Rapid dissolution cavity forming structure for injection molded structures

Abstract

A method of molding an article includes: positioning a soluble insert within a mold; filling the mold with material to form an article surrounding the soluble insert within the mold; and dissolving the soluble insert at least partially from within the article. The soluble insert forms the internal feature structure of the article and includes a porous core.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 125,032, filed on December 14, 2020, the entire contents of which are incorporated herein by reference. Background Technology 1. Technical Field

[0004] This disclosure relates to injection molding, and more specifically, to injection molding structures having internal cavities. Furthermore, a method for injection molding internal cavities is also disclosed.

[0005] 2. Discussion of related technologies

[0006] Additive manufacturing has become an important tool for product development and production. However, additive manufacturing has always been limited by the limited availability of materials compatible with additive manufacturing technology.

[0007] Some manufacturers have begun exploring ways to combine additive manufacturing with casting and molding technologies. For example, molds or castings can be produced using additive manufacturing techniques and used to mold products made from materials incompatible with additive manufacturing. In some applications, additive manufacturing has been used to produce inserts for molds or castings, replacing aluminum or steel inserts. Additively manufactured inserts can reduce the preparation time required to modify inserts to incorporate design changes.

[0008] In some applications, additively manufactured molds, castings, or inserts are durable and can be used for multiple molding or casting cycles. Such durable molds, castings, or inserts can be used to produce large quantities of the same parts, allowing for high-speed manufacturing and a wide selection of available thermoplastic materials.

[0009] In other applications, additive manufacturing molds, castings, or inserts are sacrificial or disposable, meaning they disassemble after molding or casting a single product. Such molds, castings, or inserts can allow the manufacture of complex objects with geometries that are difficult or impossible to mold using durable molds. Disassembly of such molds, castings, or inserts can take hours or days. Summary of the Invention

[0010] This disclosure relates generally to molds, castings, and inserts, including a lattice core, to reduce the disassembly time required after use of the mold, casting, or insert. The mold, casting, and insert can be manufactured using additive manufacturing techniques to provide internal flow paths, thereby allowing disassembly fluid to flow through these paths. The lattice core or internal flow paths can increase the surface area in contact with the disassembly fluid, thereby reducing the required disassembly time for the mold, casting, or insert.

[0011] According to embodiments of this disclosure, a method of molding an article includes: positioning a soluble insert within a mold; filling the mold with material to form an article surrounding the soluble insert within the mold; and dissolving the soluble insert at least partially from within the article. The soluble insert forms the internal feature structure of the article and includes a porous core.

[0012] In one embodiment, dissolving a soluble insert at least partially from within an article includes placing the article having the soluble insert in a pool of water. Dissolving the soluble insert at least partially from within the article may include allowing fluid to flow through a porous core of the soluble insert. Dissolving the porous core may cause the outer surface of the soluble insert to collapse or disintegrate. Allowing fluid to flow through the porous core body may include allowing fluid to flow through channels formed through the soluble insert.

[0013] In some embodiments, the method may include forming a dissolvable insert via additive manufacturing. Forming the dissolvable insert may include forming a porous core with a lattice structure to support the outer surface of the dissolvable insert. The outer surface may form internal feature structures of the article.

[0014] In some embodiments, the method may include forming a soluble insert from a soluble resin. The soluble resin may include polyacrylic acid (PAA), polylactic acid (PLA), polyethylene glycol (PEG), mixtures of acrylic acids, or combinations thereof.

[0015] In a particular embodiment, the method includes cooling an article within a mold by causing a cooling medium to flow through a flow channel defined by a soluble insert. The cooling medium can dissolve the soluble insert and cool the article surrounding the soluble insert.

[0016] In an embodiment, filling the mold with material includes injecting the material into the mold. Injecting the material into the mold may include injecting the material at a high temperature and / or pressure, such that the material fills any voids within the mold and between the mold and the insert.

[0017] In some embodiments, filling a mold with material includes: the resulting article is a fluid processing component having a body and at least one internal feature structure formed by a soluble insert defined within the body.

[0018] In some embodiments, filling the mold with material includes filling the mold with a thermoplastic polymer or a thermosetting polymer. Filling the mold may include filling the mold with polyolefins, thermoplastic elastomers (TPE), polycarbonate (PC), polyethylene terephthalate (PET), silicone, polyurethane, polyurea, fluororubber, or combinations thereof.

