Abstract: A mold block includes a tool body with a contoured finished surface adapted to receive a tool insert having a forming surface for forming a bottle neck in a molding operation. The tool body defines an internal channel for heat transfer with the forming surface. At least a portion of the channel is offset generally equidistant from the finished surface to provide a path contoured for conformal cooling of the insert. The tool body has a pair of ports intersecting the channel. Several methods for forming a mold block are disclosed and include machining a contoured finished surface adapted to receive a tool insert on a tool body, forming a heat transfer channel within the tool body, and forming a pair of ports into the tool body. At least a portion of the channel is offset generally equidistant from the finished surface for conformal cooling of the insert.

Abstract: A mold block includes a tool body with a contoured finished surface adapted to receive a tool insert having a forming surface for forming a bottle neck in a molding operation. The tool body defines an internal channel for heat transfer with the forming surface. At least a portion of the channel is offset generally equidistant from the finished surface to provide a path contoured for conformal cooling of the insert. The tool body has a pair of ports intersecting the channel. Several methods for forming a mold block are disclosed and include machining a contoured finished surface adapted to receive a tool insert on a tool body, forming a heat transfer channel within the tool body, and forming a pair of ports into the tool body. At least a portion of the channel is offset generally equidistant from the finished surface for conformal cooling of the insert.

Abstract: A method for forming a tool for forming an article provides a series of laminate layers to collectively form a tool body. First and second pluralities of the laminate layers are formed with a forming surface for forming an article in a forming operation. A chamber is formed through the first and second pluralities of laminate layers offset from the forming surface. A vent is formed in each of the second plurality of laminate layers intersecting the forming surface and the chamber. The series of laminate layers are stacked such that each of the first plurality of the laminate layers is alternating with the second plurality of the laminate layers. The stacked series of laminate layers are heated to a temperature wherein the layers braze together.

Abstract: A laminate aluminum block for forming an article includes a series of aluminum laminate plates to collectively form a tool body for forming an article in a forming operation. A series of aluminum brazing layers are formed for brazing together adjacent aluminum laminate plates. The series of aluminum laminate plates and the series of aluminum brazing layers are deoxidized. Draining apertures are formed through a plurality of the series of aluminum laminate plates. The series of aluminum laminate plates are stacked alternating with the aluminum brazing layers between adjacent aluminum laminate plates without a flux. The stacked series of alternating aluminum plates and aluminum brazing layers are pressed. The stacked series of alternating aluminum plates and aluminum brazing layers are heated in a vacuum furnace to a temperature wherein the aluminum brazing layers braze the aluminum laminate plates together and excess braze material drains from the draining apertures.

Abstract: A laminate aluminum block for forming an article includes a series of aluminum laminate plates to collectively form a tool body for forming an article in a forming operation. A series of aluminum brazing layers are formed for brazing together adjacent aluminum laminate plates. The series of aluminum laminate plates and the series of aluminum brazing layers are deoxidized. Draining apertures are formed through a plurality of the series of aluminum laminate plates. The series of aluminum laminate plates are stacked alternating with the aluminum brazing layers between adjacent aluminum laminate plates without a flux. The stacked series of alternating aluminum plates and aluminum brazing layers are pressed. The stacked series of alternating aluminum plates and aluminum brazing layers are heated in a vacuum furnace to a temperature wherein the aluminum brazing layers braze the aluminum laminate plates together and excess braze material drains from the draining apertures.

Abstract: A laminate aluminum block for forming an article includes a series of aluminum laminate plates to collectively form a tool body for forming an article in a forming operation. A series of aluminum brazing layers are formed for brazing together adjacent aluminum laminate plates. The series of aluminum laminate plates and the series of aluminum brazing layers are deoxidized. Draining apertures are formed through a plurality of the series of aluminum laminate plates. The series of aluminum laminate plates are stacked alternating with the aluminum brazing layers between adjacent aluminum laminate plates without a flux. The stacked series of alternating aluminum plates and aluminum brazing layers are pressed. The stacked series of alternating aluminum plates and aluminum brazing layers are heated in a vacuum furnace to a temperature wherein the aluminum brazing layers braze the aluminum laminate plates together and excess braze material drains from the draining apertures.

Abstract: A method and a tangible item 10 which is produced by the use of various softly created sectional members, such as members 12, 14, 16, which are selectively and softly and selectively moved or rotated, in whole or in part, used to create physical sectionals, and then the physical sections are moved or rotated and use to selectively construct the physical item 10.

Abstract: A methodology 40 for producing a laminated tool 10 having desired dimensional accuracy. The tool 10 is produced by the use of several sectional members, such as sectional members 14, 16 which are selectively coupled and which are measured. The measurement is used to determine whether to selectively press these previously coupled sectional members 14, 16 to ensure that their coupled arrangement has a desired dimensional accuracy. Additional measurements and needed pressing operations are accomplished each time a new sectional member is added to the previously coupled sectional member combination.

Abstract: A method 10 and a laminated tool 31 which is created by the method 10 and which is formed by the selective coupling or attachment of sectional members, such as members 14, 16. The formed tool 31 includes a finished surface 36 which is formed by the selective deposition of material 30 onto surface 22.

Abstract: An apparatus 10 and a method 50 for the creation of a tool 40. The apparatus 10 and the method 50 allow for dynamic measurement of the tool 40 as it is being created and further allows for the use of positive feedback to increase the likelihood that the produced tool will be structurally similar to a certain model. The apparatus 10 and method 50 further allow sections of varying thicknesses to be used and provide a technique to create surfaces which further increase the likelihood that the produced tool will be structurally equivalent to a desired and modeled tool.

Abstract: A tool 10 which is made by a method which efficiently allows internal passageways, such as passageway 50, which are at least partially circumscribed by thermally conductive material 103, to be formed in the tool 10, thereby allowing for enhanced cooling characteristics and allowing decreased cycle time and a reduced likelihood of damage to the formed object.

Abstract: A tool 10 and a method for creating the tool 10 which is comprised of several selectively coupled sectional members 12, 16, and which includes at least one cooling channel 14. In one embodiment, each sectional member 12, 16, which is to be used to form the at least one cooling channel 14, has respective indented channels 18, 20. Channel 18 of member 12 registers with a unique one of the channels 20 of member 16 to which member 12 is coupled, thereby forming the unique cooling passage 14. Other embodiments are disclosed which also provide desired cooling paths 14.