Injection mold and injection molding method

Abstract

The application discloses an injection mold and an injection method, relates to the technical field of injection molding, and the injection mold comprises a mold main body, a cooling channel and at least two temperature adjusting devices. The cavity of the mold main body has at least two temperature control regions with different thicknesses, and the outer side of each temperature control region is provided with a cooling channel; the cooling channels cool the corresponding temperature control regions respectively. The temperature adjusting device comprises a temperature detecting piece and a temperature adjusting piece; the temperature detecting piece is used for detecting the temperature of the corresponding temperature control region; and the temperature adjusting piece is used for heating or cooling the corresponding temperature control region according to the detected temperature of the temperature detecting piece. The injection mold provided by the application is provided with the cooling channel and the temperature adjusting device corresponding to the temperature control region, so that the temperature control region can be independently detected and adjusted in temperature, the molding requirements of different temperature control regions can be met, and the technical problem that molding defects are prone to occurring when the overall cooling cavity of the injection mold cools the cavity is solved.

Description

Technical Field

[0001] This application relates to the field of injection molding technology, and more particularly to injection molds and injection methods. Background Technology

[0002] The primary function of a server's air duct is to regulate airflow within the chassis, guiding cool air through heat-generating components such as the Central Processing Unit (CPU), graphics card, and hard drive, while simultaneously preventing hot air from flowing back, thereby improving the overall heat dissipation efficiency of the server. The air duct is formed using injection molding. During the molding process, a cooling medium at a uniform temperature flows through cooling channels within the mold body to cool the cavity. In related technologies, injection molds can only cool the cavity through the cooling medium flowing through an integrated cooling chamber. However, because the wall thickness of the air duct varies at different locations, using an integrated cooling chamber to cool areas with different wall thicknesses within the cavity can easily lead to molding defects in the air duct. Summary of the Invention

[0003] This application provides an injection mold and an injection method to at least solve the technical problem in the related art that integral cooling chambers in injection molds can easily cause molding defects when cooling the cavity.

[0004] This application provides an injection mold, comprising:

[0005] A mold body, wherein the mold body has a cavity, and the cavity has at least two temperature control zones with different thicknesses;

[0006] Cooling channels are provided inside the mold body, and at least one cooling channel is provided on the outside of each temperature control area. The cooling channels are used to cool the corresponding temperature control areas respectively.

[0007] At least two temperature regulating devices are provided, each corresponding to a temperature control area. Each temperature regulating device includes a temperature detection element and a temperature regulating element. The temperature detection element is used to detect the temperature of the corresponding temperature control area. The temperature regulating element is located on the mold body at a position corresponding to the temperature control area. The temperature regulating element is used to heat or cool the corresponding temperature control area according to the temperature detected by the temperature detection element, so as to adjust the temperature of the corresponding temperature control area to the corresponding target temperature.

[0008] The injection mold and injection method provided in this application involve setting up a cavity with multiple temperature-controlled zones of varying thicknesses. Each temperature-controlled zone is equipped with a cooling channel and a temperature regulating device. The temperature regulating device includes a temperature sensor for detecting the temperature of the corresponding temperature-controlled zone, and a temperature regulating device for heating or cooling the temperature-controlled zone based on the detected temperature. Therefore, each temperature-controlled zone can independently detect and regulate its temperature, thereby meeting the temperature requirements of temperature-controlled zones of different thicknesses and helping to reduce injection molding defects. Thus, the injection mold of this application solves the technical problem in related technologies where integral cooling chambers easily lead to molding defects during cavity cooling. Attached Figure Description

[0009] To more clearly illustrate the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0010] Figure 1 This is a schematic diagram of the structure of the injection mold provided in the embodiments of this application;

[0011] Figure 2 for Figure 1 A schematic diagram showing the positional relationship between the various temperature control zones and temperature control devices within the interior.

[0012] Figure 3 A schematic diagram showing the connection relationship of each component in the temperature control device provided in the embodiments of this application;

[0013] Figure 4 A flowchart of the injection molding method provided in the embodiments of this application;

[0014] Figure 5 This is a schematic diagram of the exponential decay curve of the holding pressure along the flow direction provided in the embodiments of this application.

[0015] The above figures include the following reference numerals:

[0016] 100-Mold body; 110-Fixed mold; 120-Moving mold; 130-Cavity; 140-Temperature control zone; 141-First temperature control zone; 142-Second temperature control zone; 143-Third temperature control zone; 150-Mounting slot; 160-Separation slot; 170-Gating area;

[0017] 200-Cooling Channel;

[0018] 300 - Temperature control device; 310 - Temperature detection element; 320 - Temperature control element; 330 - Controller. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of this application.

[0020] It should be noted that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. The terms "installed," "connected," and "linked" should be interpreted broadly, for example, they can be fixed connections, detachable connections, or integral connections; they can be mechanical connections or electrical connections; they can be direct connections or indirect connections through an intermediate medium; they can be internal connections between two elements. The terms "parallel," "perpendicular," and "equal" include the described situation and situations similar to the described situation, the range of which is within an acceptable deviation range, wherein the acceptable deviation range is determined by those skilled in the art taking into account the measurement under discussion and the error associated with the measurement of a particular quantity (i.e., the limitations of the measurement system). For example, "parallel" includes absolute parallelism and approximate parallelism, where an acceptable deviation range for approximate parallelism can be, for example, within 5°; "perpendicular" includes absolute perpendicularity and approximate perpendicularity, where an acceptable deviation range for approximate perpendicularity can also be, for example, within 5°. "Equal" includes absolute equality and approximate equality, where an acceptable deviation range for approximate equality can be, for example, a difference between the two equal items being less than or equal to 5% of either one. Those skilled in the art will understand the specific meaning of the above terms in this application based on the specific circumstances.

[0021] To enable those skilled in the art to better understand the present application, the present application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0022] In related technologies, injection molds typically have only one integral cooling chamber, through which a cooling medium of uniform temperature flows to cool the entire cavity. However, due to the varying wall thicknesses at different locations within the air guide, the solidification process of the injection molded material in areas of different wall thicknesses is difficult to synchronize. Using an integral cooling chamber to simultaneously cool areas of different wall thicknesses within the cavity can easily lead to molding defects in the air guide.

[0023] Based on this, this application provides an injection mold and an injection method. The injection mold divides at least two temperature control areas 140 with different thicknesses within the cavity 130 of the mold body 100, and sets up cooling channels 200 and temperature adjustment devices 300 corresponding to each temperature control area 140. The temperature of the corresponding area is detected by a temperature detection element 310, and the temperature adjustment element 320 heats or cools the temperature control area 140 according to the detected temperature, so as to adjust the temperature of each temperature control area 140 to the corresponding target temperature, thereby improving the molding effect of the injection mold on parts with different molding areas such as air guides, and thus solving the technical problem that the simultaneous cooling of areas with different wall thicknesses in the cavity 130 by the overall cooling cavity can easily lead to molding defects in the air guide.

[0024] like Figure 1 and Figure 2 As shown, the injection mold of this embodiment includes a mold body 100, a cooling channel 200, and at least two temperature regulating devices 300. The mold body 100 has a cavity 130, and the cavity 130 has at least two temperature-controlled areas 140 with different thicknesses. The cooling channel 200 is disposed within the mold body 100, and at least one cooling channel 200 is provided on the outer side of each temperature-controlled area 140, with each cooling channel 200 cooling its corresponding temperature-controlled area 140.

[0025] At least two temperature regulating devices 300 are configured one-to-one with the temperature control zone 140. Each temperature regulating device 300 includes a temperature sensing element 310 and a temperature regulating element 320. The temperature sensing element 310 is used to detect the temperature of the corresponding temperature control zone 140. The temperature regulating element 320 is located on the mold body 100 at a position corresponding to the temperature control zone 140. The temperature regulating element 320 is used to heat or cool the corresponding temperature control zone 140 according to the temperature detected by the temperature sensing element 310, so as to adjust the temperature of the corresponding temperature control zone 140 to the corresponding target temperature.

[0026] The injection mold provided in this application has multiple temperature control zones 140 of different thicknesses in the cavity 130. Each temperature control zone 140 is equipped with a cooling channel 200 and a temperature regulating device 300. The temperature regulating device 300 has a temperature sensing element 310 for detecting the temperature of the corresponding temperature control zone 140, and a temperature regulating element 320 for heating or cooling the temperature control zone 140 according to the detected temperature. Therefore, each temperature control zone 140 can independently detect and regulate its temperature, thereby meeting the temperature requirements of temperature control zones 140 of different thicknesses and helping to reduce injection molding defects. Therefore, the injection mold of this application can solve the technical problem in related technologies where integral cooling chambers easily cause molding defects when cooling the cavity.

[0027] It should be noted that the target temperature in this application does not refer to a fixed temperature point, but rather to a preset temperature range or a temperature range within which fluctuations are allowed. In actual injection molding processes, due to factors such as measurement errors and response delays of the temperature sensing element 310, as well as dynamic changes in heat load during injection molding, the temperature of the temperature control zone 140 is difficult to precisely control at a single fixed temperature point. Therefore, in practical applications, those skilled in the art typically set an allowable temperature range (e.g., target temperature ±1℃, ±2℃, etc.) for each temperature control zone 140 based on the type of injection molding material, the wall thickness distribution of the injection molded product, and the molding precision requirements. When the temperature detected by the temperature sensing element 310 falls within this temperature range, the temperature control zone 140 is considered to have reached the target temperature.

[0028] The mold body 100 in this application is the basic structural part of the injection mold, used to support and install the various functional components of the mold. An injection mold typically consists of two parts: a moving mold 120 and a fixed mold 110. When the moving mold 120 and the fixed mold 110 are closed, they together form the cavity 130. When the mold is opened, the moving mold 120 separates from the fixed mold 110 to allow the molded plastic product to be removed.

[0029] In one possible embodiment, the mold body 100 may be made of mold steel, pre-hardened steel, alloy steel, or a high thermal conductivity metal material. The surface of the cavity 130 may be nitrided, chrome-plated, or polished to meet the requirements of wear resistance, demolding, and heat transfer. The dimensions of the mold body 100 are generally matched with the outer contour of the thin-walled irregularly shaped plastic parts such as the molded air guide shroud. The thickness of the mold body 100 and the dimensions of the local inserts must meet the space requirements for the arrangement of the cooling channel 200, the embedding of the temperature sensing element 310, and the installation of local temperature regulation.