[0019] In another embodiment of this disclosure, a soluble insert for forming internal feature structures of a molded article includes an outer surface and a porous core. The outer surface is configured to form the internal feature structures of the molded article. The porous core body is located within the outer surface and is configured to support the outer surface such that the outer surface is rigid. The outer surface and the porous core are formed of a soluble resin configured to dissolve after an article is formed around the outer surface.

[0020] In this embodiment, the outer surface acts as a barrier to prevent material flowing through the mold from entering the porous core. The porous core may include a lattice structure. The lattice structure may include open cell structures configured to provide structural support for the outer surface. The lattice structure may form an open mesh frame defining multiple voids.

[0021] In some embodiments, the dissolvable insert includes flow channels defined by a porous core. The flow channels may be configured to allow fluid to flow through the porous core. The dissolvable resin forming the dissolvable insert may include polyacrylic acid (PAA), polylactic acid (PLA), polyethylene glycol (PEG), acrylic blends, or combinations thereof.

[0022] According to another embodiment of this disclosure, a method of molding an article includes: positioning a soluble insert within a mold; filling the mold with material to form an article around the soluble insert within the mold; and dissolving the soluble insert at least partially from within the article. The soluble insert includes a porous core within an outer surface or outer skin forming internal feature structures of the article.

[0023] In one embodiment, dissolving the soluble insert at least partially from within the article includes placing the article having the soluble insert in a pool of water. Alternatively or additionally, dissolving the soluble insert at least partially from within the article may include allowing fluid to flow through a porous core of the soluble insert. Allowing fluid to flow through the porous core body may include allowing fluid to flow through channels formed through the soluble insert.

[0024] In some embodiments, the method may include forming a dissolvable insert via additive manufacturing. Forming the dissolvable insert may include forming a porous core with a lattice structure to support the outer surface of the dissolvable insert. The outer surface may form internal feature structures of the article.

[0025] In some embodiments, the method includes forming a soluble insert from a soluble resin. Forming a soluble insert from a soluble resin may include: the soluble resin comprising polyacrylic acid (PAA), polylactic acid (PLA), polyethylene glycol (PEG), a mixture of acrylic acids, or a combination thereof.

[0026] In a particular embodiment, the method includes cooling an article within a mold by means of flowing a cooling medium through a flow channel defined by a soluble insert. Flowing fluid through the flow channel can dissolve the soluble insert and cool the article surrounding it.

[0027] In embodiments, filling a mold with material includes injecting material into the mold. Filling a mold with material may include forming a fluid-handling component having a body and at least one internal feature structure formed by a soluble insert within the body. Filling a mold with material may include filling the mold with a thermoplastic or thermosetting polymer. The material may be filled with polyolefins, thermoplastic elastomers (TPE), polycarbonate (PC), polyethylene terephthalate (PET), silicone, polyurethane, polyurea, fluororubber, or combinations thereof.

[0028] In another embodiment of this disclosure, a dissolvable insert for forming internal feature structures of a molded article includes an outer surface and a porous core. The outer surface is configured to form internal feature structures of the molded article. The porous core body located within the outer surface is configured to support the outer surface, such that the outer surface is rigid. The outer surface and the porous core are formed of a dissolvable resin configured to dissolve after the molded article is formed around the outer surface.

[0029] In an embodiment, the outer surface acts as a barrier to prevent material from entering the porous core. The porous core may include a lattice structure. The lattice structure may include an open cell structure configured to provide structural support for the outer surface. The lattice structure may form an open mesh framework defining a plurality of voids. The dissolvable insert may include flow channels defined through the porous core, the flow channels being configured to allow fluid to flow through the porous core. The flow channels may direct fluid to one or more segments defined within the insert. Directing the liquid to one or more segments defined within the insert may reduce the time required to dissolve the insert. The dissolvable resin may include polyacrylic acid (PAA), polylactic acid (PLA), polyethylene glycol (PEG), acrylic blends, or combinations thereof.

[0030] Using dissolvable inserts allows articles to be integrally formed with complex internal features. Integral forming of articles can increase the strength of the finished product and / or eliminate seams or mating lines between parts of the article. Dissolvable inserts define internal features within the molded article in ways that would be impossible without them. For example, dissolvable inserts can form internal features that are inaccessible to conventional mandrels that must be removed through openings in the finished molded article. Dissolvable inserts with porous cores reduce the amount of time required to dissolve the insert compared to inserts with solid cores.

