DE102013203366A1 - FORM ASSEMBLY WITH HEATING AND COOLING SYSTEM - Google Patents

Abstract

A mold assembly for making molded parts includes a mold having conformal fluid conduits that follow contours of a mold surface of the mold. The conformal fluid conduits are defined in the mold during casting by sacrificial displacement conduits formed by a three-dimensional printer. A temperature control station is coupled to the mold and includes a heating and a cooling fluid. A valve station controls the flow of fluid to the mold.

Description

The present invention generally relates to a mold assembly having a heating and cooling system. Various mold systems are commonly used to make moldable parts. Heating and cooling during molding of the components can be difficult to control.

In accordance with one aspect of the present invention, a mold assembly for making molded parts includes a mold having conformal fluid conduits that follow contours of a mold surface of the mold. The conformal fluid conduits are defined in the mold during casting through sacrificial displacement conduits formed by a three-dimensional printer. A temperature control station is coupled to the mold and includes a heating and a cooling fluid. A valve station controls the flow of fluid to the mold.

In accordance with another aspect of the present invention, a mold assembly for making molded parts includes a mold having a compliant fluid conduit and a compliant reservoir near a mold surface of the mold. The compliant fluid conduit and compliant reservoir are defined in the mold during casting by sacrificial core sections formed by a three-dimensional sand pressure device. A closed fluid circuit couples the mold to a temperature control station.

In accordance with yet another aspect of the present invention, a method of making a molded part includes forming a sacrificial mandrel package having sacrificial displacement conduits developed by applying a binder to multiple layers of fine particles. A mold is formed with conformal leads from the sacrificial mandrel packing and the sacrificial displacement conduits. A fluid temperature control station is coupled to the compliant conduits in the mold. A moldable material is heated and injected into a mold cavity of the mold. The moldable material is cooled in the mold cavity.

Yet another aspect of the present invention includes a sand pressure device configured to print multiple layers of binder onto multiple layers of sand to form a mandrel. The mandrel is used to construct either an insert mold, a base mold or a mold used to make molded parts. The insert mold or mold includes conformal conduits adapted to receive a heating fluid and a cooling fluid to assist in the formation of molded parts within the insert mold or mold. The conformal conduits closely follow a forming surface that lies near a mold cavity of the insert mold or mold.

These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

In the drawings:

1 Figure 11 is a top perspective view of a rigid receiving box or work box prior to forming a mandrel package by a sand pressure device;

2 is a perspective top view of the rigid receiving box of 1 during the propagation of the first layer of fine particles in the rigid containment box;

3 is a perspective top view of the rigid receiving box of 1 after several passes of a sand pressure device;

4 is a perspective top view of the rigid receiving box of 1 just before a fresh layer of fine particles is to be spread over the pressure surface of the rigid receiving box;

5 is a perspective top view of the rigid receiving box of 1 with a fresh layer of fine particles spread over the pressure surface of the rigid containment box;

6 is a perspective top view of the rigid receiving box of 1 after a full mold core has been printed in the rigid containment box;

6A is a side perspective view of the rigid receiving box of 1 containing the mandrels with excess unbound sand removed;

7 Figure 11 is a top perspective view of unassembled mold components after they are removed from the rigid containment box;

7A is a perspective top view of the assembled mold core of 7 ;

8th is a plan view of a mold core of 7A ;

9 is a perspective cross-sectional plan view on the line IX-IX of 8th ;

10 is a cross-sectional view in side elevation of the mold core of 8th on the line XX;

11 Figure 11 is a top cross-sectional perspective view of a mandrel package during filling of molten metal into a casting area defined by the mandrel package;

12 Fig. 12 is a perspective cross-sectional plan view of the formation of a mold core package after the introduction of the molten metal into the mold core package;

12A is a cross-sectional view in side elevation of the mold core of 12 ;

13 FIG. 12 is a top perspective view of the resulting mold formed from the mold core package; FIG.

14A Figure 11 is a top perspective cross-sectional view of one embodiment of a construction of conformal conduits extending through a mold;

14B Figure 11 is a top cross-sectional perspective view of another embodiment of a conformal conduit extending through a mold;

14C Figure 11 is a top cross-sectional perspective view of another embodiment of a conformal conduit extending through a mold;

14D Figure 11 is a top cross-sectional perspective view of another embodiment of a conformal conduit extending through a mold;

14E Figure 11 is a top cross-sectional perspective view of another embodiment of a conformal conduit extending through a mold;

14F Figure 11 is a top cross-sectional perspective view of another embodiment of a conformal conduit extending through a mold;

14G Figure 11 is a top cross-sectional perspective view of another embodiment of a conformal conduit extending through a mold;

14H Figure 11 is a top cross-sectional perspective view of another embodiment of a conformal conduit extending through a mold;

14I Figure 11 is a top cross-sectional perspective view of another embodiment of a conformal conduit extending through a mold;

15A Figure 11 is a top cross-sectional perspective view of one embodiment of a compliant reservoir extending through a mold;

15B FIG. 12 is a top perspective view of the compliant reservoir and mold of FIG 15A ;

