Low melting temperature metal fill for additively manufactured tools

Patent metadata

Field	Value
Publication number	US-11813656-B2
Application number	US-202016905140-A
Country	US
Kind code	B2
Filing date	Jun 18, 2020
Priority date	Sep 25, 2019
Publication date	Nov 14, 2023
Grant date	Nov 14, 2023

Abstract

A forming tool including an additive manufactured polymer shell defining a first side and an opposite second side. The forming tool includes a support structure mechanically connected to the second side of the shell. The support structure may be formed by pouring a molten backfill material into the shell, and solidifying the backfill material. The backfill material includes a low melting temperature metal, fusible alloy, or other element. The solidified backfill material has a strength and rigidity greater than the polymer used to make the shell. The first surface of the shell includes a complex surface for bringing into contact with a material in a stamping process to form a stamped part.

First claim

The invention claimed is:

1. A stamping tool configured to be connected to a press, and pressed by the press against a material to thereby form a stamped component from the material, the stamping tool comprising: an additive manufactured polymer shell defining a first side and a second side opposite from the first side, the first side including a contoured surface configured to produce a stamped surface in the material when pressed by the press against the material; and a solid phase backfill material arranged at the second side of the polymer shell
wherein: the polymer shell includes an integrally formed structure at the second side of the polymer shell; the solid phase backfill material has a strength and a rigidity greater than the polymer shell; the solid phase backfill material contacts the structure to thereby mechanically connect the solid phase backfill material to the second side of the polymer shell;
wherein: the structure includes a plurality of walls each including a plurality of apertures; and the solid phase backfill material is arranged at two sides of each wall and is continuous through the plurality of apertures to thereby mechanically connect the solid phase backfill material to the second side of the polymer shell.

2. The stamping tool according to claim 1 , wherein:
the structure includes a plurality of undercut depressions; and
the solid phase backfill material is arranged in the plurality of undercut depressions to thereby mechanically connect the solid phase backfill material to the second side of the polymer shell.

3. The stamping tool according to claim 1 , wherein:
the structure includes a plurality of tapered projections extending from the second side of the polymer shell into the solid phase backfill material, each of the projections having a tip and a base, the base being closer to the second side of the polymer shell than the tip;
each projection tapers down a) toward the tip or b) toward the base;
if a) the projection tapers down toward the tip, then the tapered projection is arranged on a side wall of the polymer shell and the solid phase backfill material is arranged around the tapered projection to thereby mechanically connect the solid phase backfill material to the second side of the polymer shell;
if b) the projection tapers down toward the base, then the solid phase backfill material is arranged around the tapered projection to thereby mechanically connect the solid phase backfill material to the second side of the polymer shell.

4. The stamping tool according to claim 1 , wherein:
the tool further comprises a piece of filler material arranged in the solid phase backfill material;
the filler material has a melting point, a thermal conductivity, a modulus of elasticity, and a strength greater than that of a polymer of the polymer shell; and
the melting point of the filler material is greater than that of the solid phase backfill material.

5. The stamping tool according to claim 4 , wherein the piece of filler material is arranged at a predetermined location with respect to the polymer shell, and the predetermined location is determined by the plurality of walls.

6. The stamping tool according to claim 4 , wherein the piece of filler material includes a recess, and the recess is filled with the solid phase backfill material to thereby mechanically connect the piece of filler material to the solid phase backfill material.

7. The stamping tool according to claim 1 , further including an adapter arranged on a side of the stamping tool opposite from the polymer shell, wherein the adapter is configured to connect the stamping tool to the press.

8. The stamping tool according to claim 7 , wherein the adapter is larger in height than a combined height of the polymer shell and the solid phase backfill material.

9. The stamping tool according to claim 7 , wherein:
the tool further comprises a piece of filler material arranged in the solid phase backfill material; and
the adapter is connected to the tool via connectors attached to the piece of filler material.

10. The stamping tool according to claim 9 , wherein:
the piece of filler material includes a recess; and
the piece of filler material is mechanically connected to the solid phase backfill material by the solid phase backfill material filling the recess.

11. The stamping tool according to claim 9 , wherein the piece of filler material is arranged at a predetermined location with respect to the polymer shell by being arranged between two walls of the plurality of walls.

12. The stamping tool according to claim 5 , wherein the plurality of walls determine the predetermined location of the piece of filler material with respect to the polymer shell by spacing the piece of filler material from the polymer shell.

13. A press configured to produce a stamped surface in a material, the press including the stamping tool according to claim 1 , and an actuator connected to the stamping tool and configured to press the stamping tool against the material to produce the stamped surface in the material.

14. The press according to claim 13 , further including an adapter connecting the stamping tool to the actuator.

15. A method of stamping, comprising:
providing a press including the stamping tool according to claim 1 ; and
operating the press to press the stamping tool against a material to thereby stamp a surface of the material.

16. The method of claim 15 , wherein the stamping tool is a first stamping tool and the material is a first material, the method further comprising:
a) removing the first stamping tool from the press;
b) separating the solid phase backfill material from the polymer shell;
c) melting the solid phase backfill material to produce a molten backfill material;
d) arranging the molten backfill material at a second side of a second polymer shell;
e) solidifying the molted backfill material at the second side of the second polymer shell to form a second stamping tool;
f) attaching the second stamping tool to the press; and
g) operating the press to press the second stamping tool against a second material to thereby stamp a surface of the second material.

17. The method of claim 16 , wherein the first stamping tool includes a piece of filler material arranged in the solid phase backfill material, the method further comprising:
before step d), separating the piece of filler material from the solid phase backfill material; and
arranging the piece of filler material in the molten backfill material at the second side of the second polymer shell.

Assignees

• Honda Motor Co Ltd

Inventors

• Hahnlen Ryan M
• Hoffman Benjamin Adam

Classifications

• B21D37/20 Primary

  Making tools by operations not covered by a single other subclass · CPC title

• B33Y70/10

  Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B44B5/026 Primary

  Dies (B44B5/028 takes precedence) · CPC title

• B44B2700/12

  Accessories; Tool or work holders · CPC title