[0031] Furthermore, within the scope of this document, any embodiment or aspect described herein may be used in conjunction with any or all other embodiments or aspects described herein. Attached Figure Description

[0032] Various aspects of this disclosure will be described below with reference to the accompanying drawings, which are incorporated in and form part of this specification, wherein:

[0033] Figure 1 This is a flowchart of a method for forming an article according to an embodiment of the present disclosure;

[0034] Figure 2 This is a side view of a portion of a mold provided according to an embodiment of the present disclosure;

[0035] Figure 3 yes Figure 2 A side view of the mold, in which the insert is received within the mold;

[0036] Figure 4 yes Figure 2 A perspective view of the mold in which the product is molded. Figure 4 On the insert;

[0037] Figure 5 yes Figure 4 A perspective view of the product, in which the insert has been removed;

[0038] Figure 6 yes Figure 5 A cross-sectional perspective view of the product, showing the internal ribs formed during the molding process;

[0039] Figure 7 This is a perspective view of a mold insert provided according to an embodiment of the present disclosure;

[0040] Figure 8 yes Figure 7 A sectional perspective view of the mold insert;

[0041] Figure 9 This is a perspective view of a fluid processing component provided according to an embodiment of the present disclosure;

[0042] Figure 10 It is provided according to an embodiment of the present disclosure for forming Figure 9 A perspective view of the insert of the internal feature structure of the fluid handling component;

[0043] Figure 11 This is provided according to an embodiment of the present disclosure for the use of Figure 10 Insert formation Figure 9 A perspective view of the mold assembly of the fluid handling component; and

[0044] Figure 12 It is along Figure 11 The section line 12-12 is cut off Figure 11 Cross-sectional view of the mold assembly. Detailed Implementation

[0045] The present disclosure will now be described more fully with reference to the accompanying drawings, wherein similar reference numerals denote the same or corresponding elements in each of the several views. These exemplary embodiments have been described in order to make the present disclosure thorough and complete and to fully convey the scope of the disclosure to those skilled in the art. Features from one embodiment or aspect may be combined with features from any other embodiment or aspect in any suitable combination. For example, any individual or common feature of a method aspect or embodiment may be applied to an apparatus, product, or component aspect or embodiment, and vice versa. The present disclosure may be embodied in many different forms and should not be construed as being limited to the embodiments described herein; rather, these embodiments are provided to enable the present disclosure to meet applicable legal requirements. In the specification and appended claims, the singular forms “a,” “the,” “described,” etc., include plural references unless the context clearly specifies otherwise. Furthermore, while quantitative measures, numerical values, geometric relationships, or the like may be referenced herein, any one or more (if not all) of these may be absolute or approximate to account for acceptable variations that may occur, such as those due to manufacturing or engineering tolerances or similar reasons, unless otherwise stated.

[0046] Now for reference Figures 1-4 According to one embodiment of this disclosure, a method for molding a product is disclosed, generally referred to as method 400. Method 400 includes selecting or providing a mold 10 having a void 20 that defines the outer surface of a product or article to be molded therein (step 310). The mold 10 includes one or more inflow channels 30 extending from the outer surface of the mold to communicate with the void 20. The mold 10 may include one or more outflow channels 40 that allow air and / or excess material to exit the void 20 during the filling process of the mold 20.

[0047] Special Reference Figure 3 Method 300 may include positioning the insert 100 within the gap 20 (step 320). The insert 100 has an outer surface 110 that defines an inner surface of the product to be molded. For example, the insert 100 may include a recess 120 that represents a rib to be formed in the molded product. In some embodiments, the outer surface 110 of the insert 100 may include protrusions or ribs (not shown) that define indentations or grooves on the inner surface of the product to be molded.

[0048] The insert 100 may also include an end portion 130 that blocks or seals the portion of the gap 20. The end portion 130 may include locator features, such as a locator ring 150, for positioning the insert 100 within the gap 20. The gap 20 may include retaining features, such as a retaining ring 50, sized and dimensioned to match the locator ring 150 for positioning the insert 100 within the gap 20. The locator ring 150 and / or the retaining ring 50 may include clocking features and / or orientation features for positioning the insert 100 within the gap 20. The clocking features may align or rotatably orient the insert 100 within the gap 20. The orientation features may orient the insert 100 within the gap 20. For example, one locator ring 150 may be larger than another locator ring 150, and the retaining ring 50 of the gap 20 may be sized similarly, such that the insert 100 can only be received in one orientation within the gap 20.

