Laminated tool and a method for forming a tool

Abstract

A tool 10 and a method 50 for producing a tool 10 by laminatingly forming a pre-tool or undersized object 16 and then casting a second material 74 unto the pre-tool 16 , thereby forming the tool 10 and allowing the tool to have the superior characteristics associated with the lamination strategy while concomitantly reducing, minimizing, and/or eliminating undesired finish surface features.

1 ) A laminated tool having a plurality of sectional members which are respectively formed from a first material and which cooperatively form a forming surface; and a layer of a second material which is cast upon said forming surface.  
   
   
       2 ) The laminated tool of  claim 1  wherein said first material comprises steel and wherein said second material comprises epoxy.  
   
   
       3 ) The laminated tool of  claim 2  wherein said layer of said epoxy is thin.  
   
   
       4 ) The laminated tool of  claim 3  wherein said plurality of said sectional members cooperatively form at lease one passage.  
   
   
       5 ) The laminated tool of  claim 1  wherein said first material comprises copper and wherein said second material comprises epoxy.  
   
   
       6 ) The laminated tool of  claim 1  wherein said first material comprises aluminum and wherein said second material comprises epoxy.  
   
   
       7 ) The laminated tool of  claim 4  wherein said at least one passage comprises a heating passage.  
   
   
       8 ) The laminated tool of  claim 4  wherein said at least one passage comprises a cooling passage.  
   
   
       9 ) A method for producing a tool comprising the steps of initially determining a desired size of said tool; forming a plurality of sections from a first material; coupling said sections, effective to cause said coupled sections to form an object having a forming surface, said object being dissimilar from said desired size; and placing a thin layer of a second material upon said forming surface, thereby forming said tool.  
   
   
       10 ) The method of  claim 9  wherein said first material comprises steel and wherein said second material comprises epoxy.  
   
   
       11 ) The method of  claim 10  further comprising the steps of forming at least one opening in each of said sections; and registering said at least one opening of each of said sections as said sections are coupled, thereby causing said registered openings to form at least one passageway within said tool.  
   
   
       12 ) The method of  claim 11  wherein said step of placing said thin layer of said epoxy upon said steel material comprises the step of casting said epoxy upon said steel material.  
   
   
       13 ) The method of  claim 12  wherein said at least one passageway traverses said tool.  
   
   
       14 ) The method of  claim 9  wherein said first material comprises copper and wherein second material comprises epoxy.  
   
   
       15 ) The method of  claim 9  wherein said first material comprises aluminum and said second material comprises epoxy.  
   
   
       16 ) The method of  claim 13  wherein said at least one passageway comprises a cooling passageway.  
   
   
       17 ) The method of  claim 13  wherein said at least one passageway comprises a heating passageway.  
   
   
       18 ) A method for forming a tool of a certain predetermined size and shape, said method comprising the steps of forming an object from a first material, said object having a shape which is substantially similar to said predetermined shape but which is smaller than said predetermined size; and placing a quantity of a second material upon said formed object, thereby forming a second object having a size and a shape which is substantially identical to said predetermined size and shape.  
   
   
       19 ) The method of  claim 18  wherein said first material comprises steel and wherein said second material comprises epoxy.  
   
   
       20 ) The method of  claim 19  wherein said step of placing said quantity of said second material upon said formed object comprises the step of casting said second material upon said formed object.  
   
   
       21 ) The method of  claim 20  further comprising the step of placing surface features upon a portion of said object which is effective to assist in binding said second material upon said formed object.  
   
   
       22 ) The method of  claim 18  wherein said first material comprises copper and wherein said second material comprises epoxy.  
   
   
       23 ) The method of  claim 18  wherein said first material comprises aluminum and wherein said second material comprises epoxy.  
   
   
       24 ) A method for forming a tool comprising the steps of determining a size and a shape to be given to said tool; forming an undersized tool having a certain surface finish, wherein said tool is formed from the cooperative combination of a plurality of sectional lamination members each of which is formed from a first material; using said surface finish to create a casting model; using said casting model to apply a second material to said certain surface finish, thereby forming said tool of said determined size and shape.  
   
   
       25 ) The method of  claim 24  wherein said second material comprises epoxy and wherein said first material comprises steel.  
   
   
       26 ) The method of  claim 25  wherein each of said plurality of said lamination members respectively includes an opening and wherein each of said respective openings are registered when said plurality of lamination members are cooperatively coupled, thereby forming at least on conformal cooling passage within said tool.  
   
   
       27 ) The method of  claim 26  further comprising the step of forming an adhering portion upon said surface finish.  
   
   
       28 ) The method of  claim 27  wherein each of said plurality of lamination members has a substantially identical thickness.  
   
   
       29 ) The method of  claim 24  wherein said first material comprises copper and wherein said second material comprises epoxy.  
   
   
       30 ) The method of  claim 24  wherein said first material comprises aluminum and wherein said second material comprises epoxy.  
   
   
       31 ) The method of  claim 27  wherein said adhering portion comprises a protuberance.  
   
   
       32 ) The method of  claim 27  wherein said adhering portion comprises a ridge.