Process for casting a plastic die

Details Process for casting a plastic die Process for casting a plastic die

1999-06-25

2001-06-19

Kuhns, Allan R. (Department: 1732)

Metal working

Method of mechanical manufacture

Combined manufacture including applying or shaping of fluent...

C249S142000, C249S176000, C264S219000, C264S299000

Reexamination Certificate

active

06247222

ABSTRACT:

FIELD OF THE INVENTION
The invention relates to an improved casting process to form a die having a multidirectional surface and in particular for a die for massive items such as aircraft wings. In particular, the invention provides a method of producing plastic dies for tooling suitable for use in forming sheet metal, aluminum or other metals, including a technique such as stretch forming, hydroforming, stamping etc.
BACKGROUND OF THE INVENTION
In the aeronautics industry, for example, the manufacturing of exterior surface portions of the wings and fuselage may included dimensional portions having lengths over 30 feet. As a result, the manufacturing process involves a number of expensive tooling operations. In addition, the massive dimensions needed in the preparation of a master die model for these exterior surface portions can be cumbersome and heavy. It is necessary therefore, that the master die model be easily movable or transportable to the manufacturing facility of the airplanes. It is also necessary to provide a master model die that is cost effective and eliminates some of the expensive tooling operations to produce the die. It is also necessary to produce a model die that is rigid yet relatively lightweight and easily transportable to the manufacturing point.
SUMMARY OF THE INVENTION
The improved process for making a plastic die according to the present invention includes constructing a wood lattice framework having a top surface in the desired contour shape. The lattice framework is built up on the sides of the wooden framework so that the contoured shape top surface forms the floor of the boxed-in model. The lateral rods function to secure wooden cores within the boxed-in model. A plurality of tapered wooden cores having arcuate corners are inserted into the wood model. The wooden cores may have different shapes and lengths to accommodate the various stress levels of the manufactured portion. Lateral rods are fed through apertures in the upper walls wooden cores to hold the wooden cores at predetermined levels above the contour floor. The cavity within the boxed-in model surrounding the wooden cores is filled with a resin material or other appropriate hardenable material. The exterior of the wood cores may be previously coated before insertion into the boxed-in model with a wax-type material so that the cores do not adhere to the resin and may be easily removed from the boxed-in model once the resin has solidified. A honeycombed surface is then provided by the removal of the cores after the resin has solidified, and the honeycomb surface forms a bottom surface for the die. The sides and the lattice framework can then be removed from the die so that the desired contour surface is exposed. The contour surface is finally machined to finish the contour to the precise die form.
It is the intent of this invention to provide an improved method of casting a plastic die for large structures such as those required in the aeronautics industry.
It is another object of this invention to provide a cost effective method of casting a plastic die for such structures.
It is further an object of this invention to provide a method of casting a plastic die that provides a relatively lightweight, yet strong die.
It is also an object of this invention to further improve the process and the resultant die as disclosed in U.S. Pat. No. 5,802,696 issued to the applicant by strengthening the overall finished die.
Other objects, advantages and applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings.


REFERENCES:
patent: 1642980 (1927-09-01), Turner
patent: 2310830 (1943-02-01), Blair et al.
patent: 2447620 (1948-08-01), Singleton et al.
patent: 2565134 (1951-08-01), Kish
patent: 2632922 (1953-03-01), Kish
patent: 2705375 (1955-04-01), Foreman et al.
patent: 2715280 (1955-08-01), Kish
patent: 2750632 (1956-06-01), Kish
patent: 2776453 (1957-01-01), Kish
patent: 4427619 (1984-01-01), Peterson
patent: 4998706 (1991-03-01), Hyll
patent: 5009826 (1991-04-01), Walker
patent: 5385700 (1995-01-01), Denton
patent: 5529733 (1996-06-01), Lee
patent: 5558883 (1996-09-01), Shinada et al.
patent: 5608961 (1997-03-01), Piegeler
patent: 5802676 (1998-09-01), Zuccarini

Affiliated with

Also associated with

Rating

Process for casting a plastic die does not yet have a rating. At this time, there are no reviews or comments for this patent.

If you have personal experience with Process for casting a plastic die, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Process for casting a plastic die will most certainly appreciate the feedback.

Rate now

Comments { 0 }

Profile ID: LFUS-PAI-O-2524435