15C Figure 11 is a top perspective cross-sectional view of another embodiment of a compliant reservoir extending through a mold;

15D FIG. 12 is a top perspective view of the compliant reservoir and mold of FIG 15C ;

15E Figure 11 is a top perspective view of another embodiment of a compliant reservoir extending through a mold;

15F Figure 11 is a top perspective view of yet another embodiment of a compliant reservoir extending through a mold;

15G Figure 11 is a top perspective view of yet another embodiment of a compliant reservoir extending through a mold;

16 Figure 11 is a top perspective view of the mold illustrating a first mold half prior to connection to a complementary second mold half;

16A is a perspective top view of the first mold half and the second mold half of 16 after the connection;

17 Fig. 12 is a perspective plan view of a molded part taken out of the first mold half and the second mold half;

18 Fig. 12 is a perspective cross-sectional plan view of the formation of an insert molding tool in a mold core package;

19 is a cross-sectional view in side elevation of the insert mold of 18 ;

20 Figure 11 is a top cross-sectional perspective view of the insert mold after removal from the mandrel package;

21 FIG. 12 is a top perspective view of the first and second insert molds prior to installation in first and second base molds; FIG.

21A is a perspective cross-sectional top view of the mold assembly of 21 ;

22 is a perspective top view of the mold assembly of 21 during the molding of a part;

23 is a perspective top view of the mold assembly of 21 during the removal of the molded part;

24 Figure 11 is a schematic view of a temperature control station in conjunction with a mold assembly and the introduction of a heating fluid into the mold assembly;

25 Fig. 12 is a schematic view of a temperature control station coupled to a mold assembly and introducing a cooling fluid into the mold assembly;

26 Fig. 10 is a schematic view of one embodiment of a heating system for use with a mold assembly;

27 Fig. 10 is a schematic view of one embodiment of a cooling system for use with a mold of the present invention;

28 FIG. 13 is an exploded top perspective view of a sand mold package having a mold top, a mold bottom, and a core exploded away; FIG.

29 is a top perspective view of the sand mold package of 28 wherein the core is inserted into the mold base;

30 is a top perspective view of the sand mold package of 28 wherein the mold top and the mold bottom are disposed adjacent to one another in preparation for pouring a molten material;

31 is a perspective view of a casting made from the sand mold package of 28 was made, the sand mold of 28 has broken away; and

32 FIG. 12 is a perspective view of a mold tool as seen through the sand mold package of FIG 28 produced.

For the purposes of the description herein, the terms "upper,""lower,""right,""left,""rear,""front,""vertical,""horizontal," and derivatives thereof are intended to refer to the invention as in 1 oriented, relate. Of course, however, the invention may take various alternative orientations, unless expressly stated otherwise. Of course, the specific devices and processes illustrated in the accompanying drawings and described in the following specification are also exemplary embodiments of the inventive concepts defined in the appended claims. Specific dimensions and other physical characteristics relating to the embodiments disclosed herein are therefore not to be considered as limiting unless the claims expressly state otherwise.

In the 1 - 27 is a mold core pack 10 illustrated. The mold core pack 10 is used to make a mold 12 train. The mold core pack 10 includes several stacked particle layers 14 with a binder 16 , The several stacked particle layers 14 form sacrificial walls 18 , An elongated sacrificial particle line 20 extends through the mold core package 10 and defines a compliant conduit 22 in the mold 12 , A mold cavity 26 is through the multiple stacked particle layers 14 Are defined.

It is considered that the mold 12 could be used in any of a variety of molding operations. Such molding operations may include injection molding, foam molding, blow molding, thermoforming, transfer molding, reaction injection molding, compression molding, extrusion, and so on. The mold 12 As set forth in the following description, is used for injection molding applications. However, it will be understood by one skilled in the art that the mold 12 using the mold core packing 10 can be used for any of the aforementioned molding applications.

In the 1 - 6 is a pattern box or work box 40 formed of any of a number of materials, including wood, metal, etc., under a printing device 42 arranged. The work box 40 defines one pressure range 44 in which the mold core package 10 ( 8th ) from the several stacked particle layers 14 is constructed. The printing device 42 includes a funnel 46 and a deposition trough 48 containing a thin layer of activated fine particles 50 such as As silica, sand, ceramic-sand mixtures, etc. in the printing area 44 stores. The particles 50 may be any size, including a diameter of 0.002 mm to 2 mm. The printing device 42 also includes a binder-depositing device or a binder distributor 52 , As disclosed in detail below, the binder distributor sprays 52 a thin layer of a binder or binder 16 in the form of a single layer of the desired mold core package 10 , The repetition of the stratification of sand and the spraying of binder 16 through the binder distributor 52 on the fine particles 50 results in the generation of three-dimensional (3D) mandrel patterns 10 , The 3D shape core pattern 10 are generated over a length of time sufficient to cover any thin layer of fine particles 50 to print. The produced mold core package 10 is finally used to the mold 12 which is used to make molded parts.