[0030] In this embodiment, the cavity 130 refers to the molding space enclosed by the inner surface of the mold body 100, used to contain molten plastic and shape it into the shape of the target product. The cavity 130 is divided into multiple temperature control zones 140 of different thicknesses to correspond to structural parts on the product with different wall thicknesses, curvatures, or heat capacity requirements. In this application, by incorporating structural parts of different thicknesses into different temperature control zones 140, the cavity 130 allows each zone to be independently temperature-managed according to its own thermal characteristics.

[0031] In this embodiment, the cavity 130 works in conjunction with the feed inlet, venting structure, and ejection mechanism. Its surface morphology can be machined into a plane, curved surface, corner surface, or molding surface corresponding to local reinforcing ribs, depending on the shape of the product. In one possible embodiment, the cavity 130 can be obtained by CNC machining, EDM, or inlay molding. Its partition boundaries can be predetermined based on wall thickness variations, cooling difficulty, and assembly requirements. The area size is usually adapted to the local contour, wall thickness gradient, and heat concentration location of the corresponding plastic part.

[0032] In this application, the temperature control zone 140 refers to an area within the mold cavity 130 that requires independent temperature control, defined according to differences in wall thickness, structural features, and cooling requirements at different locations of the injection molded product. Each temperature control zone 140 is equipped with an independent cooling channel 200 and a temperature regulating device 300, enabling independent detection and regulation of the temperature in that zone.

[0033] Because the wall thickness of injection molded products often varies in different locations, areas with thicker walls cool more slowly and shrink more, while areas with thinner walls cool more quickly and shrink less. If a uniform cooling scheme with an overall cooling cavity is used, the solidification process of the injection molded material in each area is difficult to coordinate, easily leading to molding defects such as shrinkage marks, warpage, and internal stress. Therefore, it is necessary to divide the cavity 130 into different temperature control zones 140 according to the differences in wall thickness, and to independently control the temperature of each temperature control zone 140, so that the cooling rate of each temperature control zone 140 matches the wall thickness, thereby helping to solve the problem of molding defects.

[0034] To facilitate the explanation of the structure and technical effects of the injection mold, the following uses a server air guide shroud as an example. Based on the structural features and wall thickness distribution of the air guide shroud, the cavity 130 in the injection mold can be divided into the following three temperature control zones 140: the first temperature control zone 141, the second temperature control zone 142, and the third temperature control zone 143. Specifically, the first temperature control zone 141 is the thick-walled temperature control zone 140 at the air inlet, the second temperature control zone 142 is the thin-walled curved surface temperature control zone 140 at the air outlet, and the third temperature control zone 143 is the temperature control zone 140 at the base of the clips and reinforcing ribs.

[0035] The first temperature control zone 141 corresponds to the air inlet of the air guide shroud. The air inlet is the airflow entrance and needs to withstand certain airflow impact and installation stress; therefore, it is typically designed as a thick-walled structure. Consequently, the first temperature control zone 141 has a large wall thickness, resulting in a large melt volume and slow heat dissipation. During injection molding, the outer layer of the injection molding material inside the first temperature control zone 141 solidifies first, followed by the inner layer. When the inner melt cools and shrinks, it is difficult to achieve proper shrinkage compensation, easily leading to shrinkage marks. Therefore, this application implements temperature control in the first temperature control zone 141 to delay the freezing of the outer layer and extend the shrinkage compensation time window, thereby helping to reduce the formation of shrinkage marks.

[0036] The second temperature control zone 142 corresponds to the air outlet of the air guide shroud. The air outlet is typically designed as a thin-walled curved structure to optimize airflow guidance. The second temperature control zone 142 has a small wall thickness and a small melt volume, resulting in rapid heat dissipation. While the thin-walled curved region cools quickly, the curved structure is prone to warping due to uneven cooling, and the thin-walled structure lacks rigidity before complete solidification. Therefore, this application implements rapid cooling control for the second temperature control zone 142 to accelerate melt solidification and thus suppress warping.

[0037] The third temperature control zone 143 corresponds to the root location where the clips, reinforcing ribs, and other structures on the air guide shroud connect to the main body. The third temperature control zone 143 is a transition area between thick and thin walls, where the wall thickness changes abruptly. Melt flow is impeded and stress concentration is likely to occur in this transition area. Due to the significant difference in cooling rate between the root of the clips, reinforcing ribs, and other structures and the main body, the melt at the root of these structures contracts during cooling and is constrained by the already solidified portion of the main body, generating tensile stress. This leads to white marks easily appearing at the root of the clips, reinforcing ribs, and other structures. Therefore, this application implements temperature control in the third temperature control zone 143 to gradually release residual stress, thereby reducing the defect of white marks.

[0038] The cooling channel 200 is a flow channel structure used to transfer cooling medium to the corresponding temperature control zone 140 to remove heat. At least one cooling channel 200 is provided outside each temperature control zone 140 to provide basic cooling capacity for each temperature control zone 140.

[0039] In this application, the cooling channel 200 is used to conduct heat to the mold after injection molding, allowing for zoned heat dissipation in different areas to ensure the melt solidifies and sets within a predetermined time. Multiple cooling channels 200 can be arranged at different depths near the back of the cavity 130 and connected to an external cooling unit via inlet / outlet ports. The interface can be a connector, quick-connect fitting, or threaded connection. The arrangement of the cooling channels 200 is adapted to the shape of the corresponding temperature control area 140. The cooling channels cover the outside of the temperature control area 140, and are separated from the temperature control area 140 while remaining close to each other. This ensures that the cooling medium in the cooling channel 200 regulates the temperature of the injection molded material, thus facilitating the molding of the injection molded part.

[0040] In one possible embodiment, the cooling channel 200 is a metal flow channel, an embedded copper alloy pipe, or a composite heat conduction channel formed within the mold body 100. The cross-section of the cooling channel 200 can be circular, elliptical, or irregular. The channel diameter, spacing, and embedment depth of the cooling channel 200 can be set according to the wall thickness of the cavity 130 and the cooling requirements to ensure that the corresponding temperature control area 140 can obtain stable temperature regulation.

[0041] The temperature regulating device 300 is set one-to-one with each temperature control zone 140. The temperature regulating device 300 is a local temperature control component used to perform real-time temperature correction on the corresponding temperature control zone 140. The temperature regulating device 300 collects the zone temperature through the temperature detection element 310, and the temperature regulating element 320 performs heating or cooling actions to maintain the corresponding temperature control zone 140 at the target temperature.

[0042] In this application, the temperature regulating device 300 is used to compensate for local temperature differences that are difficult to cover when relying solely on the conventional cooling channel 200, enabling temperature control areas 140 of different thicknesses to obtain temperature environments closer to their molding requirements. The temperature regulating device 300 is typically installed on the mold body 100 adjacent to the corresponding temperature control area 140, and can be embedded inside the mold body 100, attached to the back of the cavity 130, or arranged in a local insert. In one possible embodiment, the temperature regulating element 320 can be a component capable of local heating or cooling, and the temperature sensing element 310 can be a sensing element capable of detecting the temperature of the corresponding area. Both can be embedded or surface-mounted. The installation position should ensure effective temperature measurement and heat transfer response of the corresponding area, and the specific spacing can be determined according to the mold structure, area size, and heat conduction path.

[0043] In this embodiment, the temperature detection element 310 refers to a detection element disposed near the corresponding temperature control area 140, used to acquire the real-time temperature signal of the corresponding temperature control area 140. The temperature information output by the temperature detection element 310 can be used as the basis for the action of the temperature regulating element 320. In this application, the temperature detection element 310 continuously collects the temperature changes of the temperature control area 140 to identify whether a local area deviates from the target temperature.

[0044] The temperature sensing element 310 can be arranged at a certain depth from the surface of the cavity 130, inside the insert, or near the back of the cavity 130. The installation method of the temperature sensing element 310 can be embedded, press-fitted, threaded, or attached.

[0045] Temperature regulating component 320 refers to the actuator that raises or lowers the temperature of the temperature control zone 140 based on the detection results of temperature detection component 310. Temperature regulating component 320 is installed on the mold body 100 at the position corresponding to the temperature control zone 140, and directly acts to regulate the thermal state of the corresponding temperature control zone 140. In this application, temperature regulating component 320 adjusts the temperature of different temperature control zones 140 by inputting or removing heat to local areas, causing the local temperature to converge towards the target temperature. Based on the above analysis, it can be seen that in the injection mold provided in this application, during operation, after the mold body 100 is closed, molten injection material is injected into the cavity 130 by the injection molding machine and fills multiple temperature control zones 140 with different thicknesses. Multiple cooling channels 200 first provide basic heat dissipation to their respective corresponding areas, causing the material in the cavity 130 to begin cooling and solidifying according to a predetermined curing rhythm.

[0046] Meanwhile, temperature sensors 310 distributed in each temperature control zone 140 continuously acquire local temperatures, and temperature regulators 320 adjust the heating or cooling of the corresponding temperature control zone 140 according to the detected temperatures, thereby enabling regions of different thicknesses to reach their respective target temperatures within similar molding sequences. By combining basic cooling with local temperature correction, the heat distribution in different areas within the mold body 100 can be adjusted according to structural differences, thus maintaining the cooling uniformity and temperature consistency of each part within the cavity 130. This allows thin-walled irregularly shaped plastic parts to maintain a more stable dimensional state and structural integrity after demolding, and reduces warping, shrinkage marks, or assembly deviations caused by the accumulation of local temperature differences.

[0047] In one possible implementation, the temperature sensing element 310 is disposed on the mold body 100, and the distance 'a' between the temperature sensing element 310 and the inner surface of the corresponding temperature control area 140 satisfies: 0.8mm ≤ a ≤ 1.2mm. Here, by disposing the temperature sensing element 310 on the mold body 100 and limiting the numerical range of the distance between the temperature sensing element 310 and the inner surface of the corresponding temperature control area 140, it is beneficial to ensure that the temperature data collected by the temperature sensing element 310 can accurately reflect the actual temperature state of the injection molding material on the surface of the cavity 130.

[0048] Specifically, if the distance 'a' between the temperature sensing element 310 and the inner surface of the corresponding temperature control area 140 is greater than 1.2 mm, the deviation between the temperature detected by the temperature sensing element 310 and the actual temperature of the cavity 130 surface will increase, reducing the timeliness and accuracy of the temperature sensing element 310 and making it difficult to accurately detect the temperature of the corresponding temperature control area 140. If the distance 'a' between the temperature sensing element 310 and the inner surface of the corresponding temperature control area 140 is less than 0.8 mm, it will easily have an adverse effect on the structural strength of the cavity 130.

