Background of the Invention A tool, such as a mold, die, or other object formation apparatus is used to repeatedly form or create substantially similar objects or products. Conventionally, the tool is formed by machining or Mworkingw a block of material in a certain manner, thereby forming or creating the tool in a desired shape and geometrical configuration.

Alternatively, the tool may be formed by a laminar process in which various sectional members are created and selectively coupled, effective to allow the coupled members to cooperatively form the tool.

Particularly, a formed tool is adapted to be used in a wide variety of processes to create these objects or apparatuses and many of these processes cause the tool to become hot and/or cause the produced object or product to become hot. The created--heat may cause the produced product to be udeformedw or to be an undesired shape or configuration.

In order to'address these heat related difficulties, holes are typically drilled into the conventionally formed tool to create cooling passages within the tool.

Typically, a cooling medium such as water or oil is passed through the tool to extract heat from the part produced and from the tool While the foregoing approach does allow for the creation of cooling passages, it represents a relatively inefficient and costly process which undesirably increases the overall cost of production and may undesirably create distortion in the formed part. Sucn distortion is particularly undesirable since many of these parts are relatively expensive and may not be salvagable. -Thus, the distorted parts must be scrapped which adds cost and inefficiency to the manufacturing process.

. Additionally, in high-pressure manufacturing techniques such as injection molding, attention has to be

given to adequately support the tool surface so that it does not deflect under molding pressures. Therefore, cooling holes which are drilled into a tool must be at least a minimum distance from the lowest or deepest contour cut into the mold and portions of the mold which are not cut as deep as the lowest contour have more material (i. e., metal) to conduct heat through and undesirably cause uneven/inefficient cooling of the tool.

There is therefore a need for a method.. to. selectively-.-- create cooling passages within a tool which overcomes some or all of the previously delineated drawbacks of prior techniques. Moreover, there is a further need to create a tool by the use of a method which allows cooling passages to be efficiently formed within the tool and which does not potentially cause distortion in the product produced.

These and other needs are addressed by the present as is more fully delineated below.

SUMMARY OF THE INVENTION It is a first non-limiting advantage of the present invention to provide a method for creating cooling passages within a tool which overcomes some or all of the previously delineated drawbacks of prior techniques.

It is a second non-limiting advantage of the present invention to provide a method for creating a tool which overcomes some or all of the'previously delineated drawbacks and which, by way of example and without limitation, allows for the efficient formation of cooling passages within the tool.

It is a third non-limiting advantage of the present invention to provide a tool having cooling passages which may be efficiently and integrally formed within-the tool- and which allow a created item to be efficiently cooled while concomitantly increasing the quality of the produced part.

According to a fourth advantage of the present invention, a tool is provided. Particularly, the tool comprises a plurality of sectional members which are coupled together, wherein the plurality of sectional members each have at least one coolant passage and at least one of the plurality of'section members has an outer contour which is disposed a certain minimum distance from the at least one coolant passage.

According to a fifth advantage of the present invention a laminated tool having improved cooling characteristics is provided. Particularly, the laminated tool comprises a plurality of first sectional members each

having a certain contour and at least one cooling passage which is a certain predetermined distance from the forming surface; wherein the plurality of sectional members are coupled together, effective to cause the certain contours to form a forming surface and to cause the at least one cooling passages to form a cooling manifold; and an amount of material which is disposed within the cooling manifold, effective to cool the tool.

According to a sixth advantage of the present invention, a method is provided for forming a tool having improved cooling characteristics. The method comprises the steps of forming at least one first member having a first outer contour and at least one first inner passage which is disposed a certain predetermined distance from the first outer contour; forming at least one second member having a second outer contour and at least one second inner passage which is disposed the certain predetermined distance from the second outer contour; and attaching the at least one first member to the at least one second member wherein the first outer contour cooperates with the second outer contour to form a mold surface and the first inner passage is communicatively coupled to the second inner passage to form a manifold.

