Patent ID: 7731830
Filing Date: 2010-06-08
Classification: C25D

Abstract:
1. A method of making an electroformed tooling device with integral heating and cooling fluid channels for use in molding, the method comprising: a first step of fabricating an electroform, a tool by electro-depositing on a structured substrate or suitably shaped mandrel to create a molding side of the electroform to function as a molding surface while leaving an uneven deposit on a non-molding side of the electroform left as a by-product of electrodeposition; a second step of machining a metal blank base comprising a smooth flat bottom surface, a top surface having a network of open channels in the top surface, and one or more surfaces having an opening therein communicating with the network of open channels to allow fluid to flow into a first opening and flow through the network of open channels and flow out a second opening; a third step of using the electroform as an electrode to erode the top surface of the machined blank base using plunge electro-discharge machining to form a contoured surface to mate with the uneven contour of the non-molding side of the electroform by lowering the uneven contour of the non-molding side of the electroform onto the top surface of the blank base in the electro discharge machining environment; and a fourth step of interconnecting the electroformed tool and the blank base by a means of securing the electroformed tool to the blank base with the non-molding side of the electroform contacting the mating top contoured surface of the blank base to form an electroformed tool with integral conformal thermal management channels so that hot and cold fluid flowing through the blank base network of open channels contacts the electroform to heat, cool or alternately heat and cool the electroformed tool during use in molding processes.