[0049] When the insert 100 is positioned within the cavity 20 of the mold 10, the mold 10 is closed, for example, by fixing a second side of the mold 10 to a first side to close the mold (step 330). As the mold 10 closes, material flows into the cavity 20 through the inflow channel 30 (step 340). The material flowing into the cavity 20 can fill the cavity and exit the mold 10 through the outflow channel 40. The material flowing out of the outflow channel 40 indicates that the cavity 20 is full. Material can be injected into the mold 10 such that the material flows within and through the cavity 20. The material may be selected from thermoplastic polymers, such as polyolefins, thermoplastic elastomers (TPE), polycarbonate (PC), or polyethylene terephthalate (PET), or thermosetting polymers, such as silicone, polyurethane, polyurea, or fluororubber. The material may be one or more thermoplastic polymers or a combination of one or more thermosetting polymers.

[0050] When the void 20 is filled, material is allowed to cool within the mold 10 (step 350). In some embodiments, fluid may flow through the insert 100 to cool the material within the void 20. For example, the insert 100 may include a flow channel 160 extending through the insert 100 to allow cooling fluid to flow through the insert 100.

[0051] Now for reference Figure 4Once the material within the gap 20 has cooled, the mold 10 is opened to provide access to the product 200. The product 200 is formed on the insert 100, which defines the internal cavity and / or internal feature structure of the product 200. The product 200 can be considered as the overmold of the insert 100. When the mold 10 is opened, the insert 100 with the product 200 can be removed from the gap 20 of the mold 10. In some embodiments, the mold 10 can be reused with a new insert to produce another product 200.

[0052] When the insert 100 and product 200 are removed from the mold 10, the insert 100 dissolves or disintegrates, causing the insert 100 to be removed from the internal cavity 210 of the product 200 (step 360). Dissolving or disintegrating the insert 100 may include placing the insert 100 and product 200 in a liquid pool, causing the material of the insert 100 to dissolve or disintegrate without affecting the material of the product 200. In some embodiments, dissolving or disintegrating the insert 100 may include allowing liquid to flow through a flow channel 160 of the insert 100, such that the liquid dissolves or disintegrates the insert 100. In some embodiments, the insert 100 may dissolve before the product 200 is removed from the mold. In particular embodiments, the insert 100 may be dissolved by a cooling fluid flowing through the insert 100.

[0053] As detailed below, insert 100 may include an internal lattice structure 170 or flow channels 160 that increase the surface area of ​​insert 100. Increased surface area of ​​insert 100 can reduce the time required for dissolution or disintegration of insert 100. For example, an insert without flow channels 150 or internal lattice structure 170 may require 24 hours or more to dissolve or disintegrate, while a similar insert with flow channels 150 or internal lattice structure 170 may dissolve or disintegrate in a similar pool in less than an hour. Flow channels 150 or internal lattice structure 170 may be topologically optimized to maximize the flow and strength of insert 100. In some embodiments, flow channels 150 or internal lattice structure 170 may be optimized to generate turbulence within insert 100, thereby increasing the disintegration rate of insert 100. Furthermore, the use of flow channels 150 or internal grid structures 170 can reduce the material requirements for the insert, which can reduce costs, production time, and the amount of liquid required to dissolve the insert 100.

[0054] refer to Figure 5 and Figure 6When the insert 100 is removed from the cavity 210 of the product 200, the final form of the product is revealed. Specifically, the cavity 210 is formed with internal feature structures 220 extending into the cavity 210. The use of a dissolvable insert, such as the insert 100, is also to form internal feature structures that cannot be formed with a non-dissolvable insert.

[0055] refer to Figure 7 and Figure 8 According to one embodiment of this disclosure, a dissolvable insert 100 for a mold is provided. The insert 100 is configured, as detailed above, to be inserted into a mold to define an internal cavity or feature structure of a molded product. The insert 100 includes an outer surface 110 configured to support an inner surface of the molded product (e.g., product 200). The outer surface 110 may include indentations or grooves 120 that define protrusions or ribs on the inner surface of the molded product. Alternatively or additionally, the outer surface 110 may include protrusions or ribs that define indentations or grooves on the inner surface of the molded product. It is understood that the outer surface 110 of the insert 100 is a negative structure of the inner surface of the molded product (e.g., molded product 200).