[0049] In this application, by controlling the distance 'a' between the temperature sensing element 310 and the inner surface of the corresponding temperature control area 140 within the range of 0.8 mm to 1.2 mm, it is ensured that the temperature sensing element 310 can sensitively sense the temperature changes on the surface of the cavity 130 and accurately obtain the temperature data of the corresponding temperature control area 140, while also reducing the impact of the arrangement of the temperature sensing element 310 on the structural strength of the cavity 130. In specific implementations, the distance 'a' between the temperature sensing element 310 and the inner surface of the corresponding temperature control area 140 can be, for example, any value from 0.8 mm to 1.2 mm, such as 0.8 mm, 0.9 mm, 1.0 mm, 1.1 mm, or 1.2 mm.

[0050] It should be noted that, in the specific arrangement, the temperature detection element 310 should avoid the cooling channel 200 and the ejector pin holes on the mold body 100, and should avoid interference between the temperature detection element 310 and other parts of the mold, so as to ensure the integrity of the mold structure and the reliability of its operation. In specific implementation, the temperature detection element 310 in this embodiment can be a temperature sensor.

[0051] In one possible implementation, such as Figure 1 and Figure 2 As shown, at least two cooling channels 200 are provided on the outer side of the temperature control area 140, and an installation groove 150 is provided between two adjacent cooling channels 200. The temperature detection element 310 is located at the bottom of the installation groove 150.

[0052] Here, by providing at least two cooling channels 200 in each temperature control zone 140, the cooling medium can be distributed more evenly within each temperature control zone 140, improving the uniformity and efficiency of cooling the temperature control zone 140. A mounting groove 150 is provided between two adjacent cooling channels 200, and the temperature sensing element 310 is positioned at the bottom of the mounting groove 150, allowing the temperature sensing element 310 to be located near the center of the temperature control zone 140. The location of the temperature sensing element 310 between the two cooling channels 200 improves the reliability of the collected temperature data.

[0053] Meanwhile, the bottom of the mounting groove 150 is close to the surface of the cavity 130, allowing the temperature sensing element 310 to be arranged as close as possible to the surface of the cavity 130. This facilitates the setting range requirements of the distance 'a' between the temperature sensing element 310 and the inner surface of the corresponding temperature control area 140. By shortening the heat conduction path between the temperature sensing element 310 and the injection molding material, it is possible to promptly sense temperature changes on the surface of the cavity 130.

[0054] In addition, the mounting slot 150 provides an independent installation space for the temperature sensing element 310. The temperature sensing element 310 is arranged in the mounting slot 150 without occupying the position of the cooling channel 200 and the pin hole, which facilitates the installation and subsequent maintenance of the temperature sensing element 310.

[0055] It is understood that the number of two cooling channels 200 provided in each temperature control zone 140 is merely an example. Those skilled in the art can provide two, three, or more cooling channels 200 according to the size, shape, and cooling requirements of the temperature control zone 140, and these are all within the scope of protection of this application. Alternatively, it is also feasible to provide only one cooling channel 200 outside a single temperature control zone 140. In this case, the cooling channel 200 has a pre-reserved mounting groove 150 in the middle of the temperature control zone 140, so that the temperature sensing element 310 can be placed at the bottom of the mounting groove 150, thereby enabling accurate temperature detection of the temperature control zone 140.

[0056] In this embodiment, each cooling channel 200 has a water-blocking plate on the side facing each other. The water-blocking plate serves as the sidewall of the corresponding cooling channel 200, which is beneficial for separating two adjacent cooling channels 200 on the same temperature control area 140. An installation groove 150 is defined between two adjacent water-blocking plates.

[0057] In one possible implementation, such as Figure 1 and Figure 2As shown, the mold body 100 is provided with a partition groove 160, and two adjacent temperature control zones 140 are located on opposite sides of the partition groove 160. Temperature sensing elements 310 and temperature regulating elements 320 are provided on both opposite sides of the partition groove 160. Here, by setting the partition groove 160 between two adjacent temperature control zones 140, a physical separation can be achieved on the outer side of the two adjacent temperature control zones 140, reducing heat conduction between adjacent temperature control zones 140, reducing thermal interference between each temperature control zone 140, and making the temperature control of each temperature control zone 140 more independent. It should be noted that the partition groove 160 is located on the outer side of the cavity 130 and will not affect the communication relationship between the temperature control zones 140.

[0058] In practical implementation, temperature regulating components 320 are provided on both sides of the partition groove 160, corresponding to two adjacent temperature control zones 140 respectively. Each temperature regulating component 320 operates independently, heating or cooling its respective temperature control zone 140, which facilitates independent temperature regulation of adjacent temperature control zones 140. Furthermore, heat insulation components can be installed within the partition groove 160 to further reduce the temperature influence between two adjacent temperature control zones 140.

[0059] It is understood that the partition groove 160 is provided along the extension direction of the surface of the cavity 130. The depth and width of the partition groove 160 can be reasonably selected according to the thickness of the mold body 100, the distance between adjacent temperature control areas 140 and the size of the temperature regulating component 320. This application does not impose any restrictions on this.

[0060] In one possible implementation, such as Figure 3 As shown, the temperature regulating device 300 of this application also includes a controller 330, and the temperature detection element 310 and temperature regulating element 320 in each temperature regulating device 300 are electrically connected to the controller 330. The controller 330 is configured to control the temperature regulating element 320 to heat or cool the position of the corresponding temperature control area 140 on the mold body 100 based on the deviation between the temperature of the temperature control area 140 detected by the temperature detection element 310 and the corresponding target temperature, so as to adjust the temperature of the corresponding temperature control area 140 to the corresponding target temperature.

[0061] With this configuration, the controller 330 dynamically controls the temperature regulator 320 to heat or cool based on the deviation between the detected temperature (real-time feedback from the temperature sensor 310) and the target temperature, forming a closed-loop control circuit of detection, feedback, comparison, and adjustment. This closed-loop control circuit continuously adjusts according to the deviation between the actual temperature and the target temperature, ensuring that the temperature in the temperature control zone 140 always approaches and stabilizes at the target temperature. Simultaneously, the controller 330 receives the detection signal from the temperature sensor 310 in real time and dynamically adjusts the heating or cooling output of the temperature regulator 320 according to changes in the deviation. This fast response time effectively compensates for temperature fluctuations caused by changes in heat load during injection molding, ensuring the stability of the temperature in the temperature control zone 140.

[0062] In addition, each temperature control zone 140 is equipped with an independent controller 330. Each controller 330 only controls the temperature regulating component 320 of its corresponding temperature control zone 140. The temperature control of each zone is independent and does not interfere with each other. It can independently adjust the temperature according to the target temperature of each temperature control zone 140, meeting the different temperature requirements of areas with different wall thicknesses. When the temperature of a certain temperature control zone 140 deviates from its target temperature, the controller 330 corresponding to that temperature control zone 140 only adjusts the temperature of that temperature control zone 140, without affecting the temperature of other temperature control zones 140, thus ensuring the independence of the temperature of each temperature control zone 140.

[0063] In this embodiment, the controller 330 controls the temperature regulator 320 to heat or cool according to the deviation, achieving bidirectional temperature regulation. Whether heating or cooling is required, it can be achieved through the same controller 330 and temperature regulator 320, eliminating the need for two separate control devices for heating and cooling. This reduces structural complexity and allows the system to adapt to the temperature regulation needs of different temperature control zones 140 at different injection molding stages.

[0064] It is understood that the controller 330 can be a PID temperature controller 330 independently set in each temperature control zone 140, or it can be multiple controllers 330 integrated into the main control system of the injection molding machine. The target temperature of each temperature control zone 140 can be set according to the wall thickness distribution and molding requirements of the injection molded product, and this application does not impose any restrictions on this.

[0065] In one possible implementation, the temperature regulating device 300 includes a controller 330, at least two temperature sensors 310, and at least two temperature regulators 320, all of which are electrically connected to the controller 330.

[0066] Here, a controller 330 can be electrically connected to at least two temperature sensors 310 and at least two temperature regulators 320 simultaneously, improving the targeting of temperature detection and regulation for a temperature-controlled zone 140. A single controller 330 centrally controls at least two of the temperature regulators 300. This reduces the computational burden on the controller 330, enabling it to respond to temperature changes and adjust more quickly, thus improving control accuracy and response speed.

[0067] Meanwhile, each temperature control zone 140 has an independent controller 330. The temperature detection, signal processing and temperature regulation of each temperature control zone 140 do not interfere with each other, avoiding signal crosstalk or control conflict problems that may occur when multiple temperature control zones 140 share a single controller 330. This helps to ensure the independence and stability of temperature control in each temperature control zone 140.

[0068] Furthermore, when each temperature control zone 140 is equipped with at least two temperature detection elements 310 and at least two temperature regulating elements 320, the temperature detection elements 310 can be arranged at different positions within the temperature control zone 140 to improve the comprehensiveness and accuracy of temperature detection. The temperature regulating elements 320 can be arranged at different positions within the temperature control zone 140 to improve the uniformity of temperature regulation. Each temperature detection element 310 and each temperature regulating element 320 is electrically connected to a corresponding controller 330. The controller 330 centrally processes the detection signals from all temperature detection elements 310 within the temperature control zone 140 and sends control commands to all temperature regulating elements 320 within the temperature control zone 140, thereby achieving precise detection and accurate temperature regulation for each temperature control zone 140.

[0069] Optionally, when the temperature control zone 140 is equipped with multiple temperature sensors 310, the controller 330 controls the corresponding temperature regulator 320 to heat or cool based on the average or weighted average of the temperatures detected by the multiple temperature sensors 310, thereby improving the accuracy of temperature control in the temperature control zone 140. When the temperature control zone 140 is equipped with multiple temperature regulators 320, the controller 330 controls each temperature regulator 320 to heat or cool, so that the temperature in all parts of the temperature control zone 140 tends to be uniform.

[0070] Meanwhile, by controlling multiple temperature detection elements 310 and temperature regulating elements 320 in multiple temperature control zones 140 simultaneously through a single controller 330, the number of controllers 330 is reduced, simplifying the electrical connections and logic structure of the control system, and lowering hardware costs and maintenance difficulty. Understandably, it is also feasible to share a single controller 330 among multiple temperature regulating devices 300 throughout the injection mold; in specific implementation, the number of controllers 330 can be determined based on usage requirements.

