Center Pillar Hot Forming Mold With Diffusion-Bonded Cooling Channels

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Solution Overview

Problem

Existing manufacturing methods for hot forming molds struggle to consistently form cooling channels with uniform depth and distance along the edge of the forming surface, leading to variations in cooling efficiency, reduced productivity, and potential water leakage issues.

Innovation Solution

A manufacturing method involving solid phase diffusion bonding of divided metal materials with pre-processed cooling channels, allowing for precise formation of cooling channels with regular depth and distance, and adjusting cooling speed by varying material thickness, while omitting sealing tasks to reduce costs and enhance productivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If cooling channels are processed using gun drill method, then manufacturing process is simple, but cooling channel depth becomes non-uniform leading to variable cooling efficiency

Engineering Contradiction:

Improvecooling channel processing simplicityVSAvoidcooling channel depth uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The mold is divided into multiple mold plates that are stacked together. Cooling channels are formed in each individual plate, and when stacked, these channels align to create the complete cooling system. This segmentation allows each plate to be processed independently with precise cooling channel formation, eliminating the depth uniformity issues of gun drill methods while maintaining manufacturing simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Cooling channels are pre-formed in each mold plate before assembly. The channels are created with precise depth and positioning in the individual plates, then the plates are stacked and fastened together. This preliminary action ensures uniform cooling channel depth is achieved without requiring complex post-assembly adjustments.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If multiple mold plates are overlaid and fastened with long bolts, then water tightness can be ensured, but manufacturing time increases and durability decreases under impact pressure

Engineering Contradiction:

Improvewater tightnessVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The mold is segmented into multiple plates that can be quickly assembled using short fastening members rather than one long bolt. This segmentation enables parallel processing and faster assembly while maintaining structural integrity and water tightness through the stacked configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using a single long bolt to fasten the entire mold assembly, the invention inverts the approach by using multiple short fastening members distributed across the stacked plates. This inversion reduces manufacturing time and improves durability under impact while maintaining water tightness.

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of manufacture

If cooling channels are processed with non-uniform depth, then manufacturing is easier, but product quality uniformity deteriorates due to deformation

Engineering Contradiction:

Improvecooling channel processing easeVSAvoidproduct quality uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

By segmenting the mold into separate plates, each with uniformly formed cooling channels, the system achieves consistent cooling across the entire mold. This segmentation allows precise channel formation in each plate while maintaining ease of manufacture through standardized processing of individual components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The stacked plate structure ensures homogeneous cooling channel depth and spacing throughout the entire mold assembly. Each plate contributes uniformly formed channels that align perfectly when stacked, creating consistent cooling conditions across all mold surfaces and preventing product deformation.

Inventive Principle:

Principle #33Homogeneity

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 method ensures uniform cooling efficiency, minimizes water leakage, and improves product quality by forming cooling channels with consistent depth and distance, reducing manufacturing time and costs.

Implementation Method 1

a solid phase diffusion bonding step of performing solid phase diffusion bonding after sequentially locating the plurality of divided materials such that cooling channels abut to form an integrated material

Methodology Applied

Scientific EffectSolid phase diffusion bonding: Diffusion Welding

Data Source

PatentUS11679530B2Manufacturing method of hot forming mold for center pillar trim including cooling unit

Publication Date: 2023.06.20 TNP CORPORATION

AI summary

A manufacturing method of a hot forming mold of a center pillar including a cooling unit is provided. The method includes a step of preparing a material by dividing the material, a cooling channel processing step of processing cooling channels on a front surface and a rear surface within a contour line by center pillar design information input in advance to an NC processor and cooling channel design information, a solid phase diffusion bonding step, a mold material processing step of processing along the contour line by the center pillar design information input in advance through the NC processor to manufacture a mold material, and a thermal processing step of heating the mold material at a predetermined temperature.