Spray formed thin layers having fine features

Abstract

According to one embodiment, a composite mold for use in molding a part having a textured surface is disclosed. The composite mold includes a mold base that forms the base of the composite mold. The mold base includes a mold base surface. The composite mold also includes a spray formed thin layer including a first surface having one or more fine features and a second surface opposing the first surface. The second surface is coupled to the mold base to form the composite mold having the first surface as the molding surface. The composite mold is capable of forming a molded part having a textured surface including surface features representing a reciprocal facsimile of the one or more fine features on the molding surface.

1 . A composite mold for molding a part having a textured surface, the composite mold comprising:
 a mold base forming the base of a composite mold and having a mold base surface;   a spray formed thin layer including a first surface having one or more fine features and a second surface opposing the first surface,   the second surface being coupled to the mold base to form the composite mold having the first surface as the molding surface, and the composite mold being capable of forming a molded part having a textured surface including surface features representing a reciprocal facsimile of the one or more fine features.   
   
   
       2 . The composite mold of  claim 1 , wherein the one or more fine features includes one or more features selected from the group consisting of: one or more grooves and one or more projections. 
   
   
       3 . The composite mold of  claim 2 , wherein at least one of the one or more grooves includes an arcuate portion or a linear portion. 
   
   
       4 . The composite mold of  claim 2 , wherein at least one of the one or more projections includes an arcuate portion or a linear portion. 
   
   
       5 . The composite mold of  claim 1 , wherein the spray formed thin layer is formed of a metal or metal alloy. 
   
   
       6 . The composite mold of  claim 1 , wherein the spray formed thin layer has a nominal thickness of  2  to  20  mils. 
   
   
       7 . The composite mold of  claim 1 , further comprising an adhesive for adhering the second surface to the mold base. 
   
   
       8 . The composite mold of  claim 1 , wherein the mold base is formed from a metal or metal alloy. 
   
   
       9 . The composite mold of  claim 1 , wherein the molded part is a part for the interior of a vehicle. 
   
   
       10 . A spray formed thin layer comprising:
 a first surface and a second surface opposing the first surface;   a layer portion extending between the first and second surfaces,   the first surface having one or more fine features.   
   
   
       11 . The spray formed thin layer of  claim 10 , wherein the one or more fine features includes one or more features selected from the group consisting of: one or more grooves and one or more projections. 
   
   
       12 . The spray formed thin layer of  claim 11 , wherein at least one of the one or more grooves includes an arcuate portion or a linear portion. 
   
   
       13 . The spray formed thin layer of  claim 11 , wherein at least one of the one or more projections includes an arcuate portion or a linear portion. 
   
   
       14 . The spray formed thin layer of  claim 11 , wherein the spray formed thin layer is formed of a metal or metal alloy. 
   
   
       15 . The spray formed thin layer of  claim 11 , wherein the spray formed thin layer is formed of a metal or metal alloy having a metal oxide content of less than or equal to 5%. 
   
   
       16 . The spray formed thin layer of  claim 11 , wherein the one or more fine features is an intricate array of channels. 
   
   
       17 . The spray formed thin layer of  claim 11 , wherein the layer portion has a nominal thickness of 2 to 20 mils. 
   
   
       18 . A method for forming a spray formed thin layer, the method comprising:
 providing a spray target having a spray surface;   depositing a metal spray onto the spray target surface to form a deposit layer having an interfacing surface; and   releasing the deposit layer from the spray target surface.   
   
   
       19 . The method of  claim 18 , wherein the providing step includes forming one or more fine features on the interfacing surface. 
   
   
       20 . The method of  claim 18 , wherein the depositing step includes forming one or more fine features on the interfacing surface.