[0071] In one possible implementation, the temperature sensing element 310 is a PT100 array. Specifically, the PT100 array includes multiple miniature PT100 temperature sensors, each temperature sensor is located at the bottom of the mounting groove 150 and is spaced apart along the extension direction of the mounting groove 150, for multi-point temperature detection of the temperature control area 140, and the multiple temperature sensors form an embedded miniature PT100 array.

[0072] In one possible implementation, the temperature regulating element 320 is a semiconductor cooling element having two opposing first temperature regulating surfaces and a second temperature regulating surface. The first temperature regulating surface is connected to the mold body 100 and located outside the corresponding cooling channel 200. The controller 330 is configured to control the current direction of the semiconductor cooling element so that the first temperature regulating surface heats or cools the position on the mold body 100 corresponding to the temperature control area 140, thereby regulating the temperature of the temperature control area 140.

[0073] Here, the semiconductor cooling device (also known as a Peltier cooling device) operates based on the Peltier effect. When direct current passes through a pair of thermocouples composed of two different semiconductor materials, the first temperature regulating surface absorbs heat, and the second temperature regulating surface releases heat.

[0074] Specifically, the first temperature regulating surface makes thermal contact with the corresponding temperature control area 140 on the mold body 100. When the controller 330 determines, based on the detected temperature feedback from the temperature sensor 310, that the actual temperature of the temperature control area 140 is higher than the target temperature (i.e., the area is overheated and needs faster cooling), the controller 330 controls the semiconductor cooling element to pass a positive current, making the first temperature regulating surface act as a cold end, actively absorbing heat from the mold steel wall of the mold body 100, and rapidly reducing the temperature of the mold steel wall corresponding to the temperature control area 140. At this time, the temperature difference between the cooling medium flowing through the cooling channel 200 of the temperature control area 140 and the mold steel wall increases, and the rate at which the cooling medium carries away heat increases, thereby achieving rapid cooling of the temperature control area 140.

[0075] When the controller 330 determines, based on the detected temperature feedback from the temperature sensor 310, that the actual temperature of the temperature-controlled area 140 is lower than the target temperature (for example, a thick-walled area needs delayed cooling to prevent shrinkage marks), the controller 330 controls the semiconductor cooling element to pass a reverse current, switching the first temperature adjustment surface from the cold end to the hot end. This actively releases heat to the mold steel wall of the mold body 100, raising the temperature of the mold steel wall corresponding to the temperature-controlled area 140. At this time, the temperature difference between the cooling medium flowing through the cooling channel 200 of the temperature-controlled area 140 and the mold steel wall decreases, and the rate at which the cooling medium carries away heat decreases, thereby achieving delayed cooling of the temperature-controlled area 140.

[0076] Therefore, the temperature regulating component 320 of this application changes the temperature of the mold steel wall at the corresponding temperature control area 140 position on the mold body 100, thereby altering the temperature difference between the mold steel wall of the temperature control area 140 and the cooling medium, and consequently changing the rate at which the cooling medium removes heat, thus achieving differentiated temperature control for temperature control areas 140 with different wall thicknesses. The temperature regulating component 320 indirectly regulates the temperature of the temperature control area 140 through the mold body 100 and the cooling channel 200.

[0077] In this embodiment, the semiconductor cooling element serves as the temperature regulating element 320. Utilizing the advantage of its fast heating or cooling response, the semiconductor cooling element can quickly respond to the regulating commands of the controller 330 by rapidly switching the current direction, thus quickly adjusting the temperature of the temperature control zone 140. This improves the response speed and control accuracy of temperature control. Furthermore, the semiconductor cooling element is small and thin, making it easy to arrange on the mold body 100 corresponding to the temperature control zone 140. Each temperature control zone 140 can be independently equipped with its own semiconductor cooling element, achieving independent temperature control within each zone without occupying excessive mold space.

[0078] Furthermore, by adjusting the current flowing through the thermoelectric cooler, the heating or cooling power of the thermoelectric cooler can be controlled, thereby regulating the temperature. Combined with the real-time temperature feedback from the temperature sensor 310 and the closed-loop control of the controller 330, the temperature of the temperature control zone 140 can be precisely controlled at the target temperature, meeting the different temperature requirements of regions with varying wall thicknesses.

[0079] It is understood that one, two, or more thermoelectric coolers can be installed on the outer surface of the injection mold outside a temperature control zone 140. A thermally conductive medium layer (e.g., thermally conductive silicone grease) is provided between the first temperature regulating surface and the mold body 100 to reduce contact thermal resistance and improve heat transfer efficiency. The first temperature regulating surface faces the mold body 100, and the second temperature regulating surface faces the outside of the mold body 100.

[0080] In one possible implementation, a heat dissipation structure is provided on the second temperature regulating surface of the semiconductor cooling device. The heat dissipation structure is used to transfer heat from the second temperature regulating surface to the external environment.

[0081] When a thermoelectric cooler is in operation, heat is transferred from the first temperature regulating surface (the cold end of the thermoelectric cooler) to the second temperature regulating surface (the hot end of the thermoelectric cooler). If the heat on the second temperature regulating surface cannot be dissipated in time, the temperature of the hot end will continuously rise, causing the temperature difference between the cold and hot ends to gradually decrease. This leads to a decrease in the cooling efficiency of the thermoelectric cooler, and may even cause it to be damaged due to overheating. Therefore, a heat dissipation structure needs to be installed on the second temperature regulating surface to dissipate the heat accumulated at the hot end to the external environment in a timely manner, maintain a stable temperature difference between the cold and hot ends, and ensure the continuous normal operation of the thermoelectric cooler.

[0082] Optionally, the heat dissipation structure includes a heat sink and a cooling fan. The heat sink is disposed on the second temperature regulating surface to increase the heat dissipation area and transfer heat to the surrounding air. In a specific implementation, multiple heat sinks can be arranged at intervals. The cooling fan is disposed on one side of the heat sink to accelerate airflow around the heat sink and improve heat exchange efficiency. Through the synergistic effect of the heat sink and the cooling fan, the heat dissipation efficiency of the second temperature regulating surface can be significantly improved, the hot-end temperature can be reduced, thereby improving the cooling performance of the semiconductor cooling device. Of course, it is also feasible to only provide heat sinks or only provide a cooling fan on the second temperature regulating surface.

[0083] In this embodiment, the cooling fan is powered by an independent power source, such as a power source outside the injection mold, to ensure that the cooling fan can operate continuously and stably, unaffected by temperature fluctuations inside the mold. Specifically, the number and arrangement of the heat sinks and cooling fans can be rationally selected based on the power and heat dissipation requirements of the semiconductor cooling device.

[0084] It is understood that the heat dissipation structure is not limited to a combination of heat sinks and cooling fans, but can also be other forms of heat dissipation devices such as water-cooled radiators and heat pipe radiators, as long as the heat of the second temperature regulating surface can be dissipated in a timely manner. This application does not impose any restrictions on this. In addition, the second temperature regulating surface is located on the outside of the mold body 100 to facilitate the installation of the heat dissipation structure and the dissipation of heat, and to prevent heat from accumulating inside the mold and affecting the temperature control of other temperature control areas 140.

[0085] In one possible implementation, such as Figure 1 and Figure 2 As shown, the temperature regulating component 320 includes a first temperature regulating component, a second temperature regulating component, and a third temperature regulating component. The first temperature regulating component is located outside the temperature control region 140 of the thick-walled portion, and is used to raise the temperature of the temperature control region 140 to a first target temperature. The second temperature regulating component is located outside the temperature control region 140 of the thin-walled portion, and is used to cool the temperature control region 140 to a second target temperature. The third temperature regulating component is located outside the temperature control region 140 at the transition between the thick-walled and thin-walled portions, and is used to reduce the temperature gradient of the temperature control region 140 to a third target temperature. Both the second and third target temperatures are lower than the first target temperature, with the third target temperature being lower than the second target temperature.

[0086] In this configuration, the first temperature regulating component is located outside the first temperature control zone 141 of the thick-walled section. The thick-walled region has a large melt volume and slow heat dissipation; the outer layer solidifies first, and the inner layer cools later. When the inner melt cools and shrinks, it is difficult to compensate for shrinkage, easily leading to shrinkage marks. The first temperature regulating component is used to raise the temperature of the first temperature control zone 141 to a first target temperature, thereby slowing down the freezing rate of the outer melt in the thick-walled region, extending the flow compensation time of the inner melt, and ensuring that the shrinking inner melt is fully compensated, thus preventing shrinkage marks. Simultaneously, the gentle cooling process reduces the temperature gradient in the thick-walled region, reducing internal stress.

[0087] The second temperature regulating component is located outside the second temperature control zone 142 of the thin-walled section. The melt volume in the thin-walled curved area is small, and heat dissipates quickly. However, the curved structure is prone to warping deformation due to uneven cooling, and the thin-walled structure lacks rigidity before complete solidification. The second temperature regulating component is used to cool the second temperature control zone 142 to the second target temperature, thereby accelerating the cooling and solidification of the melt in the thin-walled area, shortening the setting time, enabling the curved structure to be quickly fixed and formed, improving the rigidity and structural stability after forming, and effectively suppressing warping deformation.

[0088] The third temperature regulating component is located on the outside of the third temperature control zone 143 at the transition between the thick-walled and thin-walled sections. In the transition zone (e.g., at the base of a clip or reinforcing rib), there is a sudden change in wall thickness, resulting in a significant difference in cooling rate between the base and the main body. When the melt at the base cools and contracts, it is constrained by the already solidified portion of the main body, generating tensile stress and causing white marks at the base. The third temperature regulating component is used to cool the temperature gradient of the third temperature control zone 143 to the third target temperature, thus gently releasing residual stress at the base, preventing stress concentration due to excessively rapid cooling, ensuring complete solidification of the base, eliminating white marks at the base, and balancing product appearance and structural strength.

[0089] The second and third target temperatures are both lower than the first target temperature, and the third target temperature is lower than the second target temperature. This temperature relationship matches the wall thickness characteristics and temperature control requirements of each temperature-controlled zone 140. Thick-walled zones require higher temperatures to slow cooling, thin-walled zones require lower temperatures to accelerate curing, and transition zones require the lowest possible temperature to achieve final shaping.

