Low-Cost Tooling and Method for Manufacturing the Same

Patent metadata

Field	Value
Publication number	US-2017320241-A1
Application number	US-201715662661-A
Country	US
Kind code	A1
Filing date	Jul 28, 2017
Priority date	Apr 2, 2015
Publication date	Nov 9, 2017
Grant date	—

Abstract

A tool including a tool body, the tool body including a substrate having a tool-side surface, an intermediate layer positioned over the tool-side surface, and an outer layer positioned over the intermediate layer, the outer layer including a metallic material.

First claim

What is claimed is:

1 . A method for manufacturing a tool comprising:
machining a substrate to a desired shape; applying an intermediate layer to said machined substrate, said intermediate layer having an inner surface facing said machined substrate and an outer surface facing away from said machined substrate, wherein said intermediate layer comprises an electrically conductive filler incorporated therein; and applying an outer layer over said intermediate layer, said outer layer comprising a metallic material.

2 . The method of claim 1 wherein said substrate comprises a non-solid-metal material.

3 . The method of claim 1 wherein said substrate is a machinable foam.

4 . The method of claim 1 wherein said substrate comprises at least one of a carbon foam, a polymeric foam, a silicone foam and a metallic foam.

5 . The method of claim 1 wherein said substrate comprises graphite foam.

6 . The method of claim 1 wherein said intermediate layer comprises a low-modulus material.

7 . The method of claim 1 wherein said intermediate layer comprises silicone.

8 . The method of claim 1 wherein said intermediate layer has a cross-sectional thickness ranging from about 1 mil to about 100 mil.

9 . The method of claim 1 wherein said intermediate layer has a cross-sectional thickness ranging from about 1 mil to about 10 mil.

10 . The method of claim 1 wherein said metallic material comprises steel.

11 . The method of claim 1 wherein said metallic material comprises at least one member selected from the group consisting of silver (Ag), aluminum (Al), gold (Au), beryllium (Be), cobalt (Co), chromium (Cr), copper (Cu), iron (Fe), mercury (Hg), indium (In), magnesium (Mg), manganese (Mn), molybdenum (Mo), niobium (Nb), neodymium (Nd), nickel (Ni), phosphorus (P), palladium (Pd), platinum (Pt), rhenium (Re), rhodium (Rh), antimony (Sb), tin (Sn), lead (Pb), tantalum (Ta), titanium (Ti), tungsten (W), vanadium (V), zinc (Zn) and zirconium (Zr).

12 . The method of claim 1 wherein said metallic material comprises at least two members selected from the group consisting of silver (Ag), aluminum (Al), gold (Au), beryllium (Be), cobalt (Co), chromium (Cr), copper (Cu), iron (Fe), mercury (Hg), indium (In), magnesium (Mg), manganese (Mn), molybdenum (Mo), niobium (Nb), neodymium (Nd), nickel (Ni), phosphorus (P), palladium (Pd), platinum (Pt), rhenium (Re), rhodium (Rh), antimony (Sb), tin (Sn), lead (Pb), tantalum (Ta), titanium (Ti), tungsten (W), vanadium (V), zinc (Zn) and zirconium (Zr).

13 . The method of claim 1 wherein said outer layer has a cross-sectional thickness of at most about 100 mil.

14 . The method of claim 1 wherein said outer layer has a cross-sectional thickness of at most about 50 mil.

15 . The method of claim 1 further comprising positioning a heating layer between said substrate and said outer layer.

16 . The method of claim 15 wherein said heating layer comprises a wire mesh.

17 . The method of claim 16 wherein said positioning said heating layer comprises incorporating said heating layer into said intermediate layer.

18 . The method of claim 1 wherein said electrically conductive filler is uniformly dispersed throughout said intermediate layer.

19 . The method of claim 1 wherein said electrically conductive filler is concentrated proximate said outer surface of said intermediate layer.

20 . The method of claim 1 wherein said applying said outer layer comprises electrodeposition.

Assignees

• Boeing Co

Inventors

• Tsotsis Thomas K

Classifications

• B29C33/3828

  Moulds made of at least two different materials having different thermal conductivities · CPC title

• B29C33/405

  Elastomers, e.g. rubber (B29C33/50 takes precedence) · CPC title

• B29C33/02

  with incorporated heating or cooling means · CPC title

• B29C33/40 Primary

  Plastics, e.g. foam or rubber · CPC title

• B29K2883/00

  Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as mould material · CPC title