Regarding 1 will initially be a computer aided design (CAD) program running on a computer 60 running, with the printing device 42 coupled to the desired shape of the final product in the CAD program of the printing device 42 fed. It is contemplated that CAD or any other form of 3D modeling software may be used to provide sufficient information for the 3D printing device 42 to deliver the desired mold core package 10 ( 8th ) train. Before activating the 3D printing device 42 becomes a predetermined amount of the fine particles 50 through a particle sleeve 62 together with an activation coating or an activator 70 that by an activator spout 72 is fed into the funnel 46 poured. Although the illustrated embodiment has fine sand as fine particles 50 As stated above, the fine particles 50 comprise any of a variety of materials or combinations thereof. The fine particles 50 be in the funnel 46 with the activator 70 mixed. The mixture of fine particles 50 and activator 70 can by a stirrer 74 or another such stirring device, so that the fine particles 50 to be activated. After the fine particles 50 and the activator 70 were thoroughly mixed, the fine particles 50 to the deposition trough 48 emotional.

Regarding 2 and 3 be after the fine particles 50 to the deposition trough 48 were moved, the fine particles 50 over the pressure range 44 in a fine uniform layer through the deposition trough 48 spread. After putting in a thin layer on the printing area 44 in the work box 40 are spread, become the activated fine particles 50 with the binder 16 sprayed. The binder 16 comes from the binder distributor 52 containing a thin layer of the binder 16 in a pattern 80 sprays a first thin cross-sectional layer of the desired mandrel package 10 ( 8th ). After the binder 16 is sprayed, becomes another mixture of fine particles 50 and activator 70 prepared and in the separation trough 48 poured. The deposition trough 48 then gives another layer of activated fine particles 50 over the previously spread layer of fine particles 50 in the work box 40 out. The binder distributor 52 moves again over the pressure range 44 in which he uses a thin layer of the binder 16 in the pattern 80 that is a second thin cross-sectional layer of the desired mandrel package 10 represents adjacent to the first thin cross-sectional layer sprays. These steps are repeated many times until each cross-sectional layer of the mold core package 10 has been printed ( 6 ). Using this mandrel design technique, theoretically any shape of mandrel packing may be used 10 be formed. Furthermore, the mold core package 10 have internal structural features that otherwise can not be generated by other known methods. In particular, the mold core package 10 be constructed so that they have the multiple sacrificial particle lines 20 ( 6A ), which is located in and around the mold core package 10 extend. The several sacrificial particle lines 20 are made from the binder 16 and fine particles 50 in the same way as the mold core package 10 is formed generates. As will be more fully disclosed herein, the victim particle conduits 20 used to conform to the channels or lines 22 ( 13 ) to define the rapid heating and cooling of the mold 12 ( 13 ) during injection molding of the parts.

With reference now to 7 and 7A It is also contemplated that any of the locking features may be used to connect components of a mold core package. In the illustrated embodiment, a composite mandrel 92 with a plurality of components of a mold core package 93A . 93B . 93C and 93D , which are designed for insertion in a work box. In certain cases, when large molds 12 ( 13 ), a plurality of components of a mold core package may need to be joined together to form the molds 12 train. As shown, the components of a mold core package 93A . 93B . 93C and 93D using sacrificial connectors 94 combined, to engage with receiving slots 95 in each of the components of a mold core package 93A . 93B . 93C and 93D are designed. The components of a mold core package 93A . 93B . 93C and 93D otherwise function similar to the mold core package discussed in this disclosure 10 ,

As in 8th - 11 shown includes the 3D mold core package 10 a mold surface 100 which generally represents the shape of a part that will eventually be shaped. The mold core pack 10 also includes the several sacrificial particle lines 20 , the compliant wires 22 ( 13 ) in the mold 12 define. The mold core pack 10 Also has a shape that the size and positioning of the conformal lines 22 which are elongated passages through the heating and cooling fluids during the formation of molded parts in the mold 12 stream. At the same time are conformal lines 22 around a mold surface 160 ( 13 ) arranged, which is finally the molding. The compliant lines 22 assist in heating and cooling the molding during the molding process. As in 9 and 10 shown, the mold core package 10 for the introduction of a molten material 110 prepared. The molten material 110 can be any of a variety of metals, including cast iron or an alloy. Intermittently spaced core supports 111 can in the mold core package 10 to be ordered. The core supports 111 keep the victimparty leaders 20 above the mold surface 100 at the point. Both the mold core pack 10 as well as the several sacrificial particle lines 20 are once used to a mold 12 manufacture. That is, the mold core package 10 and the several sacrificial particle lines 20 be during the production of the mold 12 generally destroyed after the molten material 110 in the mold core pack 10 has solidified. An alloy, such as. For example, those described in US Provisional Patent Application No. 61/268369, entitled "Method of Producing a Cast Skin or Slush Mold," and PCT International Publication no. WO 2010/144786 entitled "Low CTE Slush Molds with Textured Surface, and Method of Making and Using the Same", which are incorporated, shown and described in their entirety herein, may be incorporated into the mold core package 10 to be poured.

