Patent ID: 6074194
Filing Date: 2000-06-13
Classification: B29C,B29K,B33Y

Abstract:
A system for the spray forming manufacture of near net shape molds, dies and related toolings, comprising:a nozzle having a flow channel, said flow channel having an inlet end, an outlet end and a longitudinal axis;a liquid reservoir in fluid communication with said nozzle flow channel, said reservoir containing a liquid material capable of forming a mold, said liquid being pressurized in a pressurized reservoir;means for injecting said pressurized liquid from said reservoir through a conduit ending in said nozzle flow channel between said inlet and outlet ends and proximate to said nozzle longitudinal axis;means for flowing a high temperature, atomizing gas at a flow velocity ranging from high subsonic through supersonic velocities through the nozzle flow channel from the inlet end to the outlet end to atomize the liquid injected into the flow channel into a plume of atomized droplets;means for controlling the in-flight cooling of the atomized droplets by the use of a quench cell through which a quench gas is provided, said quench gas being entrained in the plume of atomized droplets;means for directing and depositing the atomized droplets onto a pattern to form the mold.