Die-Casting Mold Venting Layout for Multi-Pin Heat Sinks
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Solution Overview
Problem
The use of porous material members for degassing in conventional die-casting molds to produce heat sink pins increases production costs as the number of heat sink pins increases.
Innovation Solution
A die-casting mold design with non-overlapping first and second through-holes and recessed grooves that allow gas passage while preventing molten metal from flowing between these holes, eliminating the need for specialized degassing parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If porous material members are used for degassing in each heat sink pin, then gas can be discharged from the molding space, but the number of porous material members increases with the number of heat sink pins, raising production costs
Solution Approach 1:
The patent merges the degassing function from individual porous material members into a single integrated porous plate structure. The porous plate is positioned to receive molten metal and gas from multiple first through-holes simultaneously, consolidating what would require multiple separate porous components into one unified component, thereby reducing part count and production cost while maintaining effective degassing across all heat sink pins
Solution Approach 2:
The porous plate serves as a universal degassing component for multiple heat sink pins simultaneously. Instead of requiring dedicated porous material in each pin location, the single porous plate performs the degassing function for the entire array of pins, making the system more efficient and cost-effective as the number of pins increases
2Productivity
If the number of heat sink pins is increased, then the heat sink performance is improved, but the number of porous material members must also increase, raising production costs
Solution Approach 1:
The patent enables scaling of heat sink pin quantity without proportionally increasing degassing parts by merging multiple degassing functions into a single porous plate. This allows the system to accommodate more pins while maintaining a constant number of degassing components, thus improving productivity without increasing device complexity
Solution Approach 2:
The porous plate is designed as a universal component that can serve multiple heat sink pins simultaneously. This multi-functional design allows the system to increase the number of pins for better heat sink performance without requiring additional porous material members, breaking the direct proportionality between pin count and degassing part count
3Ease of manufacture
If through-holes are provided in mold inserts for molding heat sink pins, then molten metal can flow to form pins, but gas trapped in the molding space needs a discharge path
Solution Approach 1:
The porous plate acts as an intermediary component between the first through-holes (for molten metal flow) and the second through-holes (for gas discharge). It receives both molten metal and gas from the first through-holes, separates them by allowing gas to pass through while blocking metal, and directs gas to the second through-holes for discharge, thus resolving the conflict between pin formation and gas entrapment
Solution Approach 2:
The patent utilizes porous material in the porous plate to enable selective passage of gas versus molten metal. The porous structure allows gas to pass through while blocking the larger molten metal, providing an automatic separation mechanism that facilitates both pin formation through the first through-holes and gas discharge through the second through-holes without requiring additional complex mechanisms
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
Enables efficient production of molded items with multiple heat sink pins without the use of costly degassing components, reducing production costs and simplifying the mold configuration.
Implementation Method 1
the recessed grooves prevent the melted metal material from passing therethrough but allow the gas to pass therethrough
Data Source
AI summary
A die-casting mold includes a first mold insert located on a side of a fixed die, and a second mold insert located on a side of a movable die. The first mold insert includes first through-holes filled with a melted metal material to be used to mold heat sink pins. The second mold insert includes second through-holes usable to discharge gas in a molding space. At least one of a first facing surface and a second facing surface includes recessed grooves communicated with the first and second through-holes when the first and second mold inserts are located in place, and the recessed grooves prevent the melted metal material from passing therethrough but allow the gas to pass therethrough. As seen in a die moving direction, the first through-holes do not overlap at least a portion of the second through-holes.