[0090] During the temperature adjustment process of each temperature control zone 140, the controller 330 receives the current temperature feedback from the temperature detection element 310 in real time and calculates the deviation between the current temperature and the target temperature. If the current temperature is higher than the target temperature, the controller 330 controls the temperature regulating element 320 to cool. If the current temperature is lower than the target temperature, the controller 330 controls the temperature regulating element 320 to heat. During the gradient cooling process, the controller 330 sets the target temperature in stages according to the preset temperature curve, continuously compares the deviation between the current temperature and the target temperature of the current stage, and dynamically adjusts the cooling power of the temperature regulating element 320 to make the temperature drop smoothly along the preset curve.

[0091] It is understood that the specific values ​​of the first target temperature, the second target temperature and the third target temperature mentioned above are only examples. Those skilled in the art can make reasonable adjustments according to the type of injection molding material, the specific wall thickness distribution of the air guide and the molding requirements, all of which fall within the protection scope of this application.

[0092] Taking the first temperature control zone 141 as an example, its target temperature can be set to 28℃±1℃, that is, the controller 330 controls the temperature of the first temperature control zone 141 to fluctuate between 27℃ and 29℃. When the temperature detection element 310 detects that the temperature of the first temperature control zone is higher than 29℃, the controller 330 controls the temperature regulating element 320 to cool the first temperature control zone 141.

[0093] When the temperature sensor 310 detects that the temperature of the first temperature control zone 141 is below 27°C, the controller 330 controls the temperature regulator 320 to heat the first temperature control zone 141. When the temperature sensor 310 detects that the temperature of the first temperature control zone 141 is between 27°C and 29°C, the controller 330 controls the temperature regulator 320 to maintain the current operating state. Through this method, the temperature of the first temperature control zone 141 is controlled within a preset temperature range.

[0094] Similarly, the second target temperature of the second temperature control zone 142 can be set to 8℃±1℃, and the third target temperature of the third temperature control zone 143 corresponding to the base of the buckle and reinforcing rib can be set to 6℃±0.5℃. At this time, the temperature control principle of each temperature control zone 140 is the same as described above.

[0095] It is understood that the specific temperature range (e.g., ±0.5℃, ±1℃, ±2℃, etc.) corresponding to each temperature control zone 140 can be set according to the type of injection molding material, the wall thickness distribution of the air guide, and the molding precision requirements, and this application does not impose any restrictions on this. After reading the technical solution of this application, those skilled in the art can reasonably set the target temperature range of each temperature control zone 140 according to the actual injection molding process requirements.

[0096] It is understood that, in addition to the multiple temperature-controlled zones 140 mentioned above, the cavity 130 may also include other areas that do not require independent temperature control (hereinafter referred to as non-temperature-controlled areas). Non-temperature-controlled areas refer to areas in the cavity 130 with relatively uniform wall thickness, relatively consistent cooling rates, and no need for heating or cooling through independent temperature regulation devices.

[0097] To cool the non-temperature-controlled areas, a cooling cavity can be provided on the mold body 100. The cooling cavity is located outside the non-temperature-controlled areas and is set out along the outer side of the non-temperature-controlled areas. The cooling cavity is used to introduce a cooling medium. When the cooling medium flows through the cooling channel, it carries away the heat of the mold body 100 in the non-temperature-controlled areas through heat exchange, thereby cooling the non-temperature-controlled areas.

[0098] In other words, for non-temperature-controlled areas that do not require independent temperature control, they are cooled solely by the cooling medium in the cooling chamber, without the need for a corresponding temperature regulating device 300. This design ensures effective cooling for all areas of the cavity 130, while simplifying the mold structure by requiring independent temperature regulating devices 300 only for temperature-controlled areas with varying wall thicknesses and significant differences in cooling requirements.

[0099] Taking the server air duct as an example, the main flat area of ​​the air duct has a relatively uniform wall thickness and a relatively consistent cooling rate, and can be used as a non-temperature-controlled area. However, the thick-walled area of ​​the air inlet, the thin-walled curved area of ​​the air outlet, and the area at the base of the clips / reinforcing ribs have large differences in wall thickness and different cooling requirements, and are therefore used as temperature-controlled areas for independent temperature detection and adjustment.

[0100] It is understood that the specific division of the non-temperature-controlled area depends on the wall thickness distribution and cooling requirements of the injection molded product. Those skilled in the art can reasonably determine the location and range of the temperature-controlled and non-temperature-controlled areas based on the structural characteristics and molding requirements of the actual injection molded product, and these all fall within the scope of protection of this application.

[0101] In addition, the injection mold in this embodiment of the application needs to be used in conjunction with an injection molding machine, a mold system and peripheral auxiliary systems.

[0102] The injection molding machine is the main equipment for injection molding, used to inject molten injection material into the cavity 130 of the mold system. The injection molding machine injects the plasticized molten plastic into the mold cavity 130 under high pressure through the injection mechanism, and continuously applies pressure during the holding pressure stage to compensate for the volume loss caused by the cooling and shrinkage of the plastic.

[0103] The high-response electro-hydraulic servo proportional valve is installed at the injection end of the injection molding machine. The valve spool opening is controlled by a PLC superimposed with a sine wave signal source. This valve is used to precisely control the injection speed and holding pressure during the injection molding process. Driven by a torque motor, it features fast response, high sensitivity, and a small dead zone.

[0104] The peripheral auxiliary systems include a mold temperature controller, dryer, chiller, and forming fixture. The mold temperature controller is connected to the cooling system of the injection mold to precisely control the mold temperature. The mold temperature controller delivers a cooling medium at the set temperature to the cooling channels of the mold through circulation pipelines, and adjusts the temperature of the cooling medium according to temperature control requirements during the injection molding process to ensure that each temperature-controlled zone of the mold cavity 130 reaches its respective target temperature.

[0105] Dryers are used to dry injection molding materials and remove moisture. Before melting and processing, injection molding materials need to pass through a dryer to remove moisture, preventing defects such as silver streaks and bubbles caused by water content in the material during injection molding.

[0106] The chiller provides cooling water and works in conjunction with the mold temperature controller, supplying cooling water to the cooling channels of the mold through cooling circulation pipes. The chiller can be connected to the cooling channels 200 of each temperature-controlled zone 140 via multiple independent water supply lines. Each water supply line is equipped with an independent control valve (such as a solenoid valve or flow regulating valve) to independently control the flow rate and on / off state of the cooling water in each temperature-controlled zone 140. The cooling channels 200 of each temperature-controlled zone 140 return to the chiller through independent return water pipes. Thus, the cooling channels 200 of each temperature-controlled zone 140 form independent cooling loops, and the flow rate and temperature of the cooling medium in each loop can be independently adjusted according to the actual needs of the corresponding temperature-controlled zone 140.

[0107] The shaping fixture is used to correct the air guide cover after it has cooled and formed. After the product is demolded, it is placed in the shaping fixture and released after it has completely cooled to correct any slight warping deformation that may occur after demolding, so that the product's external dimensions are restored to the design requirements.

[0108] In the above structure, the dryer is connected to the hopper of the injection molding machine, feeding the dried injection molding material into the machine for melting and processing. The injection end of the injection molding machine is connected to a high-response electro-hydraulic servo proportional valve via hydraulic lines. The PLC controls the injection speed and holding pressure by controlling the valve core opening of this valve. The chiller is connected to the mold temperature controller and the mold's cooling channel 200 via cooling circulation lines. The mold temperature controller is located between the chiller and the mold, regulating the temperature of the cooling medium entering the mold. The shaping fixture is independently located beside the injection molding machine for product correction after injection molding.

[0109] This application also proposes an injection molding method, such as... Figure 4 As shown, an injection mold as described in any of the above embodiments is used. The injection molding method includes the following steps:

[0110] Step S100: Inject the molten injection material into the cavity 130 of the mold body 100 of the injection mold.

[0111] In practice, the molten injection material is injected into the cavity 130 of the mold body 100 through the injection system of the injection molding machine. The cavity 130 has multiple temperature control zones 140 with different thicknesses, and each temperature control zone 140 corresponds to the wall thickness difference at different positions of the injection molded product such as the air guide.

[0112] In step S300, cooling medium is introduced into multiple cooling channels 200 outside each temperature control area 140 of each injection mold. The temperature of the corresponding temperature control area 140 of the injection mold is detected by the temperature detection component 310 of the injection mold. The temperature adjustment component 320 of the injection mold heats or cools the position of the corresponding temperature control area 140 on the mold body 100 according to the detected temperature of the temperature detection component 310, so as to adjust the temperature of the corresponding temperature control area 140 to the corresponding target temperature.

[0113] In practice, each temperature control zone 140 is equipped with an independent cooling channel 200, a temperature detection element 310, and a temperature regulating element 320. The cooling channel 200 is used to introduce a cooling medium to remove some of the heat from the mold body 100 in the temperature control zone 140, achieving basic cooling. The temperature detection element 310 detects the temperature of the temperature control zone 140 in real time and feeds the detection signal back to the controller 330. Based on the deviation between the detected temperature and the target temperature, the temperature regulating element 320 heats or cools the corresponding position of the mold body 100 in the temperature control zone 140, so that the temperature of the temperature control zone 140 approaches and stabilizes at the corresponding target temperature, thereby achieving independent temperature regulation of each temperature control zone 140.

[0114] The injection molding method provided in this application embodiment can enable the injection material in different wall thickness regions of the cavity 130 to obtain a cooling rate that matches its wall thickness, and the solidification process of each region tends to be synchronized, thereby reducing molding defects caused by uneven cooling and improving the molding quality of parts with different thicknesses, such as air guides. At the same time, since each temperature control region 140 can be independently controlled at its own target temperature, it is beneficial to shorten the injection molding cycle.

[0115] In related technologies, injection molding machines typically use uniform speed or segmented constant pressure injection into the mold cavity. When the injection material fills complex structures such as thin walls, curved surfaces, and corners, problems such as sudden changes in flow rate, concentrated shear heat, and unstable melt front can easily occur. This leads to significant internal stress in the product, and surface defects such as silver streaks, flow marks, and low weld line strength are prone to appear. At the same time, the melt is prone to trapping air at the end of the mold filling process, forming micropores, which affect the structural strength and dimensional stability of the air guide.

[0116] Based on this, in one possible implementation, step S100, which involves injecting molten injection material into the cavity 130 of the mold body 100 of the injection mold, includes: filling the cavity 130 with injection material at a first injection speed on an injection molding machine to 25%-35% of its volume, and filling the remaining cavity 130 with injection material at a second injection speed on the injection molding machine, wherein the first injection speed is greater than the second injection speed.

