Closed Micro-Channel Fabrication via Injection Molding
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Solution Overview
Problem
Conventional fabrication methods for products with closed channels require time-consuming post-processing steps like adhesion or welding to couple substrate covers with channel substrates, reducing efficiency.
Innovation Solution
The method involves injection molding a channel substrate with opened micro-channels into a mold, where a substrate cover is molded on top without allowing the resin to fill the micro-channels, thereby integrating closed channels without additional coupling processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If substrate cover is coupled to channel substrate by adhesion or welding, then closed channels are formed, but fabrication time increases and efficiency decreases
Solution Approach 1:
The patent merges the substrate cover and channel substrate into a single integrated component by injecting resin directly into the mold cavity during the substrate cover molding process. This eliminates the need for separate adhesion or welding steps, achieving both closed channel formation and improved fabrication efficiency simultaneously.
Solution Approach 2:
The channel substrate is pre-mounted onto the mold before injecting the resin for the substrate cover. This preliminary positioning ensures that the resin will form the closed channels in the correct locations without requiring subsequent coupling operations, thereby improving productivity while maintaining reliability.
2Reliability
If separate molding and coupling processes are used, then closed channels are formed, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple fabrication steps (molding substrate cover, forming closed channels, and coupling components) into a single injection molding operation. This reduces manufacturing complexity while ensuring reliable channel closure through the integrated resin injection process.
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 fabrication process, saves production costs, and enhances work efficiency by eliminating the need for separate adhesion or welding, while maintaining the integrity of closed channels.
Implementation Method 1
a substrate cover molding step of molding a substrate cover by the injection molding on an upper surface of the channel substrate mounted to the mold
Data Source
AI summary
Disclosed is a fabrication method of products with closed channels by injection molding, which includes: a channel substrate mounting step of mounting a channel substrate comprising a plurality of opened micro-channels thereon to a mold; and a substrate cover molding step of molding a substrate cover by the injection molding on an upper surface of the channel substrate mounted to the mold, the substrate cover being coupled to the channel substrate while being molded. With this, the products with the closed channels can be fabricated without any additional coupling process between the channel substrate having the opened channels and the substrate cover, thereby simplifying a fabrication process and enhancing work efficiency.