Regarding 11 - 13 becomes the mold 12 by pouring the molten material 110 in the mold core package 10 produced. The molten material 110 fills all the empty space in and around the mold core pack 10 , the sacrificial walls 18 and the sacrificial party leaders 20 , The molten material 110 can do some or all of the binder 16 in the thin particle layers 14 burn. After the introduction of the molten material 110 in the mold core package 10 becomes the mold core pack 10 placed in an oven where the heat is the binder 16 in the mold core package 10 volatilized. The mold tool 12 is then from the Formkernpackung 10 by breaking up the sacrificial walls 18 Broken off and any remaining sand may be from the mold 12 be rinsed away or washed off. Likewise, the binder volatilizes 16 in the sacrificial particle lines 20 also, so that the conformal lines 22 can be plastered with a brush or a powder sprayer containing the fine particles 50 from the conforming lines 22 washes out.

It is further contemplated that the thin containment walls around the mandrel package such. B. the in 11 shown Formkernpackung 10 can be printed. It is considered that the thin containment walls are the configuration of the in 11 shown work box 40 can largely reflect. It is possible to print the thin containment walls using the above mentioned sanding process when the mandrel package 10 also is printed. A molten material, such as. For example, the above-mentioned molten material 110 , can be poured into the thin containment walls surrounding the mandrel packing 10 are printed. For the thin containment walls to withstand the casting process, a mandrel package with thin containment walls printed around the mandrel package would be inserted into foundry sand for additional support. In this manner, an additive manufacturing technique may be used to provide containment walls for containing and forming a casting when supported by foundry sand. Further, a similar technique for printing thin guard walls can be used to completely enclose a very delicate and complicated mold core package. In this way, it is contemplated that a thin-walled barrier structure can be printed that completely surrounds a sensitive mandrel package to protect the mandrel package until required for a casting process. The thin walled protective structure may then be broken away to allow the molding worker to recover the mold core package.

As in 12 - 13 shown, the molten material 110 then harden. The molten material 110 hardens to form the mold 12 , After hardening, the mold core packing becomes 10 destroyed and internal cavities are cleared out. After the mold 12 has been cleaned and treated appropriately, the finished mold 12 that left remains, forming molded parts during injection molding or other molding processes. The mold 12 includes an injection port 120 for injecting a molding material 122 ( 15B ) in the mold cavity 26 ( 16A ), which is between opposing molds 12 is defined. It is also noted that the compliant leads 22 in the mold 12 are provided. The mold 12 represents only one half of a mold assembly 130 ( 16A ), the two molds 12 includes, as the first and second mold halves 132 . 134 ( 16A ) working to form a molding 140 be used.

Regarding 14A - 14H can the victimparty lines 20 ( 12 ) are formed with different protuberances, the irregular shapes in the conformal lines 22 after applying molten material to the mandrel package 10 define. Consequently, the compliant leads can 22 a variety of configurations and features such. B. turbulence inducing elements. As in 14A shown include the conformal lines 22 a plurality of ribs 141 , the recesses 143 in the mold 12 define. The recesses 143 can provide desired thermodynamic properties, efficiently heat the molding material prior to the molding process 110 or remove heat from an already formed part. In another embodiment, as in 14B shown are the ribs 141 and recesses 143 constructed in a spiral pattern that provides extra turbulence in the conformal conduit 22 can produce when the mold 12 heated or cooled. Similar embodiments, such as. B. the in 14C - 14F shown include a diamond-shaped construction ( 14C ), a diamond-shaped construction that is in a spiral configuration ( 14D ), an oval construction ( 14E ) and an oval construction which is in a spiral configuration ( 14F ). In addition, the diameter of the conformal line may be 22 also change so that the flow through the mold 12 increases or decreases as the heating / cooling fluid passes through the compliant conduits 22 flows ( 14G ). These and other variations on the compliant leads 22 are due to the manufacture of the mold 12 using a mold core package made by the 3D printing process discussed in detail herein. Conventional cooling ducts for dies have been drilled frequently, with the consequent possibility of irregularly shaped conformal ducts 22 is eliminated. As in 14H It is also contemplated that the longitudinal extent of the conformal conduits 22 can be linear, arcuate, angled, etc. Moreover, the compliant conduits can 22 be wavy and sections that are very close to the mold surface 160 lie ( 15A ), and other sections that are not close to the mold surface 160 lie so that different areas of the conformal lines 22 a different thermal influence on the mold 12 and finally the part that is molded. As noted herein, these configurations are made possible by the 3D printing process detailed herein.

Regarding 15A - 15D is considered that the compliant leads 22 with one or more compliant reservoirs 145 be or can become part of it. Any compliant reservoir 145 is formed from a sacrificial displacement body, which is connected to the Formkernpackung 10 during the construction of the mold core package 10 is trained. The sacrificial displacement body may include various recesses, the irregular shapes in the compliant reservoirs 145 after applying molten material to the mandrel package 10 define. The compliant reservoirs 145 are designed to provide a uniform flow of heating / cooling fluid through the mold 12 near in the mold 12 defined shape surface 160 to accomplish. The mold 12 can have several compliant reservoirs 145 include, extending over the mold 12 extend. As in 15C and 15D shown are periodic columns 146 provided, which are designed so that they are loads on the mold 12 withstand, which are connected with injection molding. The periodic columns 146 make sure the injection mold 12 not near any of the compliant reservoirs 145 breaks or tears. In addition, the mold includes 12 partitions 139 that prevent mold material from entering the mold cavity 26 ( 16A ) is injected into the compliant reservoir 145 or the compliant leads 22 entry.

