Method of making tools having a core die and a cavity die

Details Method of making tools having a core die and a cavity die Method of making tools having a core die and a cavity die

1998-11-04

2001-10-30

Lin, Kuang Y. (Department: 1722)

Metal founding

Process

Shaping a forming surface

C164S045000, C164S046000

Reexamination Certificate

active

06308765

ABSTRACT:

TECHNICAL FIELD
The present invention relates to the making of tools, and more particularly to a method of making stamping or molding tools having a smooth interface between two parts of the molding tool.
BACKGROUND ART
Tools, such as injection molding tools, typically comprise a core die and a cavity die. Each die has a die face having a parting surface and a mold cavity defining surface. The dies are capable of relative movement between a first position, wherein the parting surfaces abut each other to form an interface, and a second position, wherein the die faces are spaced from each other. The mold cavity defining surfaces, when the dies are in the first position, provide a mold cavity for forming an injection molded part. When the dies are in the second position, the relative positioning of the dies allows for removal of the formed part.
The dies are typically metal deposits manufactured by spray forming. Each metal deposit is formed independent of each other by spray depositing metal on a respective spray forming pattern. After removal from the spray forming pattern, the parting surface of each deposit undergoes “spotting” to form perfectly matched parting surfaces to achieve a smooth, acceptable interface. Spotting is a relatively tedious and time consuming process that involves grinding and machining operations to remove high contact spots from the parting surfaces. As such, spotting accounts for a relatively large portion of the time and monetary expenditure in making tools.
Accordingly, it is an object of the present invention to provide a less time consuming and more economical method for making tools. It is another object of the present invention to provide a method of making metal deposits for tools without having to spot each of the deposits.
DISCLOSURE OF INVENTION
The present invention meets the above, and other, objects by providing a method of making a molding tool comprising a core die and a cavity die. The method comprises (a) providing a first metal deposit comprising one of the cavity die or the core die, the first metal deposit having a die face, (b) providing a spray forming pattern on a portion of the die face of the first metal deposit, (c) spraying metal particles onto the first metal deposit and the spray forming pattern to form a second metal deposit comprising the other of the cavity die or the core die, and (d) removing the spray forming pattern from the first and second deposit.


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