Browse Prior Art Database

FIBERSHELL TOOLING

IP.com Disclosure Number: IPCOM000026335D
Original Publication Date: 1991-Jun-30
Included in the Prior Art Database: 2004-Apr-05
Document File: 2 page(s) / 68K

Publishing Venue

Xerox Disclosure Journal

Abstract

An improved liquid resin casting process known as Fibershell Tooling for prototyping and manufacture of piece parts is disclosed. The improvement derives from using a composite fibershell tool or mold that has greater rigidity and chemical resistance than a conventional silicone rubber tool or mold. The fibershell tool provides for high part-to-part tolerance uniformity and dimensional accuracy over larger part volumes than the silicone rubber tool technology. The fibershell tool also enables the use of a wider variety of liquid resin types.

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XEROX DISCLOSURE JOURNAL

FIBERSHELL TOOLING

Proposed Jeffery R. Heath Classification

US. C1. 355/200 Int. C1. G03g 15/00

An improved liquid resin casting process known as Fibershell Tooling for prototyping and manufacture of piece parts is disclosed. The improvement derives from using a composite fibershell tool or mold that has greater rigidity and chemical resistance than a conventional silicone rubber tool or mold. The fibershell tool provides for high part-to-part tolerance uniformity and dimensional accuracy over larger part volumes than the silicone rubber tool technology. The fibershell tool also enables the use of a wider variety of liquid resin types.

The fibershell tooling process comprises:
(1) pouring a mineral filled liquid urethane onto a piece pattern to a uniform thickness and allowing this first urethane layer to partially set-up to a skin consistency at the interface between the piece pattern and the urethane;
(2) saturating fiberglass woven mesh strips with freshly prepared urethane resin;
(3) applying the urethane wet fiberglass strips to the piece pattern "flats" coated with the semi-cured first urethane layers and partially curing;
(4) applying a third layer of fresh liquid urethane resin containing cropped fiberglass fibers to act as a binder for the fiberglass woven mesh; and
(5) forming a shell by applying a fourth layer of fresh liquid urethane resin as a final coating over the third layer and curing.

The fibershell tooling process affor...