The compliant reservoirs 145 can adopt a variety of constructions and can be at different distances from the mold surface 160 depending on the desired thermal influence affecting the conformal lines 22 on the mold 12 and finally have the part to be formed arranged. It is also considered that the compliant reservoirs 145 over the whole mold 12 can meander. In particular, sections of the compliant reservoirs 145 closer to the mold surface 160 of the mold 12 lie as other sections of the compliant reservoirs 145 Thus, areas are provided which have a higher thermal impact on the mold surface 160 as those areas of compliant reservoirs 145 further from the mold surface 160 lie.

Regarding 15E - 15G may have various turbulence inducing elements within the compliant reservoirs 145 to limit the stagnation and to improve the turbulence of the heating / cooling fluid flowing through the part during the injection molding process. As in 15E shown is a number of ribs 147 arranged at angles relative to each other and these promote the flow in and around the ribs 147 , As in 15F shown are alternatively several baffles 148 in intermittent positions within the compliant reservoir 145 arranged to influence the flow of the heating / cooling fluid passing through the compliant reservoir 145 flows, and also to minimize the thermal influence of the heating / cooling fluid at the points of the baffles 148 Act. In yet another embodiment, as in 15G shown, several intermittent projections extend 149 into the compliant reservoir 145 , whereby the flow and stagnation of heating / cooling fluid in the compliant reservoir 145 to be influenced. Although the projections shown 149 comprise a cylindrical construction, the projections 149 of course accept many different shapes. It will also be understood by one skilled in the art that any of a variety of different architectures in the mold 12 can be formed as a direct consequence of being constructed by the 3D printing process disclosed herein. During the molding process, the turbulence elements are defined by a recess in the mandrel, which later with the molten material during the manufacture of the mold 12 is filled.

Regarding 16 and 16A becomes a first half of the mold 132 with a second mold half 134 connected, which have been previously formed and have a complementary shape. The first half of the mold 132 and the second half of the mold 134 make molds 12 which is using the with reference to 1 - 14 were formed in detail described printing technology. The mold cavity 26 between the first half of the mold 132 and the second mold half 134 represents the shape of the molding 140 ( 17 ) that is to be formed. The first half of the mold 132 and the second half of the mold 134 be about pins 144 connected around corners of each of the first and second mold halves 132 . 134 are arranged and the first half of the mold 132 and the second half of the mold 134 fasten laterally (X and Y directions). At the same time a press attached 150 the first half of the mold 132 on the second half of the mold 134 in a vertical direction. After the first half of the mold 132 and the second half of the mold 134 attached to each other becomes the molding material 122 through the injection opening 120 injected with a high pressure. As a result, the mold cavity becomes 26 that is between the first half of the mold 132 and the second mold half 134 is defined with the molding material 122 filled. At the same time, a heating fluid 152 ( 24 and 25 ) in an inlet 153 through the conforming lines 22 pumped near the mold surface 160 the first half of the mold 132 and the second mold half 134 are arranged, and passes through an outlet 155 out. The heating fluid 152 heats the mold surface 160 the first half of the mold 132 and the second mold half 134 what a convenient flow of the molding material 122 into the mold cavity 26 causes. After the mold cavity 26 completely with the molding material 122 filled, become the compliant leads 22 from the heating fluid 152 emptied. The compliant lines 22 then use a cooling fluid 154 filled to the mold material 122 that in the mold cavity 26 is arranged to cool quickly. It is considered that the cooling fluid 154 and the heating fluid 152 can be the same fluid. Alternatively, the cooling fluid 154 be a first fluid that works well in a cooled state, and the heating fluid 152 may be a second fluid that works well in a heated condition. After a predetermined length of time, the first mold half 132 from the second mold half 134 separated and the molding 140 ( 17 ) is taken. The first half of the mold 132 and the second half of the mold 134 are now reconnecting and introducing additional molding material 122 ready to make more moldings 140 train.

Yet another embodiment of the present invention includes an insert mold assembly 168 ( 21 ), which are a first and a second use form 170 . 172 which also acts as a cavity tool 170 and core tool 172 are known, which for engaging with a first and a second base mold 174 . 176 are designed. As in 18 - 20 shown, become the first and the second use form 170 . 172 formed in a similar process as described above with respect to 1 - 14 outlined. The same 3D printing process is used, but the 3D printing process is used, rather the first and second use forms 170 . 172 as the finished mold 12 train. The first and the second form of use 170 . 172 create a fast connection with the first and the second basic form 174 . 176 , thereby allowing a user to quickly get the first and the second use 170 . 172 from the first and the second basic form 174 . 176 alternates, thereby improving the rate at which different moldings 140 can be produced in a molding device. Compliant cables 22 and compliant reservoirs 145 can in one or both of the forms of use 170 . 172 be formed. It is also contemplated that the compliant leads 22 with the conforming lines 22 in the first and second basic forms 174 . 176 or with forwarding lines in the first and the second base form 174 . 176 can be in fluid communication. The compliant lines 22 , the compliant reservoirs 145 and any routing lines are formed by forming sacrificial core sections such as e.g. Sacrificial displacement conduits and sacrificial displacement bodies in a mold core package 10 before the introduction of molten material into the mold core package 10 produced.