[0056] Insert 100 includes an end portion 130 configured to support insert 100 within a mold (e.g., mold 10). End portion 130 may include one or more positioning features, such as positioning rings 150, for positioning and supporting insert 100 within the mold. Positioning rings 150 may be sized identically or differently from each other. When positioning rings 150 are sized differently, they may serve as orientation features requiring insert 100 to be received in a specific orientation within the mold. Insert 100 may also include one or more clockwork features that interact with the mold to orient or rotatably orient insert 100 within the mold.

[0057] Special Reference Figure 8 The insert 100 includes a porous core 140. The porous core 140 is enclosed within the insert 100 such that when the insert 100 is received within a mold (e.g., mold 10), the voids in the porous core 140 relative to the mold are sealed, thereby preventing material flowing into the mold to form the product from flowing into the porous core 140. The outer surface 110 of the insert 100 can act as a barrier to prevent material flowing into the mold from flowing into the porous core 140.

[0058] The porous core 140 may include a lattice structure 170 that supports the outer surface 110 of the insert 100, such that the outer surface 110 and the insert 100 are substantially rigid as a whole. The lattice structure 170 forms an open unit structure and is configured to provide structural support for the outer surface 110 and the insert 100 as a whole. The lattice structure 170 is composed of multiple members or arms forming an open mesh frame. The lattice structure 170 defines multiple openings or gaps between all adjacent arms. Arms may be cylindrical with a circular cross-section, or may have triangular, rectangular, pentagonal, hexagonal, or other polygonal cross-sections. Arms may form open cubic frames, open pyramidal frames, or other open frames. The gaps are sized to allow fluid flow through the lattice structure 170. The lattice structure 170 may be formed by an additive manufacturing process, such as 3D printing.

[0059] The lattice structure 170 may define flow channels 160 extending through the porous core 140. The flow channels 160 may disperse fluid through the porous core 140. In some embodiments, the flow of fluid through the flow channels 160 may cool material surrounding the outer surface 110. In some embodiments, the flow channels may allow fluid to flow through the porous core 140 to reduce the dissolution or disintegration time of the insert 100.

[0060] The entire insert 100 is formed of a soluble resin such that, after the product is molded on the insert 100, the entire insert 100 can be dissolved from within the product, leaving an internal cavity or feature structure defined by the outer surface 110 of the insert 100. The insert 100 may be formed of a water-soluble resin such that the insert 100 and the product can be placed in a pool of water to dissolve the insert 100. Examples of suitable materials for the insert 100 include, but are not limited to, polyacrylic acid (PAA), polylactic acid (PLA), polyethylene glycol (PEG), acrylic blends, and combinations thereof. In some embodiments, water may flow through the insert 100 to dissolve the insert 100. In particular embodiments, the material of the insert 100 may be formed of a material miscible with another fluid, such that the other fluid flows through the insert 100 to dissolve the insert 100. It is understood that the fluid used to dissolve the insert 100 should not react with the material forming the product 200, such that the fluid dissolves the insert 100 without reacting with the product 200.

[0061] Using a lattice structure 170 to form the porous core 140 can reduce the amount of material required to form the insert 100. Reducing the amount of material required to form the insert 100 can reduce the time required to dissolve the insert 100.

[0062] Now for reference Figure 9According to one embodiment of this disclosure, a fluid handling component, generally referred to as a fluid connector 400, is provided. The fluid connector 400 includes an input connector 410, a manifold 420, and a plurality of output connectors 430. The input connector 410 and the output connectors 430 may include barbs 412, 432 to secure fluid conduits to the respective input connector 410 or output connector 430 of the fluid connector 400.

[0063] See again Figure 10 According to one embodiment of this disclosure, an insert 500 is provided, which includes an input section 510, a manifold section 520, and an output section 530. As detailed below, the insert 500 is configured to form the inner surface and feature structures of a fluid connector 400 during a molding process; for example, the method 300 detailed above. The insert 500 includes an internal lattice structure 504 ( Figure 12 The outer surface or skin 502 of the insert 500 is supported. The outer surface 502 may be formed by the outer surfaces of the input section 510, the manifold section 520 and the output section 530, as detailed below.

