Amorphous Metal Resin Laminate Mold Thermal Management
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Solution Overview
Problem
Molding molds made of resin have low thermal conductivity, leading to slow cooling and potential filling failures, while those made of metal have high thermal conductivity, causing premature solidification and warpage in molded products.
Innovation Solution
A molding mold is manufactured using a laminate composed of an amorphous metal and a resin, which is shaped by plasticizing a first shaping material containing the amorphous metal and resin, and then laminated to form a cavity, optimizing thermal conductivity and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a molding mold is made of resin, then it is easy to manufacture and has good design flexibility, but thermal conductivity is low causing heat accumulation and slow cooling
Solution Approach 1:
The patent applies composite materials by combining resin with amorphous metal particles to create a molding mold that exhibits intermediate thermal conductivity between pure resin and metal. The composite structure allows the mold to maintain ease of manufacture from resin while incorporating the high thermal conductivity of amorphous metal particles, thereby resolving the contradiction between ease of manufacture and thermal conductivity.
2Temperature
If a molding mold is made of metal, then thermal conductivity is high enabling rapid cooling, but the material solidifies before filling the cavity causing filling failure
Solution Approach 1:
The patent uses composite materials consisting of resin matrix with dispersed amorphous metal particles. This composite structure provides intermediate thermal conductivity that is lower than pure metal, preventing premature solidification of the injection material and ensuring complete cavity filling, while still providing adequate cooling capability. This resolves the contradiction between high thermal conductivity and filling success.
3Loss of time
If a molding mold is made of metal, then cooling time is short, but molded products rapidly cool and warpage easily occurs
Solution Approach 1:
The patent employs composite materials with resin and amorphous metal particles to achieve intermediate thermal conductivity. This prevents excessive rapid cooling that causes warpage while still providing efficient heat removal. The resin matrix provides thermal insulation that moderates the cooling rate, maintaining dimensional stability of the molded product, thus resolving the contradiction between cooling time and dimensional stability.
4Reliability
If a molding mold is made of resin, then thermal conductivity is low preventing premature solidification, but heat accumulates in the molding mold
Solution Approach 1:
The patent utilizes composite materials combining resin with amorphous metal particles. The amorphous metal particles act as thermal conduits that conduct heat away from the mold cavity, preventing heat accumulation that would otherwise occur in pure resin molds. This maintains filling success while eliminating heat accumulation through the enhanced thermal pathways provided by the metal particles.
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
The laminate reduces heat accumulation, shortens cooling times, and minimizes filling failures and warpage in molded products, while allowing for stable mechanical characteristics and design flexibility.
Implementation Method 1
generating a first plasticized material by plasticizing a first shaping material containing an amorphous metal and a resin
Implementation Method 2
The laminate reduces heat accumulation, shortens cooling times
Data Source
AI summary
A method for manufacturing a molding mold used in an injection molding apparatus includes: generating a first plasticized material by plasticizing a first shaping material containing an amorphous metal and a resin; and shaping a laminate that is a part of the molding mold by discharging the first plasticized material toward a stage to laminate a layer.