surface.

The tool body 420 is illustrated with a series of fluid lines 426 extending from the tool 416. As discussed with previous embodiments, the fluid lines 426 are employed for the controlled thermal transfer of the forming surface 418. Now , with reference to Figure 23, a back side of the tool 416 is illustrated with a rear surface 428 that is spaced apart from the forming surface 418. The back surface 428 may be spaced apart to a desired thickness of the forming surface 418. for controlled thermal transfer. In one embodiment, the back surface 428 is evenly spaced from the forming surface 418 for uniform thermal transfer between the forming surface 418 and the fluid lines 426. The back surface 428 can be formed in the tool body 420 by machined or a portion of the back surface 428 can be cut into each sheet sheet to collectively provide the back surface 428. The back surface 428 can also be provided within a cavity 429 in the tool body 420.

The fluid lines 426 are each configured to be generally evenly spaced from the back surface 428. The fluid lines can be formed of steel with a wall thickness of approximately 0.06 inches, which is suitable to withstand infiltration of a fluid. conductive material during the molding operation. Alternatively, flexible or corrugated tubing may be used as illustrated with the previous modalities. The 426 fluid lines can be outlined by manual cold forming processes, automated processes or any suitable forming process. Additionally, the fluid lines 426 are suitably spaced in relation to each other to adequately cool or heat the forming surface 418. The fluid lines 426 can be supported by spacers, as in the previous embodiments or can be supported by the openings 430. which are formed in the tool body 420.

After assembling the fluid lines 426 to the tool body 420, a heat sink material can be added to the back surface 428 in the cavity 429. The heat sink material can be melted in the cavity 429 as described with the previous embodiments, to join with the back surface 428 and the fluid lines 426, to improve the rate of heat transfer between the forming surface 418 and the fluid lines 426. For example, the tool body 420 can be formed of stainless steel or aluminum and the material heat sink can be provided with copper to conduct heat to and from the tool body 420 and the fluid lines 426.

Figures 24 and 25 illustrate separate partial section views of the tool 416 taken through the tool body 420. Each view is illustrated adjacent to one of the fluid lines 426. As illustrated, the tool body 420 has a dimension to adequately withstand the fatigue associated with the corresponding molding operation. The back surface 428 is generally uniformly spaced from the forming surface 418 to adequately provide the surface characteristics required for the forming operation. The displacement of the back surface 428 of the forming surface 418 is optimized to effect the molding operation while minimizing the conductive resistance provided by the material of the tool body.

Figures 24 and 25 illustrate examples of how the fluid lines 426 can be profiled relative to the corresponding back surface 428. The fluid lines 426 are enclosed within the heat sink material 432 due to the molding operation. The heat sink material 432 can also be formed within the cavity 429 to the configuration of the back surface 428 by the use of a tool body insert during the molding operation, which is integrated into the tool body 420 or subsequently removed as illustrated.

Although various examples of tools with conductive materials pipes and their combinations are provided herein, the invention contemplates various arrangements and combinations according to the present invention. In summary, the present invention provides improved cooling and heating characteristics that are adaptable to the prescribed requirements for the formation of various articles, thus providing flexibility, improved quality and reduced cycle time to form the articles.

Although the embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.

Claims (20)

1. A method for forming a molding tool, characterized in that it comprises: forming a tool body from a plurality of laminar sheets of a first material to collectively form a forming surface to form an article and to collectively form a cavity in the tool body that is spaced apart from the forming surface; Y arranging a thermal transfer material having a coefficient of thermal conductivity greater than that of the first material within the cavity for the transfer of heat between the forming surface and the heat transfer material through the tool body during a molding operation .

2. The method of claim 1, characterized in that it further comprises: arranging a tube through the clutch cavity with the heat transfer material for heat transfer between the forming surface and the tube through the tool body and the heat transfer material during a molding operation.

3. The method of claim 1, characterized in that it further comprises: placing the tool body in clutch with a third material having a melting temperature lower than that of the first material; Y heating the tool to a temperature higher than the melting temperature of the third material so that the third material infiltrates between the adjacent laminar sheets through a capillary action by strongly welding the adjacent laminar sheets of the tool body.

