Method to incorporate cooling lines in a spray-formed article

Abstract

At least one aspect of the present invention relates to an improved method of incorporating fluid lines in a spray-formed article. The method comprises forming a first component having a backing surface followed by placing a fluid defining flexible conduit adjacent the backing surface. Next, metal droplets are sprayed over the backing surface to from a metallic adhesion layer. The metal droplets used to form the adhesion layer are sprayed in a sufficient amount that the adhesion layer at least partially encapsulates the flexible conduit whereby the conduit is fastened to the backing surface by the metallic adhesion layer. Also provided by the present invention is an article made in accordance with a method of the invention.

What is claimed:  
     
         1 . A method of making an article having fluid passages, the method comprising: 
 (a) forming a first component having a backing surface;    (b) placing a flexible conduit capable of transporting fluid adjacent the backing surface; and    (c) spraying metal droplets atop the backing surface to form a metallic adhesion layer, wherein the metal droplets used to form the adhesion layer are sprayed in a sufficient amount that the adhesion layer at least partially encapsulates the flexible conduit whereby the conduit is fastened to the backing surface by the metallic adhesion layer.    
     
     
         2 . The method of  claim 1  wherein the flexible conduit is a corrugated metal tubing.  
     
     
         3 . The method of  claim 2  wherein the flexible conduit is copper or stainless steel.  
     
     
         4 . The method of  claim 1  wherein the conduit serves as a cooling channel.  
     
     
         5 . The method of  claim 1  wherein the first component is made by spray-forming.  
     
     
         6 . The method of  claim 1  wherein the first component is a die or a mold having a face surface.  
     
     
         7 . The method of  claim 1  wherein the first component is made from steel.  
     
     
         8 . The method of  claim 1  wherein the metal droplets are steel, zinc, zinc alloy, or mixtures thereof.  
     
     
         9 . The method of  claim 1  wherein the metal droplets are zinc or zinc alloy.  
     
     
         10 . The method of  claim 1  wherein the metal droplets are a zinc alloy comprising zinc, aluminum, and copper.  
     
     
         11 . The method of  claim 1 , wherein the article is a die or mold.  
     
     
         12 . An article having fluid passages, the article comprising: 
 a first component having a backing surface;    a flexible conduit adjacent the backing surface; and    a metallic adhesion layer disposed over the backing surface of the first component, wherein 
 the metallic adhesion layer is formed by spraying metal droplets over the backing surface of the first component; and  
 the corrugated conduit is at least partially encapsulated in the metallic layer.  
   
     
     
         13 . The article of  claim 12  wherein the flexible conduit is corrugated metal tubing.  
     
     
         14 . The article of  claim 13  wherein the flexible conduit is copper or stainless steel.  
     
     
         15 . The article of  claim 12  wherein the conduit serves as cooling channels.  
     
     
         16 . The article of  claim 12  wherein the first component is made by spray-forming.  
     
     
         17 . The article of  claim 12  wherein the first component is a die or a mold.  
     
     
         18 . The article of  claim 12  wherein the article is made from steel.  
     
     
         19 . The article of  claim 12  wherein the metal droplets are steel, zinc, zinc alloy, or mixtures thereof.  
     
     
         20 . The article of  claim 12  wherein the metal droplets are zinc or zinc alloy.