Interchangeable mold inserts
AssigneeFord Motor Company
InventorsCharles Alan Rocco, Raymond Edward Kalisz, Jeffery N. Conley, Bernie Gerard Marchetti
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Abstract
A mold core package for forming a molding tool with a removable insert includes a plurality of stacked particulate layers having a binding agent. The plurality of stacked particulate layers form molding pattern walls that generally define a base mold cavity and an insert mold cavity defining a mold surface. A sacrificial displacement line extends through the insert mold cavity closely following contours of the mold surface.
Claims19
A mold core package for forming a molding tool with a removable insert, comprising:
- a plurality of stacked particulate layers including a binding agent, wherein the plurality of stacked particulate layers form molding pattern walls that generally define:
- a base mold cavity;
- and
- an insert mold cavity defining a mold surface;
- and
- a sacrificial displacement line extending through the insert mold cavity closely following contours of the mold surface.
A mold core for forming a removable insert mold for use in a base mold, comprising:
- a plurality of stacked particulate layers formed of a fine sand and a binding agent deposited in coats from a sandprinting device, the plurality of stacked particulate layers forming sacrificial mold core walls defining an insert mold cavity;
- a sacrificial displacement line extending from the mold core walls proximate a molding surface;
- and
- a core support that spaces the sacrificial displacement line from the mold core walls.
A method for molding a part, comprising:
- forming a base mold with relay lines by making a sacrificial mold core developed by printing a binding agent on multiple layers of fine particulate;
- forming an insert mold with conformal lines by making a sacrificial mold core developed by printing a binding agent on multiple layers of fine particulate, the insert mold defining a mold cavity;
- positioning the insert mold in the base mold such that the relay lines are in fluid communication with the conformal lines;
- coupling a temperature control station with the base mold that communicates a fluid through the relay lines and conformal lines;
- heating a moldable material injected into a mold cavity of the molding tool;
- and
- cooling the moldable material in the mold cavity.
Dependencies are inferred from the claim text.