Reinforced and thickened mold insert and method of manufacturing the same

Abstract

A reinforced and thickened mold insert and a method of manufacturing the same include the procedures of: first, providing an original mandrel that has an electroformed metal mold insert; next, forming a plurality of protrusive or indented coupling reinforced sections on the electroformed metal mold insert; finally forming a thickened metal layer on the electroformed metal mold insert and the coupling reinforced sections by metal spraying. The coupling reinforced sections can increase the bonding power between the electroformed metal mold insert and the thickened metal layer.

1 . A reinforced and thickened mold insert, comprising: 
 an electroformed metal mold insert;    at least one coupling reinforced section located on the surface of the electroformed metal mold insert; and    a thickened metal layer located on the surfaces of the electroformed metal mold insert and the coupling reinforced section.    
   
   
       2 . The reinforced and thickened mold insert of  claim 1 , wherein the coupling reinforced section is fabricated by depositing at least one silver paste spot on a selected location of the surface of the electroformed metal mold insert and electroforming.  
   
   
       3 . The reinforced and thickened mold insert of  claim 1 , wherein the coupling reinforced section is fabricated by bonding at least one screw to the surface of the electroformed metal mold insert and electroforming.  
   
   
       4 . The reinforced and thickened mold insert of  claim 1 , wherein the coupling reinforced section is fabricated by depositing at least one silver paste spot and bonding at least one screw to the surface of the electroformed metal mold insert and electroforming.  
   
   
       5 . The reinforced and thickened mold insert of  claim 1  further including a key bonding layer interposed between the electroformed metal mold insert and the thickened metal layer.  
   
   
       6 . The reinforced and thickened mold insert of  claim 1 , wherein the thickened metal layer includes a metal mesh.  
   
   
       7 . A method for manufacturing a reinforced and thickened mold insert, comprising the steps of: 
 providing an original mandrel and forming an electroformed metal mold insert on the surface of the original mandrel;    forming at least one coupling reinforced section on the surface of the electroformed metal mold insert;    separating the original mandrel and the electroformed metal mold insert; and    forming a thickened metal layer on the electroformed metal mold insert and the coupling reinforced section by metal spraying.    
   
   
       8 . The method of  claim 7 , wherein forming at least one coupling reinforced section includes the steps of: 
 forming at least one silver paste spot on the surface of the electroformed metal mold insert; and    submerging the original mandrel in an electroforming solution to process electroforming and deposit a metal film on the silver paste spot, the protrusive silver paste spot being the coupling reinforced section.    
   
   
       9 . The method of  claim 7 , wherein the forming at least one coupling reinforced section includes the steps of: 
 fastening at least one screw to the surface of the electroformed metal mold insert; and    submerging the original mandrel in an electroforming solution to process electroforming and deposit a metal film on the screw, the protrusive screw being the coupling reinforced section.    
   
   
       10 . The method of  claim 7 , wherein the forming at least one coupling reinforced section includes the steps of: 
 forming at least one silver paste spot and fastening at least one screw to the surface of the electroformed metal mold insert; and    submerging the original mandrel in an electroforming solution to process electroforming and deposit a metal film on the silver paste spot and the screw, the protrusive silver paste spot and the screw being the coupling reinforced section.    
   
   
       11 . The method of  claim 7 , wherein the forming at least one coupling reinforced section includes the steps of: 
 forming at least one indented trough on the surface of the electroformed metal mold insert; and    submerging the original mandrel in an electroforming solution to process electroforming and deposit a metal film in the indented trough to become the coupling reinforced section.    
   
   
       12 . The method of  claim 7 , wherein the separating the original mandrel and the electroformed metal mold insert is followed by forming a key bonding layer on the surface of the electroformed metal mold insert and the coupling reinforced section by metal spraying.  
   
   
       13 . The method of  claim 7 , wherein the forming a thickened metal layer on the electroformed metal mold insert and the coupling reinforced section by metal spraying includes placing a metal mesh in the thickened metal layer.