Coolable Moulding Tool Cover Layer Thermal Coating
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Solution Overview
Problem
Existing mold cooling technologies do not provide effective heat dissipation and protection for cooling channels, leading to inefficiencies in the cooling process and potential contamination.
Innovation Solution
A method for producing a coolable mold involves applying a metallic or oxide-ceramic cover layer over fluid paths using thermal coating processes, protecting them with a filling medium or channel device, and integrating cooling channels between the cover layer and the partial body, allowing for improved heat dissipation and contamination prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling channels are exposed on the tool surface, then heat dissipation is effective, but the channels are vulnerable to particle contamination and damage
Solution Approach 1:
A cover layer is introduced as an intermediary element between the cooling channels and the external environment. This cover layer protects the channels from particle contamination and mechanical damage while maintaining thermal contact for effective heat dissipation. The cover layer acts as a mediator that simultaneously addresses both the cooling efficiency requirement and the protection requirement.
Solution Approach 2:
The tool structure is designed as a composite system with the cover layer made of a material that provides both mechanical protection and thermal conductivity. The cover layer is applied over the cooling channels to create a protective yet thermally conductive structure, combining the protective function with the heat dissipation function in a single integrated component.
2Reliability
If a cover layer is applied over cooling channels, then channel protection is improved, but heat transfer efficiency may be reduced
Solution Approach 1:
The cover layer parameters (thickness, material composition, thermal conductivity) are optimized to maintain effective heat transfer while providing sufficient protection. By adjusting these parameters, the system achieves a balance where the cover layer is thick enough to protect against particles but thin and thermally conductive enough to allow efficient heat dissipation from the cooling channels.
3Reliability
If complex protection measures are implemented for cooling channels, then channel integrity is maintained, but manufacturing complexity increases
Solution Approach 1:
The protective function and the structural function are merged into a single cover layer component. Instead of implementing separate protection measures (such as individual protective coatings, shields, or complex sealing systems), the invention combines these functions into one integrated cover layer that is applied over the cooling channels, simplifying the manufacturing process while maintaining channel integrity.
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 method enhances cooling efficiency and maintains channel integrity by preventing particle ingress and ensuring effective heat transfer, while also simplifying the manufacturing and repair processes.
Implementation Method 1
applying a cover layer, preferably made of a metallic or oxide-ceramic material, over the protected fluid paths using a thermal coating process, for example flame spraying, laser spraying, Detonation spraying, cold gas spraying, arc spraying
Implementation Method 2
Arc spraying refers to the application of particles heated to approximately 4000°, in particular metallic and/or electrically conductive particles, to the surface. The particles can be heated and generated by means of an electric current in the presence of an outflowing compressed medium
Implementation Method 3
a flow channel running at a distance from the punch and/or die surface of the tool for a medium that removes heat from the workpiece
Data Source
Figure 1~2
AI summary
The invention relates to a method for producing a coolable moulding tool (1). In order to provide an improved moulding tool and also an improved method, the invention comprises the following steps: producing a partial body (13) of the moulding tool (1) which has fluid paths on the surface (17) of the tool, protecting the fluid paths against penetration of particles, and applying a cover layer (15) over the protected fluid paths (17) by means of a thermal coating process.