These and other features, aspects, and advantages of the present invention will become apparent to those of ordinary skill in the art from a reading of the following detailed description of the preferred embodiment of the invention and by reference to the following drawings.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a perspective view of a tool which is made in accordance with the teachings of the preferred embodiment of the invention having a partial hidden view of the cooling manifold.

Figure 2 is a side view of one of the sectional members which form the tool which is shown in Figure 1.

Figure 3 is a top sectional view of the tool which is shown in Figure 1 through the cooling manifold.

Figure 4 is a flow chart showing a method for forming the tool which is shown in Figures 1-3.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION Referring now to Figures 1 and 2, there is shown a tool 10 which is made in accordance with the teachings of the preferred embodiment of the invention. It should be realized that tool 10 may be of any substantially desired

shape or. geometric configuration and that nothing in this Application is intended to limit the applicability of the invention to a particular type of tool or apparatus.

Rather, the tool 10 is only one non-limiting example of a tool which may be produced according to the invention. In the preferred embodiment of the invention, tool 10 comprises a mold member having a contoured forming or mold surface 11.

As shown best in Figures 1 and 2, mold surface 11 is formed by the coupling of a plurality of adjacent sectional members (e. g., members 12-17). That is, at least one of these sectional members 16 include a predetermined contour or shape 19 formed into its"top"surface 21. As each adjacent section member 12-17 is connected together, each contour 19 cooperates to form mold surface 11.

It should be appreciated that tool 10 represents"one- half of a molding tool and another tool having a mold surface complementary to mold surface 11 (not shown) is conventionally used to create an item. While both complementary mold tools are conventionally and cooperatively used in a molding process, the following discussion will focus upon tool 10 as both tools are made in a substantially identical. manner.

Particularly, tool 10 is made by the use of a lamination process in which several sectional members, such as sectional members 12,13, 16, 17 are selectively formed and then selectively coupled or connected in a predetermined manner in order to cooperatively form the tool 10. It should be appreciated that nothing in this Application is meant to limit the applicability of the invention to a particular type, shape, or configuration of <BR> <BR> <BR> <BR> . sectional aamberB. Moreover, the-BCrcttonal members'which are shown in Figures 1-3, such as sectional members 12,13, 16,17 are used for illustrative, purposes only and are not meant to limit the scope of the invention in any manner.

Tool 10 is made by the use of a lamination process in which several sectional members, such as sectional members 12,13, 16,17 are selectively formed and then coupled or connected together in a predetermined order to cooperatively form the tool 10 having a mold surface 11 and a cooling manifold 18 formed by a plurality of cooling passages 14 which are formed within selected sectional members 12,13, 16, 17.

Particularly, as will be noted from the discussion below and according to the preferred embodiment of the invention, cooling passages are selectively formed between adjacent sectional members having at least one cooling

passage 14 (e. g. , members 12, 13) by the cooperation of respective portions of the sectional members having a desired shape or geometric configuration and these cooling passages interconnect to form cooling manifold 18 and allow water, oil, ethylene glycol ; and/or other material 40 to traverse the tool 10 in order to cool the tool 10 and to cool the item or product which may be formed within mold surface 11. The term'adjacent* as is used in this description means the sectional.. members, abut and are- physically connected. It should be apparent that by allowing this cooling manifold 18 to be created by structural portions or physical attributes and/or characteristics of the sectional members 12-17 the need to drill cooling holes through the. tool 10 is obviated.

This reduces/eliminates the potential for damage to the tool 10 and concomitantly provides a more efficient distribution of the cooling material 40 through the tool 10.

As shown in Figure 2, each unique sectional member, such as sectional member 16 may include an upper mold contour 19 and a plurality of cooling passages 14. In the preferred embodiment of the invention, each sectional member 16 is formed of a relatively strong and wear resistant material, for example and without limitation, a

steel. Cooling passages 14 are formed within member 16 substantially"beneath"contour 19.