[0117] This configuration allows the injection molding machine to use a high initial injection speed for rapid filling in the early stages of injection. This enables the melt to quickly pass through the thin-walled area of ​​the air guide, shortening the melt's residence time in the thin-walled section. This prevents insufficient filling, missing material, or excessive shearing due to rapid cooling, ensuring complete filling of complex thin-walled structures. Simultaneously, the rapid flow of the melt through the gating system during high-speed injection generates frictional heat, raising the melt temperature and improving the surface finish and weld line strength of the finished product.

[0118] Once the melt has filled 25% to 35% of the cavity volume (130), it has essentially covered the thin-walled area, entering the pressure-holding and shrinkage-compensating stage. Filling continues with pressure pulsations during injection at the second injection rate. These periodic pressure fluctuations disturb the residual flow at the melt tip, breaking up air clumps trapped at the end of mold filling and preventing porosity, shrinkage cavities, and silver streaks. This setup also homogenizes shear heat distribution, reducing uneven molecular orientation caused by localized overheating and significantly lowering internal stress in the product. Simultaneously, it enhances molecular entanglement in the weld line area, improving the structural strength and deformation resistance of the air guide.

[0119] In specific implementation, step S100 involves injecting the molten injection material into the cavity 130 using a two-stage pulsating injection process. The two-stage pulsating injection process controls the injection speed and pressure through a high-response electro-hydraulic servo proportional valve. The valve core opening of the high-response electro-hydraulic servo proportional valve is controlled by a programmable logic controller (PLC) superimposed with a sine wave signal source.

[0120] Specifically, the two-stage pulsed injection process includes a first injection stage and a second injection stage performed sequentially. The first injection stage is the first 25%-35% of the cavity's 130-unit filling volume, employing high-flow-rate injection to allow the molten injection material to quickly penetrate the thin-walled area of ​​the air guide shroud. By shortening the residence time of the melt in the thin-walled section, defects such as insufficient filling, missing material, or localized excessive shearing caused by premature cooling of the melt can be avoided, thus ensuring the complete filling of the complex thin-walled structure of the air guide shroud. Simultaneously, the rapid flow of the melt through the gating system during high-flow-rate injection generates frictional heat, raising the melt temperature and improving the surface finish and weld line strength of the finished product.

[0121] The second injection stage involves the last 65%-75% of the filling volume of cavity 130, corresponding to the transition period when the melt has essentially filled cavity 130 and is about to enter the holding and compensating stage. At this time, a low-frequency, small-amplitude pressure fluctuation is actively applied through a high-response electro-hydraulic servo proportional valve to physically disturb the residual flow at the melt tip. The frequency of the pressure fluctuation is 0.5Hz to 2Hz, and the amplitude is ±5MPa. This pressure fluctuation is controlled by a PLC controller superimposed with a sine wave signal source to control the valve opening of the high-response electro-hydraulic servo proportional valve.

[0122] This application utilizes the aforementioned two-stage pulsating injection process to ensure rapid and complete filling of thin-walled areas with high flow rates in the early stage of mold filling, and to improve the flow state at the end of mold filling with low-frequency pressure pulsation in the later stage of mold filling. The two work together to fundamentally improve the injection filling quality of thin-walled irregular parts.

[0123] It is understood that those skilled in the art can, based on the rheological properties of the injection molding material, the wall thickness distribution of the air guide, and the flow path morphology, set the switching node within 25% to 35% of the cavity 130 volume, all of which fall within the scope of protection of this application. Similarly, the frequency and amplitude of pressure fluctuations are not limited to 0.5Hz to 2Hz and ±5MPa, and those skilled in the art can optimize and adjust them within the above range based on the actual mold filling effect, or pre-determine suitable pulsation parameters through CAE mold flow simulation analysis.

[0124] In one possible implementation, step S300 involves introducing a cooling medium into multiple cooling channels 200 outside each temperature control zone 140, detecting the temperature of the corresponding temperature control zone 140 of the injection mold via a temperature detection element 310, and adjusting the temperature of the corresponding temperature control zone 140 on the mold body 100 according to the detected temperature by the temperature detection element 310, thereby adjusting the temperature of the corresponding temperature control zone 140 to the corresponding target temperature. This includes:

[0125] Step S310: The first temperature regulating component of the injection mold raises the temperature of the temperature control zone 140 corresponding to the thick-walled part to the first target temperature.

[0126] Step S320: The second temperature regulating component of the injection mold cools the temperature of the temperature control zone 140 corresponding to the thin-walled part to the second target temperature.

[0127] Step S330: The third temperature regulating component of the injection mold cools the temperature gradient of the temperature control area 140 corresponding to the transition part between the thick-walled part and the thin-walled part to the third target temperature. Both the second target temperature and the third target temperature are lower than the first target temperature, and the third target temperature is lower than the second target temperature.

[0128] Here, the thick-walled section corresponds to the air inlet of the air guide shroud, i.e., the first temperature control area 141. The first temperature control area 141 has a large wall thickness, resulting in a large melt volume and slow heat dissipation. During injection molding, the outer melt first contacts the mold wall and cools and solidifies to form a hard shell, while the inner melt remains in a high-temperature molten state. When the inner melt cools and shrinks, the outer layer has already solidified into a rigid shell, and the inner layer cannot obtain new melt replenishment, leading to surface depressions and shrinkage marks. By raising the temperature of the first temperature control area 141 of the thick-walled section to the first target temperature (e.g., 28℃±1℃) through the first temperature regulating component, the freezing rate of the outer melt in the thick-walled area can be slowed down, and the flow compensation time window of the inner melt can be extended, allowing the shrinking inner melt to be fully compensated, thereby avoiding the formation of shrinkage marks.

[0129] The thin-walled section corresponds to the air outlet of the air guide shroud, which is also the second temperature control zone 142. The second temperature control zone 142 is a thin-walled curved structure with a small wall thickness, small melt volume, and rapid heat dissipation. The curved structure is sensitive to cooling uniformity; differences in cooling rates in different parts lead to uneven shrinkage, generating internal stress and causing warping deformation. Simultaneously, the thin-walled structure has extremely low rigidity before complete solidification, making it highly susceptible to deformation after demolding due to stress release. By using a second temperature regulator to cool the second temperature control zone 142 of the thin-walled section to a second target temperature (e.g., 8℃±1℃), the cooling and solidification of the melt in the thin-walled area can be accelerated, shortening the setting time, allowing the curved structure to be quickly fixed and formed, improving the rigidity and structural stability after molding, and effectively suppressing warping deformation.

[0130] The transition area corresponds to the root position where the structures such as clips and reinforcing ribs on the air guide cover connect to the main body, which is also the third temperature control zone 143. The third temperature control zone 143 exhibits a sudden change in wall thickness, abruptly transitioning from thick wall to thin wall. The cooling rate differs greatly between the root and the main body; the root has a large melt volume (thick wall) and cools slowly, while the main body has a small melt volume (thin wall) and cools quickly.

[0131] When the root melt cools and shrinks, the main body has partially solidified into a rigid skeleton, exerting a tensile force on the root and generating tensile stress. This leads to microcracks or voids within the material, manifesting as white marks (stress whitening) on ​​the surface. A third temperature regulator gradually cools the third temperature control zone 143 of the transition area to the third target temperature (e.g., gradually decreasing from 12℃±1℃ to 6℃±1℃). Initially, the temperature is maintained at 12℃±1℃ for 2 to 4 seconds to allow the root melt and the main body melt to cool synchronously and achieve initial shaping, avoiding stress concentration due to excessively rapid cooling. The temperature is then gradually reduced to 6℃±1℃ to ensure complete solidification of the root. This gradient cooling reduces the difference in cooling rate between the root and the main body, allowing shrinkage stress to be released gradually over a longer period rather than concentrating instantaneously. This prevents tensile stress from exceeding the material's yield strength, thus reducing white marks and cracks at the root.

[0132] In one possible implementation, the gradient cooling curve of the third temperature control region 143 is determined using an infrared thermal imager. At the moment the injection mold opens, the temperature field of the third temperature control region 143 at the base of the snap-fit ​​and reinforcing rib is collected. Temperature field data at the moment of mold opening is collected for more than one hundred mold opening cycles to obtain temperature distribution samples of the third temperature control region 143 under different mold cycles.

[0133] Multiple sets of collected temperature field data were image registered to ensure precise spatial correspondence between infrared thermal images of different modes. Temperature interpolation was then performed on the registered temperature field data to obtain complete temperature distribution information at each location within the third temperature control zone 143 at the moment of mold opening.

[0134] Based on the interpolated temperature field data, a regression model of structural parameters and mold temperature gradient was constructed using the structural parameters of the third temperature control region 143 (such as wall thickness distribution, geometry, stiffener height, and root fillet radius) as independent variables and the temperature gradient at the moment of mold opening as the dependent variable. The optimal gradient cooling curve for the third temperature control region 143 under different structural parameters was fitted using the regression model. Through the collection and regression analysis of a large amount of experimental data, the gradient cooling curve of the third temperature control region 143 can be determined for the snap-fit ​​and stiffener root areas of different structures, thereby achieving temperature control of the third temperature control region 143 and effectively avoiding stress concentration defects caused by improper cooling.

[0135] It is understood that those skilled in the art can also use other types of infrared thermal imagers or non-contact temperature measurement devices to acquire the temperature field. The specific algorithms for image registration, temperature interpolation, and regression model construction can employ any suitable algorithm known in the art, and this application does not impose any limitations on this. Furthermore, the second target temperature (e.g., 8℃±1℃) and the third target temperature (e.g., 6℃±0.5℃) are both lower than the first target temperature (e.g., 28℃±1℃), and the third target temperature (e.g., 6℃±0.5℃) is lower than the second target temperature (e.g., 8℃±1℃). The above temperature relationships match the wall thickness characteristics and temperature control requirements of each temperature-controlled region 140. Thick-walled regions require higher temperatures to delay cooling, thin-walled regions require lower temperatures to accelerate curing, and transition regions require the lowest temperatures to complete final shaping. These three temperatures exhibit a gradient distribution, respectively matching the wall thickness characteristics and cooling requirements of each region.

[0136] It is understood that the specific values ​​of the first, second, and third target temperatures mentioned above are merely examples. Those skilled in the art can make reasonable adjustments based on the type of injection molding material, the specific wall thickness distribution of the air guide, and the molding requirements, all of which fall within the scope of protection of this application. There is no restriction on the order of steps S310, S320, and S330; they can be executed simultaneously or sequentially in any order.

