US5079974A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Sprayed metal dies
Assignee: Carnegie Mellon University
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Filing: 1991-05-24
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Granted: 1992-01-14
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Expires: 2011-05-24
Abstract
Abstract A method for forming a sprayed metal die comprising the steps of first building a positive pattern of the die. Then, there is the step of spraying a first metal, having a first melting temperature, onto the pattern to form a first metal substrate. Next, there is the step of separating the pattern from the first metal substrate. Next, there is the step of spraying a second metal, having a second melting temperature higher than the first melting temperature, onto the first metal substrate to form a second metal substrate which bonds to the first metal substrate to resist shrinkage due to residual stress within the second metal substrate. Next, there is the step of heating the first and second substrates to a temperature higher than the first melting temperature, yet lower than the second melting temperature, to melt away the first metal substrate from the second metal substrate.
Inventors
- 👤 Lee E. Weiss
- 👤 Lawrence L. Schultz
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 17:52
CPC Classifications
B; B23; B23P; B23P15/00; B23P15/24; B22; B22F; B22F3/00; B22F3/115; B22F5/00; B22F5/007; B22F2998/00; B22F2998/10; B33; B33Y; B33Y80/00; Y; Y02; Y02P; Y02P10/00; Y02P10/25
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
129 words
A method for forming a sprayed metal die comprising the steps of: building a positive pattern of the die; spraying a first metal, having a first melting temperature, onto the pattern to form a first metal substrate; separating the pattern from the first metal substrate; spraying a second metal, having a second melting temperature higher than the first melting temperature, onto the first metal substrate to form a second metal substrate which bonds to the first metal substrate to resist shrinkage due to residual stress within the second metal substrate; and heating the first and second substrates to a temperature higher than the first melting temperature, yet lower than the second melting temperature, to melt away the first metal substrate from the second metal substrate to form the die.
Claim 2
Independent Claim
129 words
A method for forming a sprayed metal die comprising the steps of: building a positive pattern of the die; spraying a first metal, having a first melting temperature, onto the pattern to form a first metal substrate; separating the pattern from the first metal substrate; spraying a second metal, having a second melting temperature higher than the first melting temperature, onto the first metal substrate to form a second metal substrate which bonds to the first metal substrate to resist shrinkage due to residual stress within the second metal substrate; and heating the first and second substrates to a temperature higher than the first melting temperature, yet lower than the second melting temperature, to melt away the first metal substrate from the second metal substrate to form the die.
Claim 3
Dependent Claim
23 words
A method as described in claim 1 wherein the building step includes the step of building the positive pattern by solid freeform fabrication.
Claim 4
Dependent Claim
21 words
A method as described in claim 2 wherein the building step includes the step of building the positive pattern by stereolithography.
Claim 5
Dependent Claim
47 words
A method as described in claim 3 including after the building step, the step of mounting a first frame on the pattern; and wherein the step of spraying a first metal includes the step of spraying the first metal around an inside edge of the first frame.
Claim 6
Dependent Claim
49 words
A method as described in claim 4 including after the separating step, the step of mounting a second frame onto the first metal substrate; and wherein the step of spraying a second metal includes the step of spraying the second metal around an inside edge of the second frame.
Claim 7
Dependent Claim
28 words
A method as described in claim 5 including before the separating step, the step of pouring a first backing material onto the first metal substrate to support it.
Claim 8
Dependent Claim
14 words
A method as described in claim 6 wherein the first backing material is epoxy.
Claim 9
Dependent Claim
26 words
A method as described in claim 7 which includes before the spraying a first metal step, the step of applying a releasing agent to the pattern.
Claim 10
Dependent Claim
16 words
A method as described in claim 8 wherein the releasing agent is comprised of polyvinyl alcohol.
Claim 11
Dependent Claim
32 words
A method as described in claim 9 which includes after the spraying a second metal step, the step of pouring a second backing material onto the second metal substrate to support it.
Claim 12
Dependent Claim
25 words
A method as described in claim 10 which includes before the second pouring step, the step of orienting cooling channels about the second metal substrate.
Claim 13
Dependent Claim
21 words
A method as described in claim 11 wherein the second backing material is comprised of a chemically bonded ceramic or epoxy.
Claim 14
Dependent Claim
34 words
A method as described in claim 1 wherein the die is a first die half; and including after the heating step, the step of forming a mating die half with the first die half.
Claim 15
Dependent Claim
120 words
A method as described in claim 13 wherein the step of forming the mating die half includes the steps of: building a positive pattern of the mating die half; spraying the first metal onto the pattern to form a third metal substrate; separating the pattern from the third metal substrate; spraying the second metal onto the third metal substrate to form a fourth metal substrate which bonds to the third metal substrate to resist shrinkage due to residual stress; and heating the second and third substrates to a temperature higher than the first melting temperature, yet lower than the second melting temperature to melt away the third metal substrate from the fourth metal substrate to form the mating die half.
Claim 16
Dependent Claim
30 words
A method as described in claim 5 including before the separating step, the step of spraying continually the first metal to form a backing to support the first metal substrate.
Claim 17
Dependent Claim
26 words
A method as described in claim 15 which includes before the spraying a first metal step, the step of applying a releasing agent to the pattern.
Claim 18
Dependent Claim
32 words
A method as described in claim 16 which includes after the spraying a second metal step, the step of pouring a second backing material onto the second metal substrate to support it.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-01-13 | 1995-07-15 | 1996-01-14 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-01-13 | 1999-07-15 | 2000-01-14 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-01-13 | 2003-07-15 | 2004-01-14 | $7700.00 | Window Closed / Lapsed |