4. The method of claim 1, characterized in that it further comprises: placing the tool body in clutch with a thermal transfer material having a melting temperature lower than that of the first material; Y heating the tool to a temperature higher than the melting temperature of the thermal transfer material so that the thermal transfer material infiltrates between the adjacent laminar sheets through the capillary action and flows into the cavity thus welding the laminar sheets strongly adjacent to the tool body and placing the heat transfer material in the cavity.

5. The method of claim 1, characterized in that it further comprises: Place the powdered metal inside the cavity; and welding in strong copper in said powder metal to said tool body.

6. The method of claim 1, characterized in that it further comprises forming a first sheet sheet and a second sheet sheet each with a frame portion defining an internal area, a portion of the rod attached to said frame portion and an open circular portion that provides the portion of the formation of passage.

7. The method of claim 1, characterized in that it further comprises forming an article from said tool.

8. A tool formed from the method of claim 1.

9. The method of claim 1, characterized in that it further comprises: placing a third material having a melting temperature higher than that of the thermal transfer material in the cavity; Y melt the thermal transfer material in the cavity.

10. A method for forming a molding tool, characterized in that it comprises: providing a tool body from a first material with a forming surface to form an article in a molding operation; melting a thermal transfer region from a second material having a coefficient of thermal conductivity greater than that of the first material and a melting temperature lower than that of the first material, to the tool body for heat transfer between the surface of the formation and the thermal transfer region during a molding operation; fix a plate to the tool body; Orient the second material on the plate; and heating the tool to a temperature higher than the melting temperature of the second material so that the second material melts and flows towards the junction with the tool body.

11. A method for forming a molding tool, characterized in that it comprises: providing a tool body from a first material with a forming surface to form an article in a molding operation; melting a thermal transfer region from a second material having a coefficient of thermal conductivity greater than that of the first material and a melting temperature lower than that of the first material, to the tool body for heat transfer between the surface of the formation and the thermal transfer region during a molding operation; fixing side walls to the tool body; orienting the second material on the tool body within the side walls; and heating the tool to a temperature higher than the melting temperature of the second material so that the second material melts and flows to bond with the tool body.

12. The method of claim 11, characterized in that it further comprises: providing at least one tube in the tool body separated from the forming surface; Y melt the thermal transfer region to the tool body in conjunction with the at least one tube to install the tube to the tool body for heat transfer between the forming surface and the tube through the tool body and the transfer region thermal during a molding operation.

13. The method of claim 11, characterized in that it further comprises: forming a conduit inside the tool body; Y melting the thermal transfer region to the tool body and the conduit for heat transfer between the forming surface and the conduit through the tool body and the thermal transfer region during a molding operation.

14. The method of claim 13, characterized in that it further comprises: provide at least one tube in the pipe prior to the molding process.

15. The method of claim 13, characterized in that it further comprises: inserting a particulate material having a melting temperature greater than the melting temperature of the second material, into the conduit, prior to melting the thermal transfer region.

16. A tool for forming an article in a molding operation, characterized in that it comprises: a tool body formed from a plurality of laminar sheets of a first material, the laminar sheets being each configured to collectively form a forming surface for forming the article, and at least one of the plurality of laminar sheets being formed. to form a cavity in the tool body that is separated from the forming surface; Y a heat transfer material having a coefficient of thermal conductivity greater than that of the first material, disposed within the cavity for the transfer of heat from the forming surface to the thermal transfer material through the tool body during an operation of molding

17. The tool of claim 16 characterized in that a duct is collectively formed in the tool body by means of the laminar sheets for transporting a fluid, and the duct is connected with the heat transfer material for the transfer of heat between the surface of the tool. formation and fluid through the tool body and the thermal transfer material during a molding operation.

18. The tool of claim 16, characterized in that it further comprises an installation plate for the tool, the installation plate being installed in the tool body separated from the forming surface for receiving the thermal transfer material prior to a molding operation which disposes the thermal transfer material in the cavity.

19. The tool of claim 18, characterized in that it further comprises a plurality of supports extending from the tool body to be joined with the installation plate for the support of the tool body on the installation plate.

20. The tool of claim 19, characterized in that one of the plurality of supports is fixed to the installation plate and at least one of the plurality of supports is in transverse clutch with the installation plate to accommodate the variable thermal expansion rates. of the tool body and the installation plate.