[0137] In one possible implementation, such as Figure 4 As shown, after injecting molten injection material into the cavity 130 of the mold body 100 of the injection mold, the injection molding method further includes step S200, holding pressure in the cavity 130. S200, holding pressure in the cavity 130, includes:

[0138] Step S210: The gate area 170 of the cavity 130 is pressurized with a first pressure P1 for a first time t1, the first pressure P1 is reduced to a second pressure P2 within a second time t2, the second pressure P2 is reduced to a third pressure P3 within a third time t3, and then the third pressure P3 is gradually reduced to 0 MPa.

[0139] Here, as Figure 1As shown, the gate area 170 is the entrance for melt filling and one of the last areas to cool and solidify in injection molding. It is prone to shrinkage marks and cavities due to melt contraction during cooling. The core of maintaining a first pressure P1 for a first duration t1 is to replenish the material lost due to melt contraction into the cavity 130 through continuous high pressure, filling the gaps formed during cooling. This helps reduce shrinkage marks and cavities in and around the gate area 170, ensuring a smooth, dent-free surface after the air guide is formed. Simultaneously, sufficient holding pressure and duration enhance the density of the melt, improving the structural strength of the gate area 170 and reducing the risk of breakage due to insufficient strength during subsequent use. Subsequently, the first pressure P1 is gradually reduced to the second pressure P2, then to the third pressure P3, and finally gradually reduced to 0 MPa.

[0140] As the gate gradually solidifies, the melt flow resistance increases, and the required feeding pressure gradually decreases. By gradually reducing the pressure, the surge in internal stress caused by sudden pressure changes is avoided, while ensuring that there is appropriate feeding pressure at different solidification stages, so that the feeding process can be smoothly transitioned.

[0141] Step S220: For the curved area 170 degrees away from the gate area, use the fourth pressure P4 as the initial pressure and maintain the pressure. The maintaining pressure of the curved area is as follows: The relationship decays, where Px is the holding pressure at x, 170 from the gate area, k is the decay coefficient, e is the base of the natural logarithm, x is the distance from the gate area 170, and the fourth pressure P4 is less than the first pressure P1.

[0142] Here, in the curved area far from the gate, the melt flow path is relatively long, resulting in significant differences in melt temperature and pressure gradients, and the curved structure is prone to slight unevenness in wall thickness. The feeding demand in the corresponding region gradually decreases along the flow path, and the required holding pressure also decreases accordingly. Using the fourth pressure P4 as the initial holding pressure, the holding pressure is calculated according to... The pressure decay at different locations ensures that the holding pressure at each location precisely corresponds to the shrinkage at that location. The pressure is high near the gate and gradually decreases further away from the gate, avoiding excessive pressure at the far end that could lead to localized over-compression or insufficient pressure to compensate for shrinkage. This reduces the shrinkage difference between different areas and suppresses warping deformation. At the same time, reasonable pressure decay can prevent cracks from forming in curved areas due to stress concentration.

[0143] The attenuation coefficient k represents the proportion of the nonlinear and gradual attenuation of the holding pressure with respect to the propagation distance x in the direction of melt flow. The larger the value of k, the faster the pressure drops, and the smaller the value of k, the more stable the pressure drops.

[0144] Figure 5 This is a schematic diagram of the exponential decay curve of the holding pressure along the flow direction provided in the embodiments of this application. Figure 5In the diagram, the horizontal axis represents the distance x from the gate, in mm, and the vertical axis represents the relative holding pressure (P). X The unit is MPa, which represents the ratio of the current pressure to the initial pressure. Figure 5 The figure shows three exponential decay curves with different decay coefficients: k=0.1 (gradual decay), k=0.3 (moderate decay), and k=0.8 (rapid decay).

[0145] When k=0.1, the holding pressure decreases most gradually along the flow direction, maintaining a relatively high pressure over a longer flow path. When k=0.3, the holding pressure decreases at a moderate rate along the flow direction, with a faster decrease closer to the gate and a slower decrease further away. When k=0.8, the holding pressure decreases most rapidly along the flow direction, with a significant decrease in pressure over a short distance.

[0146] The three curves above show that the value of the attenuation coefficient k determines the attenuation rate of the holding pressure along the flow direction: the smaller the value of k, the gentler the pressure attenuation and the farther the pressure transmission distance. The larger the value of k, the more rapid the pressure attenuation and the shorter the pressure transmission distance. In practical applications, those skilled in the art can determine a suitable attenuation coefficient k value based on the wall thickness distribution, flow length ratio, flow path morphology, and rheological properties of the injection molded product, through conventional injection molding rheological tests, CAE mold flow simulation analysis, or pressure sensor measurements, so that the attenuation law of the holding pressure along the flow direction matches the shrinkage requirements at various locations in that region.

[0147] Step S230: The area in cavity 130 where the insert is set is pressurized with a fifth pressure P5 for a fourth time t4. The fourth time t4 is less than the total pressurization time of the gate area 170. The fifth pressure P5 is less than the first pressure P1 and greater than the fourth pressure P4.

[0148] Here, the coefficients of thermal expansion and cooling shrinkage rates of the insert and the injection molding material differ significantly. The injection molding material shrinks considerably upon cooling, while the insert shrinks very little. If the holding pressure is maintained for the normal duration, the continuous shrinkage of the injection molding material during the holding pressure process will generate a continuous shrinkage clamping force on the insert. This force will exceed the frictional force between the insert and the positioning point of cavity 130, causing the insert to shift or deviate, affecting the assembly accuracy and performance of the air guide. The holding pressure is set at the fifth pressure P5 for the fourth duration t4. The fourth duration t4 is less than the total holding pressure duration of the gate area 170, the fifth pressure P5 is less than the first pressure P1, and the fifth pressure P5 is greater than the fourth pressure P4. By prematurely terminating the holding pressure and stopping the application of holding pressure, the clamping force of the plastic shrinkage on the insert is reduced, preventing displacement of the insert due to uneven stress. By releasing the pressure early, the necessary shrinkage compensation of the melt around the insert is ensured while avoiding insert displacement caused by excessive holding pressure.

[0149] Compared to traditional uniform pressure holding methods, this application achieves precise adaptation to regions with different structures and shrinkage characteristics through a three-zone collaborative pressure holding mechanism: 170° high-pressure feeding in the gate zone, gradient pressure stabilization in the curved surface zone, and early pressure release in the insert zone. This solves common industry problems such as shrinkage marks, warpage, internal stress, and insert misalignment from a process perspective, significantly improving the appearance, dimensional accuracy, structural strength, and assembly performance of the server air guide. It is especially suitable for molding high-precision structural parts with thin walls, complex curved surfaces, and inserts, which can significantly reduce the defect rate and improve production stability and economic benefits.

[0150] In one possible implementation, during step S200, when the cavity 130 is held under pressure, the first pressure P1, the second pressure P2, the third pressure P3, the fourth pressure P4, and the fifth pressure P5 respectively satisfy the following:

[0151] 90MPa≤P1≤100MPa, 40MPa≤P2≤50MPa, 20MPa≤P3≤30MPa, 40MPa≤P4≤48MPa; 48MPa<P5≤55MPa. The first duration t1, the second duration t2, and the third duration t3 satisfy the following conditions respectively: 0.5s≤t1≤1.1s, 0.8s≤t2≤1.2s, and 1.2s≤t3≤3.0s.

[0152] Here, the initial first pressure P1 of the gate area 170 is set to 90MPa to 100MPa (preferably 95MPa). The gate area 170 is the entrance for melt filling and one of the last areas to cool and solidify in injection molding, where shrinkage is greatest. If the first pressure P1 is lower than 90MPa, the compensation pressure is insufficient to fill the volume gap caused by cooling shrinkage, easily resulting in shrinkage marks and cavities in and around the gate area 170. If the first pressure P1 is higher than 100MPa, flash is easily generated, and excessive pressure will increase the internal stress of the product, affecting dimensional stability. Controlling the first pressure P1 within the range of 90MPa to 100MPa ensures that the gate area 170 receives sufficient compensation without generating flash, achieving a balance between compensation effect and internal stress control.

[0153] The second pressure P2 is set to 40 MPa to 50 MPa (preferably 45 MPa), and the third pressure P3 is set to 20 MPa to 30 MPa (preferably 25 MPa). As the gate gradually solidifies, the melt flow resistance increases, and the required feeding pressure gradually decreases. The values ​​of the second pressure P2 and the third pressure P3 ensure that there is appropriate feeding pressure at each solidification stage during the transition from high-pressure feeding to low-pressure feeding in the gate zone 170, while the gradual reduction of pressure avoids the surge in internal stress caused by sudden pressure changes.

[0154] The initial pressure in the curved surface region, also known as the fourth pressure P4, is set to 40 MPa to 48 MPa (preferably 45 MPa). The fourth pressure P4 is lower than the first pressure P1 and partially overlaps with the range of the second pressure P2 (which is 40 MPa to 50 MPa, and the fourth pressure P4 is 40 MPa to 48 MPa). The fourth pressure P4 serves as the starting pressure for the exponential decay of the curved surface region, and its value range is lower than that of the first pressure P1, ensuring that the initial compensation pressure in the curved surface region is moderate. The fourth pressure P4 is set according to... The relationship decays exponentially along the flow path, allowing different locations far from the gate to receive compensating pressure corresponding to the shrinkage amount. This helps to solve the problem of excessively high pressure at the far end leading to local over-compression or insufficient pressure to compensate for shrinkage.

[0155] Here, the coefficients of thermal expansion and cooling shrinkage rates of the injection molding materials differ greatly. The injection molding material shrinks significantly upon cooling, while the insert shrinks very little. If pressure is maintained for the normal duration, the continuous shrinkage of the injection molding material during this process will exert a continuous shrinkage clamping force on the insert. This force will exceed the frictional force between the insert and the cavity 130 positioning point, causing the insert to shift or deviate, affecting the assembly accuracy and performance of the air guide.

[0156] Compared to traditional uniform pressure holding methods, this application achieves precise adaptation to regions with different structures and shrinkage characteristics through a three-zone collaborative pressure holding mechanism: 170° high-pressure feeding in the gate zone, gradient pressure stabilization in the curved surface zone, and early pressure release in the insert zone. This solves common industry problems such as shrinkage marks, warpage, internal stress, and insert misalignment from a process perspective, significantly improving the appearance, dimensional accuracy, structural strength, and assembly performance of the server air guide. It is especially suitable for molding high-precision structural parts with thin walls, complex curved surfaces, and inserts, which can significantly reduce the defect rate and improve production stability and economic benefits.