[0064] During the molding process, the input segment 510 includes an outer surface 512 positioned within the mold to define the inner surface and internal features of the input connector 410. The manifold segment 520 includes an outer surface 522 positioned within the mold to define the inner surface and internal features of the manifold 420. The output segment 530 includes an outer surface 532 positioned within the mold to define the inner surface and internal features of the output connector 430. The segments 510, 520, and 530 of the insert 500 can be formed integrally as shown, or they can be formed as separate components, which are separately fixed within the mold. The entire insert 500 can be formed using additive manufacturing techniques, such as 3D printing, so that the insert 500 is integrally formed. The insert 500 can be formed of a solvent-soluble resin, allowing a fluid (e.g., water) to flow through the insert 500 to dissolve it.

[0065] Within the outer skin 502 of the insert 500 is a lattice structure 504 supporting the outer skin 502. The lattice structure 504 has multiple voids and can form one or more fluid channels through which fluid flows. The lattice structure 504 reduces the amount of material required to form the insert 500. Reducing the amount of material reduces the amount of time it takes for the insert 500 to dissolve from within the fluid connector 400 after the fluid connector is formed on the outer skin 502 of the insert 500. In some embodiments, the lattice structure 504 can promote turbulence within the insert 500 to reduce the amount of time it takes for the insert 500 to dissolve. In some embodiments, the fluid channels within the lattice structure 504 can promote fluid flow to specific portions of the insert 500 to reduce the amount of time it takes for the insert 500 to dissolve.

[0066] Now for reference Figure 11 and Figure 12 According to one embodiment of this disclosure, a mold assembly 600 is provided. The mold assembly 600 includes a mold 602, a fluid connector 400, an insert 500, and core pins 606, 608. The mold 602 defines the outer surface of the fluid connector 400 and may be formed from one or more portions. As shown, the mold 602 has an input portion 610, a manifold portion 620, and an output portion 630. The portions 610, 620, and 630 are connected together to form the mold 602, such that a cavity 603 of the mold 602 defines the outer surface of the fluid connector 400. Specifically, the input portion 610 forms the outer surface of the input connector 410, the manifold portion 620 forms the outer surface of the manifold 420, and the output portion 630 forms the outer surface of the output connector 430. As shown, the input portion 610 and the output portion 630 are integrally formed, and the manifold portion 620 is formed from two segments. In some embodiments, each portion of the mold 602 may be formed by one or more segments connected together to form a corresponding portion, thereby defining a cavity 603. In some embodiments, the mold 602 may have a single portion, two portions, or more than three portions connected together to form the mold 602 and define its cavity 603.

[0067] For details, please refer to the following: Figure 12The mold assembly 600 includes core pins 606 and 608. Core pins 606 and 608 are received within a cavity 603 of the mold 602 to seal the cavity 603 and position the insert 500 within the cavity 603. As shown, the mold assembly 600 includes a single input core pin 606, which is received in an input portion 610 of the mold 602 and engages with an input segment 510 of the insert 500. The engagement between the input core pin 606 and the input segment 510 positions the input segment 510 to the cavity 603 (e.g., coaxially aligned) such that the gap between the input segment 510 and the input portion 610 defines a space for receiving material to form the input connector 410 of the fluid connector 400. In some embodiments, a portion of the input core pin 606 may form part of the inner surface of the input connector 410. Similarly, the output core pin 608 can be received in the output portion 630 of the mold 602 to engage and position the output segment 530 of the insert 500 within the cavity 603 of the mold 602. As shown, the mold assembly 600 includes an output core pin 608 for each output connector 430 of the fluid connector 400. Each output core pin 608 seals a portion of the cavity 603 and engages with the output segment 530 to position the insert 500 within the cavity 603, thereby forming a gap or space between the output segment 530 and the output portion 630 of the mold 602, which defines the output connector 430 of the fluid connector 400. Furthermore, the engagement between the input core pin 606 and the output core pin 608 positions the manifold segment 520 of the insert 500 within the manifold portion 630 of the mold 602 to form a gap or space therebetween, which defines the manifold 430 of the fluid connector 400. In some embodiments, a portion of the output core pin 602 defines a portion of the output connector 430. Although not explicitly shown, the mold 602 may include one or more input channels, such as inflow channel 30. Figure 3 ), and may include one or more outflow channels, such as outflow channel 40 ( Figure 3 This facilitates the flow of material into the cavity 603 of the mold 602 to form the fluid connector 400.