It should be appreciated that each individual sectional member, such as member 16, can maintain the predetermined minimum required"wall thickness"or distance 30 for the particular material tool 10 is made from to ensure tool 10 does not deflect during high pressure applications. That is, each cooling passage 14 formed into a sectional member 16 can be formed a predetermined distance from the portion of the contour 19 which is directly above or adjacent to that passage 14. It should be appreciated that distance 30 will vary for various molding operation and is dependent upon the pressures involved and the material tool 10 is formed from. For example and without limitation, the pressures involved in an injection molding process are higher than in foam or blow molding processes and subsequently distance 30 would necessarily be-larger for an injection molding tool than in a foam molding tool or blow molding tool.

In one non-limiting example, a tool 10 formed from a steel material may have a distance 30 of approximately. 25 -. 50 inches (6.35-12. 7 millimeters) to provide sufficient rigidity and strength to avoid deflection during a relatively high pressure molding process, such as an

injection molding operation. In relatively low pressure molding processes, such as foam molding or blow molding, the distance 30 for a steel tool 10 would be approximately . 1-. 25 inches (2.54-6. 35 millimeters), as the pressures involved are not as high. It'should be appreciated that the distance 30 varies depending upon which material tool 10 is formed from, as each tool 10 may be formed from substantially any material a variety of strength characteristics.

Further, depending upon the depth and shape of the contour 19, cooling passage 14 may be raised or lowered relative to an adjacent sectional member's corresponding cooling passage to accommodate changes in the surface of mold surface 11. Cooling manifold 18, therefore, may be dynamically configured to FfollowX the shape of surface 11 by changing the location and/or shape of the cooling passages 14 to correspond to the contour 19 which is immediately above that passage. Subsequently, the preferred embodiment of the invention increases the cooling efficiency of tool 10 while concomitantly maintaining the necessary wall thickness 30 to prevent any deflection during high pressure use.

As shown in Figures 2 and 3, the support provided by the predefined"minimum"wall thickness 30 is augmented by

a plurality of support members 23 which traverse cooling manifold 18. These supports 23 are disposed throughout manifold 18 and are formed by the spaces present between the individual coolant passages 14. Support members 23 cooperatively cause cooling passages 14 which form manifold 18 to cut a winding, ehoney-combedn, or non-linear path through tool 10. This non-linear configuration of manifold 18 increases turbulent flow of material 40 through tool 10 and thereby increases the thermal. transfer,. characteristics of tool 10. Furthermore, the gradually varying wheightsn or locations of interconnecting cooling passages 14, i. e., the geometry transitions of adjacent passages having different"elevations° due to changes in contour 19, creates an offset or"stair step"between adjacent sectional members which further results in greater turbulent flow.

As shown in Figures 1 and 3, tool 10 further includes conduits or bores 20,22 and 50, 52 which are formed from aligned apertures formed within the outer-most sectional members (e. g. , members 12,13, and 17) of tool 10. As shown, conduits 20,22, 50,52 communicatively couple cooling manifold 18 with the exterior of tool 10. In the preferred embodiment of the invention, conduits 20,22 are coupled to a source 39 of coolant material 40 while

conduits 50,52 function to remove or exhaust heated material 40 from tool 10. In one non-limiting embodiment of the invention conduits'50, 52 are coupled to a heat exchanger assembly (not shown) to cool and/or condense the heated"material 40 exiting tool 10 and redirect the material 40 back to source 39 (e. g. , conduits 50,52 cooperate with a heat exchanger which is coupled to source 39 and as act as a self contained coolant return system).

It should be apparent that the above description of conduits 20,22, 50, and 52 are for exemplary purposes only and that'various configurations and numbers of coolant conduits coupling manifold 18 to a source 39 of material 40 are intended. For example and without limitation, one embodiment of tool 10 may omit exhaust conduits 50,52 and instead use a first conduit 20 on one side of the tool 10 to supply material 40, while utilizing another conduit 22 on the same side to function as the return back to source 39.

