Devices, methods, and systems involving castings

• US 7,141,812 B2
• Filed: 12/03/2002
• Issued: 11/28/2006
• Est. Priority Date: 06/05/2002
• Status: Expired due to Term

• Current Assignee: Rtx Corporation
• Original Assignee: Mikro Systems, Inc.
• Inventors: Fraser, Iain, Atkinson, James E., Appleby, Michael
• Primary Examiner(s): Vanore, David A.
• Application Number:
  US10/308,545
• Publication Number:
  US 20030235272A1
• Time in Patent Office: 1,456 Days
• Field of Search: 250/505.1, 378/147, 378/149, 378154-155
• US Class Current: 250/505.1
• CPC Class Codes: B29C 33/302 Assembling a large number of mould elements to constitute one cavity
• CPC Class Codes: B29C 33/3842 Manufacturing moulds, e.g. shaping the mould surface by machining
• CPC Class Codes: B29C 33/42 characterised by the shape of the moulding surface, e.g. ribs or grooves
• CPC Class Codes: B29C 39/021 by casting in several steps
• CPC Class Codes: B29C 39/34 for undercut articles
• CPC Class Codes: B29C 69/001 a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts for reinforced material B29C70/545; B29C49/4278, B29C51/268 take precedence
• CPC Class Codes: B29K 2083/00 Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as moulding material
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: G21K 1/02 using diaphragms, collimators
• CPC Class Codes: G21K 1/025 using multiple collimators, e.g. Bucky screens; other devices for eliminating undesired or dispersed radiation

Abstract

Certain exemplary embodiments comprise a device comprising a cast collimator derived from a metallic foil stack lamination mold, said collimaxor defining a feature adapted to contain a plurality of radiation detection elements. In certain embodiments, the collimator can define a feature adapted to contain a plurality of radiation detection elements, such as scintillators. Certain exemplary embodiments comprise a device comprising a cast component derived from a metallic foil stack lamination mold. In various exemplary embodiments, the cast components can be a mechanical, electrical, electronic, optical, fluidic, biomedical, and/or biotechnological component.

Claims

1. A device, comprising a collimator comprising a collimator surface comprising a layered plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said layered plurality of 3-dimensional micro-features comprising at least one protruding undercut, said collimator defining a feature adapted to contain a plurality of scintillators, wherein said collimator comprises a ceramic.

2. A device, comprising a component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component having an aspect ratio of greater than 25:

1, said component defining a feature having a dimension of less than 4 centimeters, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

3. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component having an aspect ratio of greater than 25:

1, said component defining a feature having a dimension of less than 3 centimeters, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

4. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component having an aspect ratio of greater than 25:

1, said component defining a feature having a dimension of less than 2 centimeters, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

5. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component having an aspect ratio of greater than 25:

1, said component defining a feature having a dimension of less than 1 centimeter, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

6. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component having an aspect ratio of greater than 25:

1, said component defining a feature having a dimension of less than 500 microns, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

7. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component having an aspect ratio of greater than 25:

1, said component defining a feature having a dimension of less than 250 microns, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

8. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component defining a feature having a dimension of less than 200 microns, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

9. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component defining a feature having a dimension of less than 150 microns, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

10. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component defining a feature having a dimension of less than 100 microns, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

11. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component defining a feature having a dimension of less than 50 microns, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

12. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component defining a feature having a dimension of less than 25 microns, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

13. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component defining a feature having a dimension of less than 20 microns, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

14. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component defining a feature having a dimension of less than 15 microns, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

15. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component defining a feature having a dimension of between approximately 4 centimeters and approximately 30 centimeters, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

16. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, said component defining a feature having a dimension of greater than 4 centimeters, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.

17. A device, comprising a cast component comprising a plurality of component surfaces, a component surface from said plurality of component surfaces comprising a plurality of 3-dimensional micro-features that substantially spatially invertedly replicate a mold surface formed by a plurality of layers of a metallic foil stack lamination parent mold, said plurality of 3-dimensional micro-features comprising at least one protruding undercut, having an aspect ratio of greater than 25:

1, wherein a selected cross-section of said component, taken substantially parallel to said component surface, defines a cross-sectional surface that intersects a subset of said plurality of component surfaces and is not comprised by said plurality of component surfaces, and wherein a central area of said cross-sectional surface comprises a majority of said cross-sectional surface, said central area not intersecting any of said plurality of component surfaces, said central area not geometrically evidencing the plurality of layers of the metallic foil stack lamination parent mold.