Mold useful for injection molding of plastics, and methods of pr

Powder metallurgy processes – Powder metallurgy processes with heating or sintering – Making porous product

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419 19, 419 27, 419 37, 419 45, 419 54, 419 57, 264219, B22F 100

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active

056781628

ABSTRACT:
A mold useful for injection molding, comprising: a porous network of metal and oxidized metal and a cured epoxy resin dispersed in the porous network. The mold can be prepared by a process comprising the sequential steps of (a) forming a mixture of a metal powder and a polymer binder; (b) heating the mixture at a temperature in the range from about 100.degree. C. to about 300.degree. C. to remove a majority of the polymer binder from the mixture; (c) heating the mixture resulting from step (b) at a temperature greater than about 300.degree. C. and less than the melting point of the metal in the presence of oxygen to oxidize at least a portion of the metal to form a self-adhering porous network of metal and oxidized metal; (d) contacting the self-adhering porous network with an epoxy resin to fill at least a portion of the porous network with epoxy resin; and (e) curing the body resulting from step (d) to form the mold. The shape of the mold can be performed by selective laser sintering of the mixture.

REFERENCES:
patent: 3755213 (1973-08-01), Kendall et al.
patent: 4464485 (1984-08-01), Kishima et al.
patent: 5021213 (1991-06-01), Nishio et al.
patent: 5061427 (1991-10-01), Hirzel
patent: 5284695 (1994-02-01), Barlow et al.
Tobin et al., "Indirect Metal Composite Part Manufacture Using teh SLS Process", Solid Freeform Fabrication Symposium Processings, The University of Texas, Austin, Texaz, pp. 303-307 1993.
Badrinarayan et al., "Selecrive Layer Sintering of a Copper-PMMA System", Solid Freedom Fabrication Symposium Proceedings, pp. 141-146 1992.

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