Mould tool, method of assembling a mould tool and method of manufacture using a mould tool

Abstract

A mould tool (100) is provided which has a multipart mould layer assembly (200; 300; 400; 500; 600) which may either be formed from a carrier (202; 302; 402; 502) and an insert (206; 306; 406; 506) defining a mould profile, or a mould face component (602; 702) having a plurality of stackable blocks (630, 632, 634) which can be assembled to form a mould layer.

1 - 43 . (canceled) 
     
     
         44 . A mould layer assembly comprising:
 a carrier defining a mould contact face on a first side, and a temperature control face on a second side opposite the first, which temperature control face is separated into a plurality of temperature control zones, each zone comprising a fluid chamber at least partially defined by the temperature control surface; and,   an insert defining a mould profile for forming a moulded article, the insert being disposed in the carrier such that the insert overlaps at least one of the temperature control zones.   
     
     
         45 . The mould layer assembly according to  claim 44 , wherein one of:
 the insert overlaps a plurality of the temperature control zones;   the mould profile overlaps a plurality of the temperature control zones;   the insert comprises a mould contact face adjacent the mould profile, which mould contact face is parallel and adjacent to the mould contact face of the carrier.   
     
     
         46 . The mould layer assembly according to  claim 44 , wherein the insert comprises an insert temperature control surface that is opposite the mould profile and that is in direct thermal contact with at least one fluid chamber. 
     
     
         47 . The mould layer assembly according to  claim 46 , wherein the carrier comprises a support surface for supporting the insert. 
     
     
         48 . The mould layer assembly according to  claim 47 , wherein at least one of:
 the carrier comprises an opening for the insert;   the support surface comprises a peripheral support around the opening; and   the fluid chambers are defined by chamber sidewalls, and wherein the support comprises ends of the chamber sidewalls.   
     
     
         49 . A mould layer assembly according to  claim 47 , wherein the fluid chambers contain ribs, and wherein the support surface comprises ends of the ribs. 
     
     
         50 . The mould layer assembly according to  claim 49 , wherein the chamber sidewalls form a rectangular lattice, and wherein the ribs extend at an angle to the chamber sidewalls. 
     
     
         51 . The mould layer assembly according to  claim 49 , wherein the ribs define concave formations facing away from the insert. 
     
     
         52 . The mould layer assembly according to  claim 51 , wherein the ribs are arch-shaped, such that a plurality of ribs extend from the chamber sidewalls to an impingement region. 
     
     
         53 . The mould layer assembly according to  claim 44 , wherein the carrier comprises a support surface for supporting the insert. 
     
     
         54 . The mould layer assembly according to  claim 53 , wherein at least one of:
 the carrier comprises an opening for receiving the insert;   the support surface covers the base of the opening; and   the support surface is integral with the carrier.   
     
     
         55 . A mould tool comprising:
 a plurality of temperature control assemblies each comprising a heater; and,   a mould layer assembly according to  claim 44 ,   wherein the temperature control assemblies is controllable to individually heat each of the chambers.   
     
     
         56 . The mould tool according to  claim 55 , wherein each of the temperature control assemblies comprises a fluid outlet directed into the respective chamber, such that at least one of:
 each of the temperature control assemblies is configured to alternately heat and cool a respective chamber with fluid from the outlet; and   at least one of the fluid outlets is directed towards the insert.   
     
     
         57 . A method of moulding an article, comprising:
 providing a mould tool according to  claim 55 ;   providing a material to be moulded in thermal contact with the mould profile; and,   moulding the material to be moulded into an article.   
     
     
         58 . A mould layer assembly comprising:
 a mould face component defining a mould profile for forming a moulded article on a first side thereof, and a temperature control surface on an opposite side to the mould profile, which temperature control surface is separated into a plurality of temperature control zones, each zone comprising a fluid chamber at least partially defined by the temperature control surface and,   a plurality of support elements stacked on the temperature control surface side of the mould face component to provide a support surface for the mould layer assembly.   
     
     
         59 . The mould layer assembly according to  claim 58 , wherein the plurality of support elements extend in three dimensions. 
     
     
         60 . The mould layer assembly according to  claim 58 , wherein the plurality of support elements define a flat, planar support surface distal to the mould face component. 
     
     
         61 . The mould layer assembly according to  claim 58 , wherein the support elements are stacked in columns extending from the temperature control surface, and wherein the mould layer assembly further comprises a mechanical fastener configured to secure the elements of each column to the mould face component such that each column corresponds to at least one fluid chamber of the mould face component. 
     
     
         62 . The mould layer assembly according to  claim 58 , wherein each of the plurality of support elements defines at least one of:
 conduits for the passage of a temperature control assembly; and   a thermocouple from the support surface to the fluid chambers, such that the conduits extend normal to the support surface.   
     
     
         63 . The mould layer assembly according to  claim 58 , wherein the plurality of elements comprises different shapes of element. 
     
     
         64 . A mould tool comprising a mould tool layer assembly according to  claim 58 . 
     
     
         65 . The mould tool according to  claim 64 , comprising:
 a plurality of temperature control assemblies each comprising a heater that is configured to individually heat a respective one of the chambers,   wherein each of the temperature control assemblies comprises a fluid outlet directed into a respective chamber, such that each of the temperature control assemblies is configured to alternately heat and cool a respective chamber with fluid from the fluid outlet.   
     
     
         66 . The mould tool according to  claim 65 , comprising a plurality of temperature sensors in contact with the mould face component. 
     
     
         67 . The mould tool according to  claim 66 , wherein each of the plurality of temperature sensors extends from the support surface to the mould face component and is resiliently biased into contact with the mould face component. 
     
     
         68 . A method of moulding an article, comprising:
 providing a mould tool according to  claim 64 ;   providing a material to be moulded in thermal contact with the mould profile and,   moulding the material to be moulded into an article.   
     
     
         69 . A method of manufacturing a mould layer assembly, comprising:
 providing a mould face component defining a mould profile configured to form a moulded article on a first side thereof, and a temperature control surface on an opposite side to the mould profile, which temperature control surface is separated into a plurality of temperature control zones, each temperature control zone comprising a fluid chamber at least partially defined by the temperature control surface;   providing a plurality of support elements and,   stacking the plurality of support elements on the temperature control surface side of the mould face component to provide a support surface for the mould layer assembly.   
     
     
         70 . The method of manufacturing a mould layer assembly according to  claim 69 , further comprising at least one of:
 securing the plurality of support elements using mechanical fasteners, and   machining the support surface to make it level.