Adhesive-Bonded Plastic Injection Mold with 3D Printed Cooling
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Solution Overview
Problem
The existing methods for manufacturing plastic injection molding molds are limited by the complexity and inefficiency of traditional tooling processes, particularly in combining metallic and plastic components, and in providing effective cooling systems.
Innovation Solution
A tool for plastic injection molding is created by combining a metallic mold with a plastic carrier using an adhesive layer, where both components are manufactured through 3D printing, allowing for simplified assembly and integration of cooling ducts, and optionally using injection back-molding for enhanced rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional metal molds are manufactured using conventional machining methods, then manufacturing precision and strength are improved, but manufacturing time and complexity increase significantly
Solution Approach 1:
The patent changes the manufacturing method from conventional machining to 3D printing (additive manufacturing), fundamentally altering the production parameters. This allows complex mold geometries to be created directly from digital models without traditional machining constraints, reducing manufacturing time while maintaining precision through controlled deposition processes
Solution Approach 2:
The patent incorporates cooling ducts and other internal features directly into the mold structure during the 3D printing process itself, rather than adding them as separate post-processing steps. This preliminary integration of cooling systems and structural elements eliminates subsequent assembly operations and reduces overall manufacturing time
2Strength
If metal mold thickness is increased to improve strength and rigidity, then structural integrity is improved, but manufacturing complexity and time increase
Solution Approach 1:
The patent changes the material from metal to plastic for the mold structure, fundamentally altering the strength-to-weight ratio and structural requirements. This material parameter change allows thinner walls and simpler structures to achieve the same structural integrity, reducing manufacturing complexity while maintaining strength through the inherent properties of the plastic material and optimized geometry
Solution Approach 2:
The patent uses 3D printing technology to create complex three-dimensional mold structures with optimized geometry that cannot be achieved through traditional machining. This enables strength to be achieved through intelligent spatial design and distribution of material rather than simply increasing overall thickness, reducing structural complexity
3Temperature
If complex cooling systems are integrated into traditional metal molds, then cooling efficiency is improved, but manufacturing complexity and assembly time increase
Solution Approach 1:
The patent merges the cooling system with the mold structure itself, creating an integrated design where cooling ducts are built directly into the mold body during 3D printing. This combination eliminates the need for separate cooling system assembly and reduces the number of components, simplifying the overall device while maintaining effective cooling through direct thermal contact between the ducts and mold cavity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the manufacturing process, reduces the thickness requirements for metallic molds, and enables the production of smaller components with improved cooling efficiency, facilitating the assembly of complex molds with increased rigidity and ease of installation in injection molding machines.
Implementation Method 1
the metallic mold and the plastic carrier are connected to one another by an adhesive layer or by adhesion
Implementation Method 2
both of which are themselves constructed from a number of plates... A tool for the hot forming of metal sheets, which has a functional layer applied to a base block of the tool in a laser sintering process... the at least one metallic mold is manufactured by a 3D printing process
Implementation Method 3
the plastic carrier and/or the metallic mold to exhibit recesses which serve as cooling ducts
Data Source
AI summary
Tool for plastic injection molding consisting of at least one metallic mold and at least one plastic carrier, wherein the metallic mold and the plastic carrier are connected to one another by an adhesive layer.