Claims
- 1. A method for manufacturing a mold component having a conformal thermal management system, comprising:
forming a first mold segment and a second mold segment, each comprising a first surface having a profile defined by said first surface; disposing a channel pattern in at least one of said first mold segment and second mold segment, said channel pattern being disposed beneath said surface defined by said profile; aligning said first mold segment and said second mold segment; and joining said first surfaces of said first mold segment and said second mold segment together to form said mold component.
- 2. The method recited in claim 1, wherein said disposing said channel patterns further comprises disposing a channel pattern substantially conforming to said profile.
- 3. The method recited in claim 1, wherein said forming first mold segment and said second mold segment further comprises a method selected from the group consisting of casting, additive process, and combinations comprising at least one of the foregoing methods.
- 4. The method recited in claim 1, wherein said disposing said channel pattern further comprises a method selected from the group consisting of machining, casting, and combinations comprising at least one of the foregoing methods.
- 5. The method recited in claim 1, further comprises accessing said channel patterns by drilling from a second surface of at least one of said first mold segment and said second mold segment to said channel pattern.
- 6. The method recited in claim 1, further comprising disposing a tube within said channel pattern.
- 7. The method recited in claim 1, further comprising pressing said first mold segment and said second mold segment together in a hot isostatic pressing process.
- 8. A mold component having a conformal thermal management system made according to the method recited in claim 1.
- 9. A method for manufacturing a mold component having a conformal thermal management system, comprising:
depositing a first layer of metal on a first pattern comprising a first surface having a profile, placing a tube on said pattern in said first layer of metal; depositing a second layer of metal over said pattern and said tube to encapsulate said tube between said first layer of metal and said second layer of metal to form a first mold segment; joining said first mold segment and a second mold segment to form said mold component.
- 10. The method recited in claim 9, wherein said depositing further comprises utilizing a method selected from the group consisting of metal plating techniques, spray metallizing, and combinations comprising at least one of the foregoing methods.
- 11. A method for manufacturing a mold component having a conformal thermal management system, comprising:
forming a first mold segment comprising a first surface having a profile comprising a detail of an article and a second surface comprising a mold cavity having a negative detail of said profile; a channel pattern in said second surface; disposing a tube within said channel pattern; sealing said first mold segment to form said mold component; and accessing said tube.
- 12. The method recited in claim 11, further comprising:
casting a first metal into said mold cavity and onto said tube to encapsulate said tube, wherein said first mold segment and said tube comprise a second metal, wherein at least a portion of said first metal is said second metal; and pressing said first mold segment, said first metal, and said tube together in a hot isostatic pressing process to eliminate an air gap.
- 13. The method recited in claim 11, further comprising:
filling said mold cavity with said first metal to substantially cover said tube, wherein said first mold segment and said tube comprise a second metal, wherein at least a portion of said first metal is said second metal; placing a cover over said mold cavity to contain said first metal; and pressing said cover, said first mold segment, said first metal and said tube together in a hot isostatic pressing process to eliminate an air gap.
- 14. A method for manufacturing a mold component having a conformal thermal management system, comprising:
casting a first mold segment and a second mold segment, each comprising a first surface having a profile; placing a tube in said first surface of at least one of said first mold segment and said second mold segment; and joining said first mold segment and second mold segment together with said tube disposed therebetween to form said mold component.
- 15. The method recited in claim 14, wherein said tube is configured over its length to substantially conform to a contour of said profile.
- 16. The method recited in claim 14, wherein said tube is encapsulated in said mold segment.
- 17. A mold component made according to the method recited in claim 14.
- 18. A mold component having a conformal thermal management system, comprising:
a first mold segment and a second mold segment disposed in operable communication with each other, wherein each mold segment further comprises a first surface having a profile; and a network of channels disposed between said first mold segment and said second mold segment.
- 19. The mold component recited in claim 18, wherein said network of channels are formed by a tube.
- 20. The mold component recited in claim 18, wherein said channels are disposed along the contours of features of said profile at a distance from said first surface of less than or equal to about one inch.
- 21. The mold component recited in claim 18, wherein said mold segments further comprise a material selected from the group consisting of aluminum, copper, beryllium-copper alloy, and combinations comprising at least one of the foregoing materials.
- 22. The mold component recited in claim 18, wherein said network of channels substantially conform to said profile.
- 23. A method for molding an article, comprising:
introducing a molten molding material to a mold cavity comprising a mold component comprising a network of channels that conform to a profile; passing a fluid through said network of channels; cooling said molding material to below a softening point temperature of said molding material to form said article; and removing said article from said mold.
- 24. A molded article produced according to the method recited in claim 23.
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application Serial No. 60/302,320 filed Jun. 29, 2001, the entire content of which is incorporated herein by reference.
Provisional Applications (1)
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Number |
Date |
Country |
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60302320 |
Jun 2001 |
US |