Patent Application
20190358702
There are three prior systems still in use:
1, Machine a negative (mold) from a solid metal block, with help of digital controlled machines.
2, Create a mold by melting metal and spraying it on the part intended to be copied.
3, Same intend as #2 but using Thermal Metal-spray Systems.
1, Machine a Negative from a Solid Metal Block.
Making a plastic-injection-molds requests highly skilled operators, precision milling machines, a big number of milling cutters, designers, special tool steel, adding up to high costs. The latest technology is to use computer controlled milling machines (CNC) which requests engineers to program these machines which sometimes take longer than the milling itself. Creating special surface structures needs special computer programs and still dependent on the tools intended to create the cavities.
2, Create a Mold by Melting Metal and Spraying it on the Part Intended to be Copied. This is the First Attempt to Get Away from Machining.
Carrying a container with molten liquid metal and use it as a spray-gun describes the main problem with this solution producing a long list of serious accident statistics. The environmental impacts and health hazards using this apparatus are just slightly less than those what its successor creates.
No doubt this method is the most complicated and most dangerous system. The smallest problem is its weight starting at 500 lbs. Than follows the high electric consumption needed for resistance melt and evaporate wires continuously. All this must happen in a spray-booth costing more than the spray-equipment itself and finally the necessity to wear a pressurized “space-suit” blowing filtered air inside to prevent metal dust reaching the operator. Forgetting to wear this suit causes death.
The current method was created to eliminate the enormous negative impact of the previous systems on human health and the environment. Not less important was the social economic impact of the new system on the merging markets (development countries) enabling groups to accomplish work and produce products only the “Western-World” was previously capable to produce. The factors paralizing this part of the world namely: *no infra structure, *no power stations, *no experts, *no machinery, *low income, *no raw-materials—was eliminated with a simple process>>which puts factories where the waste-materials is generated, household power is sufficient now to create precision molds and run compression presses, the system isn't digital, 90% of the convential wood-working machinery is eliminated, copying products in fractions of time needed before generating staggering profits now, using mainly agricultural remnants turning into hardwood quality products. Result: the poorest start exporting to the richest. And the richest isn't ignoring this system either.
Is to create a multi-structural metal mold composite with permanent release ability, supreme heat conducting, adjustable flexibility and machanical factors, resulting in carbon-steel similar properties. To find a common binder and way to bond metallic, ceramic and inorganic particles together with supreme results. During the creation steps of this metal composite the particles must be sprayable in liquid form, than turn into solids, creating special cavities for bonding grip within and to the next backing layer, fullfilling the main purpose of all these steps, namelich to copy the finest details of the pattern surface. All these without creating emissions, using minimum energy and occupying semi skilled operators.
The operator starts always with the product to be copied or duplicated. It can be anything: hardwood, plaster, metal, etc. The mold surface zinc content a natural permanent parting agent secures a self-parting layer to the model but uninterrupted production later as well. If the model to be copied is weak or porous no damage is done to it, this metalspraying is a very gentle process. The sprayed skin will reproduce the finest scratches like wood-grain, or imperfections, etc. impossible to create with the best CNC programs. Pressing up the flat backing later on to the sprayed skin even so this spray-metal reproduced the smallest cavities of the original pattern the backing-mix-binder (which has multi purpose) cannot bond to the original and acts now like a shield distributing surface pressure and preventing damage to the finest details created before. (see Chemical Function)
Depending on the preferred application for which the mold is used is the metal component chosen. For self-releasing molds (resin bonded composites) the metal component is zinc-oxide. For other applications most metal powders function without changing the formulas.
The liquid metal alloy: the formula is volumetric—45% metal powder (preferably 5 micron) mixed before application with 55% ethyl silicate. Preferred spray-temperature 60-70 degree F. After spraying in 1/16 ″thickness the skin sets in 25 minutes. The air-drying is important because the high fluid content (necessary for spay ability) has to evaporate to allow the components to react. This mixture in liquid form has 4 hours potlife. The set skin needs further processing which happens as the backing mold mix is pressed on. This is the most important part of the invention and is explained in the next chapter: chemical function
The sprayed skin after setting is on the quality level of a paint—not suitable as a abrasion resistant mold surface! At this point abrasion resistance is secondary. Primary is to follow the model shape in the greatest accuracy, creating a cold setting water-based metal skin without the disadvantages and dangers of spraying melted metals. As the sprayed skin dries the liquid components have to evaporate. This is possible only in one direction to the open back-side. As moisture leaves micro cavities are created to the back of this skin. The front, touching the pattern because no solvent passing through stays undamaged and reproducing the surface perfect. The set skin is already hard enough to protect the pattern surface from unwanted damages during the next steps (pressing on the flat back) these steps are changing the mechanical properties of the mold-composite to carbon steel quality. Pressing on the backing: the backing mix is again volumetric, 70%—20-30 mesh aluminum powder mixed with 30% phenol powder. A collapsible (foam) frame is positioned around the liquid-metal sprayed dry model which is filled with the backing mix. At this time if required reinforcement (wire-mesh) is positioned in the powder mix. This mixture under heat and pressure collapsing up to 30%. The main act to create a 3 dimensional metal composite mold follows. The platten-press used must be able to produce 200 PSI pressure and be heatable up to 200 degree Centigrade. Establish the final thickness of the mold and place metal stops around to calibrate this—close the press slowly. Temperature setting: 130 to 170 degree Centigrade of the top pressplate—bottom pressplate cold, pressure up to 500 PSI depending on model material. A hard-wood model takes 300 PSI. As temperature reaches 120 C.—phenol diffusing into the empty micro-cavities left from the evaporating liquid metal but stops at the glass-hard pattern surface and cannot enter the porous model—making parting model and the ready mold later easy. As top pressplate hits the stops—the precision metal mold is ready. The paint-quality metal front-skin is changed to carbon steel quality as the metalpowder plus silicates unite with phenol diffusion. Settings at 130 C heat and 250 PSI pressure (with slower closing) producing perfect molds. Adjusting mold quality: If patterns are more solid like metal, pressure can go to full 500 PSI and temperatures to 170 C resulting in 400% plus in mechanical properties which is desired if making molds over 20 sq.ft.
Changing the solid mold components to other metal oxides or certain ceramics is possible solong the ethyl-silicat fluid kept which makes the mix sprayable and provides after drying the glass hard mold surface. (explained in the Chemical Function section.)
Changing the backing mix: Any reason to replace the phenolic powder to a liquid, heat resistant resin: catalised phenolics, catalised silicon resins and phenol novolac resins were successful tested. The advantages of a clean simple process was lost with those changes.
This application claims priority in accordance with 37 CF.R. ¶ 1.19(e) to U.S. Provisional Patent Application Ser. No. 62/595,655 filed for INTEGRATED COMPOSIT FORMING SYSTEM Dec. 7, 2017 which is included herein in its entirety by reference.