[0157] It is understood that the specific values ​​of the holding pressure and holding time mentioned above (e.g., P1=95MPa, P2=45MPa, P3=25MPa, P4=45MPa, P5=50MPa, t1=0.8s, t2=0.8s to 1.2s, t3=1.2s to 3.0s, t4=1.2s) are merely examples. Those skilled in the art can make reasonable adjustments based on the type of injection molding material, the specific structure of the air guide, and the flow path morphology through conventional injection molding process experiments or CAE mold flow simulation analysis. All of these are within the scope of protection of this application.

[0158] It should be noted that the gate area 170, curved surface area, and insert area in the above-mentioned pressure holding step are pressure holding regions divided based on the distance from the gate and the flow path, which is a different region division method from the aforementioned temperature control area 140 divided based on wall thickness. The pressure holding area is used to determine the pressure holding at different locations, and the temperature control area 140 is used to determine the cooling temperature at locations with different wall thicknesses; the two are independent of each other.

[0159] In one possible implementation, such as Figure 4 As shown, after step S300 above, the temperature of each temperature control zone is independently adjusted to the corresponding target temperature so that the injection material in the cavity 130 is formed into an injection molded part, the injection molding method further includes step S400: taking the cooled and formed air guide cover out of the cavity 130 and placing it into the shaping fixture for correction.

[0160] Specifically, step S400 includes the following sub-steps: smoothly remove the air guide cover after injection molding, cooling and initial shaping from the cavity 130, and then accurately place the air guide cover inside the cavity 130 of the matching shaping fixture, so that the outer contour, inner contour and each structural feature surface of the air guide cover are completely in contact with the positioning surface and pressing surface of the shaping fixture.

[0161] After ensuring the air guide cover is properly positioned without tilting or warping, activate the clamping mechanism of the forming fixture to apply forming pressure to the entire air guide cover. This allows the air guide cover to undergo dimensional correction and stress release under the constraint of the fixture, eliminating slight deformation, warping, and springback tendencies that may occur after demolding. Once the correction is complete and the product's dimensions have returned to design requirements, release the forming pressure, open the forming fixture, and smoothly remove the corrected air guide cover from the fixture.

[0162] This application uses a shaping fixture to perform dimensional correction and stress release on the air guide after demolding. This effectively eliminates slight deformation and warping caused during injection molding cooling and demolding, ensuring that the product's external dimensions are restored to the design requirements, and further improving the dimensional accuracy and assembly consistency of the air guide.

[0163] The above provides a detailed description of an injection mold and injection method provided in this application. Specific examples have been used to illustrate the principles and implementation methods of this application. The descriptions of the embodiments above are merely for the purpose of helping to understand the method and core ideas of this application. It should be noted that those skilled in the art can make various improvements and modifications to this application without departing from its principles, and these improvements and modifications also fall within the protection scope of this application.

Claims

1. An injection mold, characterized in that, include: The mold body (100) has a cavity (130) inside, and the cavity (130) has at least two temperature control zones (140) with different thicknesses. Cooling channel (200) is provided inside the mold body (100). At least one cooling channel (200) is provided on the outside of each temperature control area (140). The cooling channel (200) is used to cool the corresponding temperature control area (140) respectively. At least two temperature regulating devices (300) are provided, each corresponding to a temperature control area (140). Each temperature regulating device (300) includes a temperature detection element (310) and a temperature regulating element (320). The temperature detection element (310) is used to detect the temperature of the corresponding temperature control area (140). The temperature regulating element (320) is located on the mold body (100) at a position corresponding to the temperature control area (140). The temperature regulating element (320) is used to heat or cool the corresponding temperature control area (140) according to the temperature detected by the temperature detection element (310), so as to adjust the temperature of the corresponding temperature control area (140) to the corresponding target temperature.

2. The injection mold according to claim 1, characterized in that, The temperature detection element (310) is disposed on the mold body (100), and the distance a between the temperature detection element (310) and the inner surface of the corresponding temperature control area (140) satisfies: 0.8mm≤a≤1.2mm.

3. The injection mold according to claim 2, characterized in that, At least two cooling channels (200) are provided on the outside of the temperature control area (140), and an installation groove (150) is provided between two adjacent cooling channels (200). The temperature detection element (310) is located at the bottom of the installation groove (150).

4. The injection mold according to claim 1, characterized in that, The temperature regulating component (320) includes a first temperature regulating component, a second temperature regulating component, and a third temperature regulating component; the first temperature regulating component is located outside the temperature control area (140) in the thick-walled portion, and is used to raise the temperature of the temperature control area (140) to a first target temperature; the second temperature regulating component is located outside the temperature control area (140) in the thin-walled portion, and is used to cool the temperature control area (140) to a second target temperature; the third temperature regulating component is located outside the temperature control area (140) in the transition portion between the thick-walled portion and the thin-walled portion, and is used to cool the temperature gradient of the temperature control area (140) to a third target temperature; both the second target temperature and the third target temperature are lower than the first target temperature, and the third target temperature is lower than the second target temperature; And / or, the mold body (100) is provided with a partition groove (160), two adjacent temperature control areas (140) are located on opposite sides of the partition groove (160), and the temperature detection element (310) and the temperature adjustment element (320) are provided on opposite sides of the partition groove (160).

5. The injection mold according to claim 1, characterized in that, The temperature regulating device (300) further includes a controller (330), and the temperature detection element (310) and the temperature regulating element (320) in each of the temperature regulating devices (300) are electrically connected to the controller (330); The controller (330) is configured to control the temperature regulator (320) to heat or cool the position on the mold body (100) corresponding to the temperature control area (140) based on the deviation between the temperature of the temperature control area (140) detected by the temperature detector (310) and the corresponding target temperature, so as to adjust the temperature of the temperature control area (140) to the corresponding target temperature.

6. The injection mold according to claim 5, characterized in that, The temperature regulating device (300) includes a controller (330), at least two temperature sensors (310) and at least two temperature regulators (320), and the temperature sensors (310) and the temperature regulators (320) are all electrically connected to the controller (330); And / or, the temperature regulating element (320) is a semiconductor cooling element having two opposing first temperature regulating surfaces and a second temperature regulating surface, the first temperature regulating surface being connected to the mold body (100) and located outside the corresponding cooling channel (200), the controller (330) being configured to control the current direction of the semiconductor cooling element so that the first temperature regulating surface heats or cools the position on the mold body (100) corresponding to the temperature control area (140) to regulate the temperature of the temperature control area (140).

7. An injection molding method, using the injection mold according to any one of claims 1 to 6, characterized in that, The injection molding method includes the following steps: Molten injection material is injected into the cavity (130) of the mold body (100) of the injection mold; Cooling medium is introduced into multiple cooling channels (200) outside each temperature control area (140) of each injection mold. The temperature of the corresponding temperature control area (140) of the injection mold is detected by the temperature detection element (310) of the injection mold. The temperature adjustment element (320) of the injection mold heats or cools the position on the mold body (100) corresponding to the temperature control area (140) according to the detected temperature of the temperature detection element (310) so as to adjust the temperature of the corresponding temperature control area (140) to the corresponding target temperature.

8. The injection molding method according to claim 7, characterized in that, The process of injecting molten injection material into the cavity (130) of the mold body (100) of the injection mold includes: The injection molding machine (400) fills the cavity (130) with the injection material at a first injection speed to 25%-35% of the volume, and the injection molding machine (400) fills the remaining cavity (130) with the injection material at a second injection speed, wherein the first injection speed is greater than the second injection speed; And / or, the step of introducing cooling medium into the plurality of cooling channels (200) outside each of the temperature control zones (140), detecting the temperature of the corresponding temperature control zone (140) of the injection mold through the temperature detection element (310) of the injection mold, and the temperature adjustment element (320) of the injection mold heating or cooling the position on the mold body (100) corresponding to the temperature control zone (140) according to the detected temperature of the temperature detection element (310), so as to adjust the temperature of the corresponding temperature control zone (140) to the corresponding target temperature, includes: The first temperature regulating component of the injection mold raises the temperature of the temperature control area (140) corresponding to the thick-walled part to the first target temperature; The second temperature regulating component of the injection mold cools the temperature of the temperature control area (140) corresponding to the thin-walled portion to the second target temperature; The third temperature regulating component of the injection mold cools the temperature gradient of the temperature control area (140) corresponding to the transition between the thick-walled portion and the thin-walled portion to a third target temperature, where both the second target temperature and the third target temperature are lower than the first target temperature, and the third target temperature is lower than the second target temperature.

9. The injection molding method according to claim 7, characterized in that, After injecting molten injection material into the cavity (130) of the mold body (100) of the injection mold, the injection molding method further includes: holding pressure on the cavity (130), wherein holding pressure on the cavity (130) includes: The gate area (170) of the cavity (130) is pressurized with a first pressure P1 for a first time t1, the first pressure P1 is reduced to a second pressure P2 within a second time t2, the second pressure P2 is reduced to a third pressure P3 within a third time t3, and then the third pressure P3 is gradually reduced to 0 MPa. For the curved area far from the gate area (170), the fourth pressure P4 is used as the initial pressure for holding pressure, and the holding pressure of the curved area is according to... The relationship decays, where P x It is the holding pressure at a distance x from the gate area (170), k is the attenuation coefficient, e is the base of the natural logarithm, x is the distance from the gate area (170), and the fourth pressure P4 is less than the first pressure P1; The area in the cavity (130) where the insert is located is held under pressure for a fourth time t4 with a fifth pressure P5. The fourth time t4 is less than the total holding time of the gate area (170). The fifth pressure P5 is less than the first pressure P1 and greater than the fourth pressure P4.

10. The injection molding method according to claim 9, characterized in that, During the pressure holding process of the cavity (130), the first pressure P1, the second pressure P2, the third pressure P3, the fourth pressure P4, and the fifth pressure P5 respectively satisfy the following: 90MPa≤P1≤100MPa, 40MPa≤P2≤50MPa, 20MPa≤P3≤30MPa, 40MPa≤P4≤48MPa; 48MPa<P5≤55MPa; And / or, the first duration t1, the second duration t2, and the third duration t3 respectively satisfy: 0.5s≤t1≤1.1s, 0.8s≤t2≤1.2s, 1.2s≤t3≤3.0s.

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