As in the embodiment of 21 - 23 are the first and the second form of use 170 . 172 for insertion into the first or the second base mold 174 . 176 designed. The first and the second form of use 170 . 172 be on pins 180 aligned around corners of the first and second basic shapes 174 . 176 are arranged. Although the pins 180 in the embodiment shown in FIG 21 - 23 is shown, for engagement with the first and the second use form 170 . 172 are designed, the present invention is not limited thereby to this embodiment. The pencils 180 function as a guide that can guide the inserts, the base shapes, the inserts, and the base shapes, or the pins 180 can be completely removed. The first basic form 174 , the first use 170 , the second form of use 172 and the second basic form 176 are then securely bonded and molding material 122 is through an inlet opening 179 in the first basic form 174 and by the first use 170 introduced. The molding material 122 occupies the mold cavity 26 that's between the first use form 170 and the second form of use 172 is defined. The molding material 122 will then be on the compliant lines 22 heated, which is a heating fluid 152 included in an inlet 182 , through the conforming lines 22 and from an outlet 184 a mold surface 188 the first and the second use form 170 . 172 is pumped. After the molding material 122 completely within the mold cavity 26 was pressurized, is cooling fluid 154 into the conforming lines 22 introduced to the molding material 122 to cool or cool quickly, creating a hardened molding 140 is trained. The molding 140 then gets out of the mold cavity 26 ( 23 ) and the first basic shape 174 , the first use 170 , the second form of use 172 and the second basic form 176 are then reconnected and again with the mold material 122 filled to additional moldings 140 train.

If you look now 24 and 25 is generally considered that the heating fluid 152 and the cooling fluid 154 passing through either the molding tool 12 or the insert mold assembly 168 (collectively called "Form Arrangement 200 from a temperature control system 202 is forwarded. The temperature control system 202 includes the heating fluid 152 and the cooling fluid 154 that with the mold 12 or the insert mold assembly 168 keep in touch. When the mold assembly 200 is to be heated, typically during the initial introduction of molding material 122 in the mold assembly 200 , opens a valve station 204 valves 206 on the warm side, which is a transfer of the heating fluid 152 from a reservoir 208 for heated fluid to the mold assembly 200 enable. At the same time valves are 210 on the cold side, which is the transfer of the cooling fluid 154 from a reservoir 212 for cooled fluid to the mold assembly 200 control, closed, leaving the cooling fluid 154 the mold arrangement 200 can not reach. After the mold assembly 200 has reached the desired temperature for the desired length of time, the heating fluid 152 then to the reservoir 208 returned for heated fluid and the valves 206 the warm side, the fluid transfer of the heating fluid 152 to the mold arrangement 200 allow to be closed. At the same time, as in 25 shown are the valves 210 the cold side, between the reservoir 212 for cooled fluid and the mold assembly 200 have been closed, open, leaving the cooling fluid 154 to the mold arrangement 200 can flow, and consequently the molding material 122 is cooled and the cured molding 140 is trained.

26 represents an embodiment of a heating system 300 for use in the mold assembly 200 as described above. The heating system 300 includes a Heizfluidleitung 302 holding a mudflap 304 which removes any dirt or debris that is in the heating fluid 152 can be located. The heating fluid 152 then flows through a degassing tank 306 , The degassing tank 306 removes unwanted gases and other impurities from the heating fluid 152 before passing through a pump 308 to a heater 310 is moved. The heating fluid 152 is generally cooler than desired because the heating fluid 152 from the mold assembly 200 returns where heat transfer has occurred. Consequently, it is desirable to use the heating fluid 152 in the heater 310 heat. The heater 310 increases the temperature of the heating fluid 152 to a desired temperature before the heating fluid 152 through a heat exchanger 312 is directed, regulating the heat of the heating fluid 152 supported. The heat exchanger 312 is with a cooling water outlet 314 and a cooling water supply 316 coupled, which prevents the heat exchanger 312 reached too high a temperature. The heating fluid 152 then flows through first and second temperature sensors 317 . 318 indicating the temperature of the heating fluid 152 confirm before the heating fluid 152 through a flow meter 320 flows, which is a volume flow rate of the heating fluid 152 that to the mold arrangement 200 flows, provides.

