Fluid-release mold and the method of manufacturing the same

Claim 2

A fluid-release mold comprising: a preformed, porous mold body having a mold face formed on a first exterior surface and a second surface; at least one narrow groove formed in said second surface; tape covering said groove and attached to said second surface to form a conduit between the surface of said groove and the surface of said tape facing said groove for directing pressurized release fluid to said mold; and a fluid-impermeable backing material disposed over said second surface of said mold body to direct the egress of fluid from said conduit through said mold body in a direction away from said second surface.

Claim 3

A fluid-release mold in accordance with claim 1 wherein said tape is comprised of flexible tape having a width greater than the width of said groove at said second surface of said mold body, said tape being attached to the said second surface of said mold body on both sides of said groove.

Claim 4

A fluid-release mold in accordance with claim 2 wherein said flexible tape is comprised of an aluminum foil tape.

Claim 5

A fluid-release mold in accordance with claim 3 wherein said aluminum foil tape has an adhesive on one of its surfaces for attaching said aluminum foil tape to the second surface of said mold.

Claim 6

A fluid-release mold in accordance with claim 1 wherein said backing material covers substantially all of said second surface of said mold and substantially all of said tape.

Claim 7

A fluid-release mold in accordance with claim 5 wherein said backing material is comprised of a mixture of sand and fine gravel bonded together by an epoxy resin.

Claim 8

A fluid-release mold in accordance with claim 1, 2 or 6 further comprising a metal casing surrounding said mold body and said backing material.

Claim 9

A fluid release mold comprising: a preformed, porous mold body, made from an alumina containing ceramic material fired to a point short of the theoretical density for said material; said preformed mold body having a first exterior surface and a second opposite interior surface; a mold face formed on said first surface and at least one narrow fluid directing groove formed in said second surface; flexible tape covering said groove to form a conduit between the surface of said groove and the surface of said tape facing said groove for directing pressurized release fluid to said mold, said surface of said tape having an adhesive coating for attaching said tape to said second interior surface, said tape having a width greater than the width of said groove at the second interior surface of said mold body wherein said tape is attached to said second interior surface on both sides of said groove; and a fluid impermeable backing material secured to and disposed over substantially the entire interior surface of said mold body to direct egress of fluid said conduit through said mold body in a direction away from said second interior surface, said backing material comprising a mixture of sand and fine gravel bonded together by an epoxy resin.

Claim 10

A fluid release mold comprising: a preformed, porous mold body, made from an alumina containing ceramic material fired to a point short of the theoretical density for said material; said preformed mold body having a first exterior surface and a second opposite interior surface; a mold face formed on said first surface and at least one narrow fluid directing groove formed in said second surface; flexible tape covering said groove to form a conduit between the surface of said groove and the surface of said tape facing said groove for directing pressurized release fluid to said mold, said surface of said tape having an adhesive coating for attaching said tape to said second interior surface, said tape having a width greater than the width of said groove at the second interior surface of said mold body wherein said tape is attached to said second interior surface on both sides of said groove; and a fluid impermeable backing material secured to and disposed over substantially the entire interior surface of said mold body to direct egress of fluid said conduit through said mold body in a direction away from said second interior surface, said backing material comprising a mixture of sand and fine gravel bonded together by an epoxy resin.

Claim 11

A fluid-release mold in accordance with claim 8 wherein said ceramic mold body comprises at least 70% alumina, up to 15% ball clay and up to 15% talc by weight.

Claim 12

A fluid-release mold in accordance with claim 8 wherein the conduit formed by said groove and tape is arranged such that the release fluid supplied to said conduit is conveyed through the mold body to substantially the entire mold face.

Claim 13

A fluid-release mold in accordance with claim 8 wherein said tape is comprised of aluminum foil adhesive tape.

Claim 14

A fluid-release mold in accordance with claim 8 wherein said groove is approximately 3/8 inches wide and said tape is approximately at least 3/4 inches wide.

Claim 17

A method in accordance with claim 13 wherein the step of covering said groove includes applying adhesive tape of a width greater than the width of the groove at the second surface to said second surface on either side of said groove.

Claim 18

A method in accordance with claim 14 wherein said tape is comprised of an aluminum foil tape with an adhesive material applied to one of its surfaces.

Claim 19

A method in accordance with claim 13 wherein the step of covering said mold body includes applying a mixture of sand and fine gravel bonded together by an epoxy resin directly to said second surface and said tape.

Claim 20

A method in accordance with claim 13 wherein the step of covering said mold body includes first applying a layer of relatively liquid epoxy resin to said second surface and thereafter applying a mixture of sand and fine gravel bonded together by an epoxy resin.

Claim 21

A method in accordance with claim 17 wherein the epoxy resin applied to said second surface and the epoxy resin used to bond said sand and fine gravel are the same.

Claim 22

A method in accordance with claim 13 further comprising the step of mounting the mold body and backing material in a metal casing.

Claim 25

A method in accordance with claim 20 wherein said ceramic mold body comprises at least 70% alumina, up to 15% ball clay and up to 15% talc by weight.

Claim 26

A method in accordance with claim 20 further comprising the step of mounting said mold body and said backing material in a metal casing.

Claim 27

A method in accordance with claim 22 further comprising the step of forming a gypsum plaster cap over the back of the resin bonded sand and gravel.

Claim 28

A method in accordance with claim 20 further comprising the step of applying a layer of liquid epoxy resin to said second surface and said tape prior to covering said second surface with said resin bonded sand and gravel.

Claim 29

A method in accordance with claim 24 wherein the same epoxy resin is used for application to said second surface and for bonding said sand and gravel.