As shown in Figure 2, in another non-limiting embodiment of the invention each sectional member 12-17 includes a first aperture 24 and a second aperture 25 which, when the members 12-17 are connected, form a hole, bore, or channel through the tool 10. It should be appreciated that holes 24,25 are formed within tool 10 to

allow a bolt/dowel/pin (not shown) to be inserted therein to further support tool 10 and assist in guiding or aligning each sectional member as it is abutted against its predefined adjacent sectional member.

As shown in Figure 4, a method 100 for cooling a tool 10 is provided. Particularly, method 100 begins at step 102 in which a plurality of sectional members 12-17 are formed. Step 104 follows step 102 and in this step a certain-outer outer irs-formed upon each of the sectional members formed in step 102. Step 106 follows step 104 and in this step a plurality of coolant passages 14 and/or apertures 20,22 are formed within sectional members 12-17 a predetermined distance from the respective outer contour 19. Additionally, each coolant passage 14 within a unique sectional member, e. g., sectional member 16, is set apart or separated, from the other coolant passages 14 formed therein.

Step 106 is followed by step 108 and in this step each sectional member 12-17 is attached and coupled to the corresponding and adjacent sectional member to cooperatively form tool 10. Each individual contour 19 abuts the contour 19 of the adjacent sectional member to form a relatively smooth forming or mold surface 11.

Additionally, each coolant passage 14 communicatively

couples with the coolant passage 14 of the adjacent sectional member to form a coolant manifold portion 18. It should be appreciated that the separations between coolant passages formed in a particular sectional member, e. g., sectional member 16, form support members 23 within the manifold 18. As is best shown in Figure 3, support members 23 are distributed throughout manifold 18 by gradually increasing and decreasing the size and location of coolant passages 14 and the separations between the passages 14 between adjacent sectional members, e. g., sectional members 12,13.

Step 110 follows step 108 and in this step a coolant material 40 is passed through manifold 18 and removes heat from tool 10. It should be appreciated that turbulent flow attributed to the offset configuration of adjacent sectional members and/or to the non-linear path through manifold 18 caused by support members 23 further increase the heat transfer effects provided by the above methodology.

It is to be understood that the invention is not limited to the exact construction and method steps which have been described above, but that various changes and modifications may be made without departing from the spirit and the scope of the inventions as are more fully

delineated in the following claims. For example and without limitation, steps 102,104, and 106 of methodology 100 described above may be performed in substantially any order and/or combined to accommodate various manufacturing techniques or equipment which may be available.

It should further be appreciated that substantially any liquefied material may be used as coolant 40 and that the above description should not be limited to the above delineated, materials alone-an& other materials which t provide. for thermal transfer in tool 10 are may be used in the above described manner. In other non-limiting embodiments, manifold 18 may include additional injection molding features such as ejector pin sleeves (not shown) that are formed in a substantially similar manner to that described above for forming support members 23. That is, cooling passages 14 and support members 23 may be arranged within manifold 18 to form voids or channels that permit an ejector pin to be inserted therein to assist in ejecting a part formed within tool 10.

Additionally, the above description provides a tool 10 having a manifold 18 which may be used to cool the tool 10 by forcing a coolant material 40 through the manifold 18.

It should be readily appreciated that the above described manifold 18 in tool 10 may be utilized with a material

similar to material. 40 (e. g., an oil) which is pre-heated to provide additional thermal energy (i. e. , heat) to the tool 10. That is, the principles of thermal transfer between the tool 10 and the material 40 passing there through may be applied'in situations where the tool 10 may need to be. heated rather than cooled and/or cycled between heated and cooled during the manufacturing process. For example and without limitation, both a first coolant source 39 and second hçated source 39 (i.e., a source 39 coupled to a heater assembly) may be coupled to conduits 20,22 of tool 10 to selectively supply heated or cooled material through manifold 18.