Regarding 27 is a cooling system 400 shown, for connection to the mold assembly 200 is designed. The cooling fluid 154 flows through a strainer 402 and in a cooling tank 404 where the cooling fluid 154 cooled to a desired temperature. The cooling fluid 154 is generally warmer than desired because the cooling fluid 154 from the mold assembly 200 returns where heat from the mold assembly 200 and the molding 140 on the cooling fluid 154 was transferred. Consequently, it is desirable to have the cooling fluid 154 in the cooling tank 404 cool. A temperature sensor 406 monitors the temperature in the cooling tank 404 , The cooling tank 404 is through a dipping evaporator 408 Chilled in the cooling tank 404 is arranged. The immersion evaporator 408 is coupled with a coolant attached to a compressor 410 flows past, that between a high and low pressure protection 412 . 414 is arranged. After passing the compressor 410 the coolant is in a condenser 416 cooled. After leaving the condenser 416 the coolant flows through a collector 418 and a check valve 420 as well as a filter dryer 422 before looking at a sight glass 424 moved past, where the coolant can be checked for color, consistency, contamination, etc. The coolant then flows through an expansion valve 426 where the coolant cools quickly before entering the cooling tank 404 entry. When the coolant passes through the cooling tank 404 flows, the coolant cools the cooling tank 404 and the contents of the cooling tank 404 so that the cooling fluid 154 in the cooling tank 404 is cooled to a desired temperature. the temperature of the cooling fluid 154 is through the temperature sensor 406 supervised. The cooling fluid 154 then gets out of the cooling tank 404 taken from a pump and the mold assembly 200 and in particular to the compliant conduits 22 in the mold arrangement 200 crowded.

Even though 26 and 27 Illustrative embodiments of heating and cooling systems that may be used in conjunction with a mold are contemplated using other heating and cooling systems in conjunction with the mold, and particularly the mold, insert molds, and base molds as disclosed above can be.

Regarding 28 Another embodiment of the present invention is shown wherein a sand mold package 530 an upper mold or a mold top 532 , a lower mold or a mold base 534 and a core 522 includes. The sand mold package 530 is made entirely from mold and core components that are printed by a sand printer and then removed from the work box. The sand mold package 530 , as shown, is prepared for casting a molten material in a similar manner as described above.

Regarding 29 and 30 is the core 522 in a cavity 539 shown inserted on an upper surface of the mold base 534 is arranged, wherein the cavity 539 forms a cavity formed by the union of the mold shell 532 with a cavity 537 and the mold part 534 is defined. As in 30 shown, the sand mold package 530 complete with the mold top 532 and the mold bottom 534 put together, which are stacked on each other. As in 28 Shown is a mold cavity through the union of the cavities 537 . 539 generated, each in both the Formoberteil 532 as well as in the mold base 534 are arranged. As in 28 - 30 shown are openings 536 and 538 on the upper surface of the mold top 532 shown arranged. The opening 536 provides an access point for pouring a molten material into the sand mold package 530 as in 30 together. The access point 536 also connects to a series of sprue channels 541 , as in 28 shown, which allows the molten material from the top mold 532 to the mold base 534 through the access point 536 flows. In this way fill the sprue channels 541 the cavity formed by the union of the cavities 539 . 537 of the mold shell 532 or of the lower part of the mold 534 is generated, from bottom to top. As the molten material fills the mold cavity, excess molten material begins to rise 538 to fill that on an upper surface of the mold shell 532 are arranged. The risers 538 help the foundry worker know if the mold cavity of the sand mold package 530 and also allows molten material to be available to fill any areas of the mold cavity as the molten material settles.

Once the molten material inside the sand mold package 530 has solidified, the sand mold package 530 broken away, as in 31 shown to a casting 540 expose. As in 32 shown is the casting 540 Shown with casting material that is used to access point 536 , the sprue system 541 and the risers 538 the sand mold package 530 , in the 28 - 30 shown is to fill that at a molding tool 542 hardened and solidified. This as 536A . 538A and 541A specified casting configurations are from the mold 542 machined away or otherwise removed to expose a tool ready for use in a molding process.

The mold core package and the components contained therein as well as the methods for Preparation of mold core package tools, as disclosed herein, provides an improved ability to uniformly cool all areas of a mold, thereby reducing the potential for distortion, tears, and the like. In addition, the accuracy associated with manufacturing the dies from the printing process provides better part quality, accuracy, and design flexibility. The conformal leads allow for improved thermal capabilities. Multiple heating and cooling lines are eliminated in favor of integrated compliant heating and cooling lines, which can be configured to meet the desired thermal load required to improve tool quality, as well as tool and part quality. Further, the mold core package components and the tools consisting of the mold core package components may be configured to improve cycle time, thereby increasing part manufacturing capacity. Class A surfaces which provide a smooth, glossy surface finish (ie, piano black) can be developed without the need for additional paint or glaze on the finished parts. Further, etched pattern Class A surfaces may be developed by etching a pattern on a mold surface of a mold, resulting in a finished part having a pattern embossed thereon.

It will be understood by one of ordinary skill in the art that the construction of the described invention and other components is not limited to any specific material. Other exemplary embodiments of the invention disclosed herein may be formed from a wide variety of materials, unless otherwise described.

For the purposes of this disclosure, the term "coupled" (in all its forms, coupling, coupling, coupled, etc.) generally means the direct or indirect connection of two components (electrical or mechanical) to each other. Such a connection may be stationary or moving. Such a connection can be achieved with the two components (electrical or mechanical) and any additional intermediate elements integrally formed as a single unitary body with each other or with the two components. Such a compound may be permanent in nature or may be removable or detachable unless otherwise specified.

