Light-weight mold making material and process of manufacture of the same

Abstract

The invention describes making core structures for tooling panels air permeable and resistant to higher temperatures. Core structures may be a non-woven made from fibers that may be treated with an adhesion promoter. The fiber is then treated with an outer-coating. Proper choice of outer coating allows the tooling panel to function at higher temperatures. The non-woven core may be constructed in various dimensions. Air permeability allows tooling panels to show superior response to changing temperatures. The non-woven may be bonded with another to form a larger tooling panel. The outer surface of the tooling panel may be coated with a material such as rigid foam that can be machined to a pattern placed in contact with material in manufacture a part. The permeable core structure can be made from permeated plastic, wood, metal, ceramic and the like.

What is claimed is: 
     
         1 . A product comprising:
 (a) a non-woven material containing fibers that have been coated with a resin; and   (b) a coating on an outer surface of the non-woven structure with a material that can be formed into desired contours.   
     
     
         2 . The material according to  claim 1 , wherein a segment of a non-woven material may be bonded to another segment of non-woven material to form a larger structure. 
     
     
         3 . The material according to  claim 1 , wherein the coating on fibers of the non-woven is a melamine resin. 
     
     
         4 . The material according to  claim 1 , wherein fibers are coated an adhesion prompter that is a styrene butadiene emulsion. 
     
     
         5 . The material according to  claim 1 , wherein the outer surface is coated with urethane foam capable of being machined into various configurations. 
     
     
         6 . The material according to  claim 1 , wherein the adhesive to bond non-woven segments is a two-part polyurea or a polyurethane or a combination of polyurea and polyurethane. 
     
     
         7 . A product comprising:
 (a) a permeated core structure; and   (b) a coating on an outer surface of the permeated core structure with a material that can be formed into desired contours.   
     
     
         8 . The material according to  claim 7 , wherein the permeated core structure is made from a plastic foam, metal, wood, wax or ceramic. 
     
     
         9 . The material according to  claim 7 , wherein the perforations are of uniform diameter. 
     
     
         10 . The material according to  claim 7 , wherein the perforations are not of uniform size. 
     
     
         11 . The material according to  claim 7 , wherein the perforations are made by drilling or suitable mold. 
     
     
         12 . A product comprising a permeated core structure. 
     
     
         13 . The material according to  claim 12 , wherein the perforations are of uniform diameter. 
     
     
         14 . The material according to  claim 12 , wherein the perforations are not of uniform size. 
     
     
         15 . The material according to  claim 12 , wherein the perforations are made by drilling or using a suitable mold. 
     
     
         16 . The material according to  claim 12 , wherein the core material is made from plastic, foam, metal, ceramic or wax. 
     
     
         17 . A product comprising coated fibers that forms a core structure that can operate at elevated temperatures. 
     
     
         18 . The material according to  claim 17  that is coated with phenol formaldehyde resin or a melamine resin. 
     
     
         19 . The material according to  claim 17  that can operate continuously at temperatures up to 250° F. or intermittently to 300° F.