Mould with conformal cooling

Abstract

A method of providing a mould with a conformal cooling passage includes rough machining a mould cavity generally corresponding to a moulded part shape using CAD data. Conformal cooling slots are cut in the mould cavity using the CAD data. The conformal cooling slots are welded shut using the CAD data to provide conformal cooling passages. A class A surface is machined over the conformal cooling passage and corresponds to a finished mould part shape using the CAD data.

1 . A method of providing a mould with a conformal cooling passage comprising:
 cutting conformal cooling slots into a mould cavity;   shutting the conformal cooling slots to provide conformal cooling passages;   laying weld beads in the conformal cooling slots until the weld beads are proud of an adjacent surface of the mould; and   machining a surface over the conformal cooling passage corresponding to a finished mould part shape.   
     
     
         2 . The method according to  claim 1 , wherein the step of shutting the conformal cooling slots includes welding shut the conformal cooling slots with a first number of weld beads that span the conformal cooling slots. 
     
     
         3 . The method according to  claim 2 , wherein the step of laying weld beads in the conformal cooling slots includes laying additional weld beads on the first number of weld beads. 
     
     
         4 . The method according to  claim 1 , wherein the cut conformal cooling slot includes first and second widths, the second width greater than the first width, and wherein the conformal cooling slots are shut adjacent the intersection of the first and second widths. 
     
     
         5 . The method according to  claim 4 , wherein each of the cut conformal cooling slots includes a first depth and a second depth less than the first depth, the second depth including the second width. 
     
     
         6 . The method according to  claim 4 , wherein the cut conformal cooling slots each include an angled surface providing the second width, the angled surfaces being angled relative to a centerline of a respective one of the cut conformal cooling slots. 
     
     
         7 . The method according to  claim 6 , wherein each angled surface is arranged at an obtuse angle relative to a true horizontal plane. 
     
     
         8 . The method according to  claim 1 , further comprising heating the mould after cutting the conformal cooling slots to relieve stress from the mould. 
     
     
         9 . A part-producing mold, comprising:
 at least one conformal cooling passage located subjacent to a molding surface to be cooled, said at least one conformal cooling passage formed from:
 a series of interconnected open channels placed in a molding surface of said mold, said channels substantially conforming to the contour of said molding surface, the open channels being sealed at a distance from a bottom of each channel so as to form an enclosed cooling passage at the bottom thereof, and 
 a plurality of weld beads that substantially fill a volume of each channel above said distance, said weld beads shaped to conform to said molding surface of said mold surrounding that channel; 
   an inlet associated with said at least one conformal cooling passage for receiving pressurized cooling fluid from a source thereof; and   an outlet associated with said at least one conformal cooling passage for expelling cooling fluid to a heat removal device after said cooling fluid has passed through said at least one conformal cooling passage.   
     
     
         10 . The mold of  claim 9 , wherein said open channels have a first width below said distance and a second width greater than said first width above said distance. 
     
     
         11 . The mold of  claim 9 , wherein said channels are sealed by a bridging weld located within each channel, said bridging welds comprising a series of connected weld beads, said bridging welds spanning each channel. 
     
     
         12 . The mold of  claim 9 , wherein said mold is a plastic injection mold. 
     
     
         13 . The mold of  claim 9 , wherein said inlet and outlet of said at least one conformal cooling passage are accessible from an exterior of said mold. 
     
     
         14 . A method of producing a part, comprising:
 providing a part-producing mold, said part-producing mold comprising:
 at least one conformal cooling passage located subjacent to a molding surface to be cooled, said at least one conformal cooling passage formed from:
 a series of interconnected open channels placed in a molding surface of said mold, said channels substantially conforming to the contour of said molding surface, the open channels being sealed at a distance from a bottom of each channel so as to form an enclosed cooling passage at the bottom thereof, and 
 a plurality of weld beads that substantially fill a volume of each channel above said distance, said weld beads shaped to conform to said molding surface of said mold surrounding that channel; 
 
 an inlet associated with said at least one conformal cooling passage for receiving pressurized cooling fluid from a source thereof; and 
 an outlet associated with said at least one conformal cooling passage for expelling cooling fluid to a heat removal device after said cooling fluid has passed through said at least one conformal cooling passage; and 
   molding a part using said part-producing mold.   
     
     
         15 . The method of  claim 14 , wherein said channels are sealed by a bridging weld located within each channel, said bridging welds comprising a series of connected weld beads, said bridging welds spanning each channel. 
     
     
         16 . The method of  claim 14 , wherein said open channels have a first width below said distance and a second width greater than said first width above said distance. 
     
     
         17 . The method of  claim 14 , wherein said molding step includes plastic injection molding said part. 
     
     
         18 . The method of  claim 14 , wherein said inlet and outlet of said at least one conformal cooling passage are accessible from an exterior of said mold. 
     
     
         19 . The method of  claim 14 , further comprising establishing a flow of pressurized cooling fluid and directing said flow of pressurized cooling fluid to said inlet. 
     
     
         20 . The method of  claim 19 , wherein said flow of pressurized cooling fluid is directed to said inlet during said step of molding said part.