It is also important to note that the construction and arrangement of the elements of the invention, as shown in the exemplary embodiments, are only illustrative. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art, who are reviewing this disclosure, will readily recognize that many modifications are possible (eg, changes in sizes, dimensions, structures, shapes, and the like) Ratios of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.), without departing substantially from the novel teachings and advantages of the recited subject matter. For example, elements shown to be integral may be constructed of multiple parts, or elements shown as multiple parts may be formed integrally, the functionality of the interfaces may be reversed or otherwise altered, the length or width of the structures and / or elements or the connection element or other elements of the system can be changed, the type or number of adjustment positions provided between the elements can be changed. It should be noted that the elements and / or arrangements of the system of any of a wide variety of materials that provide sufficient strength or durability can be constructed in any of a wide variety of colors, textures, and combinations. Consequently, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made to the design, operating conditions, and arrangement of the desired embodiments and other exemplary embodiments without departing from the spirit of the present innovations.

Of course, any described processes or steps within the described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for purposes of illustration and are not to be construed as limiting.

Of course, changes and modifications may also be made to the structures and methods mentioned above without departing from the concepts of the present invention and, of course, such concepts are, of course, to be covered by the following claims, unless expressly stated otherwise by their language.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• WO 2010/144786 [0066]

Claims (20)

A mold assembly for the production of molded parts, comprising: a mold having conformal fluid conduits that follow contours of a mold surface of the mold, wherein the conformal fluid conduits in the mold are defined during casting by sacrificial displacement conduits formed by a three-dimensional printer; a temperature control station coupled to the mold and having a heating and cooling fluid; and a valve station for controlling fluid flow to the mold. A mold assembly according to claim 1, wherein the fluid used for heating is the same as the fluid used for cooling. The mold assembly of claim 1, wherein the conformal fluid conduits include walls having ribs impacting the fluid flow. The mold assembly of claim 1, wherein the mold comprises a conformal reservoir having a cross-sectional area other than a cross-sectional area of the conformal fluid conduits, the conformal reservoir closely following the contours of the mold surface. Mold assembly according to claim 1, wherein the temperature control station comprises a cooling arrangement with an evaporator, which is immersed in a fluid-collecting tank that holds cooling fluid. Mold assembly according to claim 1, wherein the temperature control station comprises a closed fluid circuit which is connected to both a heating arrangement and a cooling arrangement, and wherein the heating arrangement and the cooling arrangement thermally adjust the fluid. A mold assembly for the production of molded parts, comprising: a mold having a conformal fluid conduit and a conforming reservoir near a mold surface of the mold, wherein the conformal fluid conduit and the compliant reservoir in the mold are defined during casting by sacrificial core portions formed by a three-dimensional sand pressure device; and a closed fluid circuit that couples the mold to a temperature control station. The mold assembly of claim 7, wherein the compliant fluid conduit includes walls having protrusions that affect the flow of fluid through the compliant fluid conduit. The mold assembly of claim 7, further comprising: Flow influencing elements disposed in the compliant reservoir. Mold assembly according to claim 7, wherein the temperature control station comprises a heating arrangement with a heating element, which is coupled to a heat exchanger. The mold assembly of claim 7, wherein the temperature control station comprises a cooling arrangement having an evaporator submerged in a fluid collection tank holding cooling fluid. Mold assembly according to claim 7, wherein the temperature control station comprises a closed fluid circuit which is connected to both a heating arrangement and a cooling arrangement, and wherein the heating arrangement and the cooling arrangement thermally adjust a heat-influencing fluid. The mold assembly of claim 11, wherein the conformal fluid conduit meanders such that the space between the conformal fluid conduit and a mold surface of the mold varies. A method of making a molded part comprising: Fabricating a sacrificial mandrel package having sacrificial displacement conduits developed by applying a binder to multiple layers of fine particles; Forming a mold with conformal leads from the sacrificial mandrel packing and the sacrificial displacement conduits; Coupling a fluid temperature control station to the compliant conduits in the mold; Heating a moldable material that is injected into a mold cavity of the mold; and cooling the moldable material in the mold cavity. The method of claim 14, further comprising: Forming the conformal leads so as to substantially uniformly follow contours of a forming surface of the forming tool. The method of claim 14, further comprising: Use a fine sand as fine particles. The method of claim 14, further comprising: Forming an injection port in the mold which introduces the moldable material into the mold cavity. The method of claim 14, wherein the step of heating a moldable material further comprises: rapidly heating the mold by passing the single fluid through the conformal lines of the mold, wherein the single fluid is in a heated state. The method of claim 14, wherein the step of cooling the moldable material further comprises: rapidly cooling the mold by passing the single fluid through the conformal lines of the mold, wherein the single fluid is in a cooled state. The method of claim 14, wherein the step of forming a conformal line tool further comprises: Burning the binder so that the binder is removed from the sacrificial mold core and the sacrificial displacement lines.

Images