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 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: In one embodiment, a tool for forming an article in a molding operation has a tool body formed from a non-particulate material, with a particulate material bonded to the body. The body provides a forming surface for forming the article. The particulate material, or the particulate material and the tool body collectively provide a duct for conveying a fluid for transfer of heat with the forming surface. In another embodiment, the tool has a tool body formed from a non-particulate material with a cavity and the particulate material is disposed within the cavity. A heat transfer material is disposed in the cavity bonding the particulate material to the tool body. Methods for manufacturing such tools are also disclosed.

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 tool for forming an article in a forming operation is provided with a plurality of individually formed laminate sheets that are aligned, stacked and assembled to collectively form a tool body, each having a coefficient of thermal expansion. A series of the laminate sheets has a plurality of apertures coaxially formed therethrough. A plurality of pins collectively have a coefficient of thermal expansion and sized to be received within the plurality of apertures the plurality of pins extending through at least a plurality of the laminate sheets and collectively extend through the series of the laminate sheets. The coefficient of thermal expansion of the pins is higher than the coefficient of thermal expansion of the laminate sheets such that the laminate sheets and pins expand to secure the pins within the apertures to maintain the laminate sheets in stacked alignment while being heated to form the tool.