[0068] The above description of the mold assembly for forming fluid handling components pertains to the mold assembly 600 for forming the fluid connector 400 using mold 602, insert 500, and core pins 606, 608. It is understood that other fluid components and general components can be injection molded using similar components and methods. Specifically, components that cannot be formed by injection molding due to internal structural features or cavities can be formed using similar components, including one or more inserts that are dissolvable after the component is molded around the inserts. Forming inserts with porous, dissolvable cores, such as inserts with an internal lattice structure, can reduce material usage and / or the time required to dissolve the inserts. It is understood that each insert 500 is a single-use component and will be dissolved after a single use. In some embodiments, the entire mold 602, portions of the mold 602, or core pins 606, 608 may be single-use or reusable.

[0069] While several embodiments of the invention are illustrated in the accompanying drawings, this is not intended to limit the invention thereto, as the intent of the invention is to expand its scope to the extent permitted by technology, and the specification thereof is read in the same manner. Any combination of the above embodiments is also conceivable and falls within the scope of the appended claims. Therefore, the above description should not be construed as restrictive, but merely as illustrative of particular embodiments. Those skilled in the art will envision other modifications within the scope of the appended claims.

Claims

1. A method for molding an article, the method comprising: A soluble insert is positioned within a mold, the soluble insert comprising a porous core, the porous core being closed and sealed relative to the mold's voids through the outer surface of the soluble insert, the soluble insert being integrally formed; The mold is filled with material to form an article within the mold surrounding the soluble insert, such that the soluble insert forms the internal feature structure of the article; The soluble insert is at least partially dissolved from the article by means of allowing fluid to flow through a flow channel defined by the soluble insert; as well as The dissolvable insert is formed via additive manufacturing technology. The porous core has a lattice structure to support the outer surface of the dissolvable insert. The lattice structure is optimized to generate turbulence when fluid flows through the porous core. The outer surface forms the internal feature structure of the article. as well as The article within the mold is cooled by allowing fluid to flow through the flow channel defined by the soluble insert.

2. The method of claim 1, wherein dissolving the soluble insert at least partially from the article comprises placing the article having the soluble insert in a pool of water.

3. The method of claim 1, wherein dissolving the soluble insert at least partially from the article comprises allowing fluid to flow through the porous core of the soluble insert.

4. The method of claim 3, wherein flowing fluid through the porous core body comprises flowing fluid through a channel formed by the soluble insert.

5. The method of claim 2, wherein dissolving the soluble insert at least partially in the water tank comprises dissolving the porous core within one hour.

6. The method of claim 1, further comprising forming the soluble insert from a soluble resin.

7. The method of claim 6, wherein forming the soluble insert from the soluble resin comprises: The soluble resin includes polyacrylic acid (PAA), polylactic acid (PLA), polyethylene glycol (PEG), acrylic acid mixtures, or combinations thereof.

8. The method of claim 1, wherein filling the mold with material comprises injecting the material into the mold.

9. The method of claim 1, wherein filling the mold with material comprises: The resulting article is a fluid processing component having a body and at least one of the internal feature structures formed by the soluble insert defined within the body.

10. The method of claim 1, wherein filling the mold with material comprises filling the mold with a thermoplastic polymer or a thermosetting polymer.

11. The method of claim 1, wherein filling the mold comprises filling the mold with a polyolefin, thermoplastic elastomer (TPE), polycarbonate (PC), polyethylene terephthalate (PET), silicone, polyurethane, polyurea, fluororubber, or a combination thereof.

12. A dissolvable insert for forming internal feature structures of a molded article, the dissolvable insert comprising: The outer surface is configured to form the internal feature structure of the molded article; as well as A porous core, located within the outer surface and configured to support the outer surface such that the outer surface is rigid, the outer surface and the porous core being formed of a soluble resin configured to dissolve after the molded article is formed around the outer surface, the porous core having a lattice structure optimized to generate turbulence as fluid flows through flow channels defined by the porous core, and a soluble insert configured to cool the molded article as fluid flows through the flow channels.

13. The soluble insert of claim 12, wherein the outer surface is a barrier for preventing material flowing through the mold from entering the porous core.

14. The dissolvable insert of claim 12, wherein the lattice structure comprises an open cell structure configured to provide structural support for the outer surface.

15. The soluble insert of claim 12, wherein the lattice structure forms an open mesh frame defining a plurality of voids.

16. The soluble insert of claim 12, wherein the soluble resin comprises polyacrylic acid (PAA), polylactic acid (PLA), polyethylene glycol (PEG), an acrylic mixture or a combination thereof.

17. The dissolvable insert of claim 12, wherein the porous core is configured to dissolve the porous core within one hour when fluid flows through the porous core.

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