Dual-Texture Injection Mould Surface for Faster Demoulding
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Solution Overview
Problem
Existing moulding technologies require a significant running-in time to achieve a steady production cycle, particularly in multi-cavity injection moulding, due to the buildup of material on the mould surface and difficulty in removing objects, which affects efficiency and maintenance.
Innovation Solution
A mould design with a surface structure featuring sharper first features and less pronounced second features, combined with a coating, to facilitate rapid material buildup and easy demoulding, reducing or eliminating the need for a running-in period.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional mould surface is used, then the mould structure is simple, but a running-in time is required to build up sufficient material layer for steady production
Solution Approach 1:
The mould surface is pre-treated with a dual-layer structure (first section with sharp features and second section with rounded features) before production begins. This preliminary surface preparation eliminates the need for running-in time by pre-establishing the optimal material buildup conditions, allowing immediate steady-state production.
Solution Approach 2:
Different regions of the mould surface are given different geometric properties: the first section has sharp features that promote rapid material buildup, while the second section has rounded features that facilitate demoulding. This local differentiation allows each region to perform its specific function optimally without requiring a running-in period.
2Ease of operation
If a conventional mould surface is used, then the manufacturing process is simple, but demoulding of the object becomes difficult
Solution Approach 1:
The second section of the mould surface features rounded geometric structures that specifically facilitate demoulding operations. These rounded features reduce friction and stress concentration during ejection, making demoulding easier without requiring complex external mechanisms.
Solution Approach 2:
The mould surface is divided into functionally distinct sections: the first section optimized for material buildup and the second section optimized for demoulding. This segmentation allows each region to independently perform its specialized function, improving overall operational ease.
3Manufacturing precision
If a conventional mould surface is used, then the structure is simple, but geometrical conformity of the moulded object is reduced
Solution Approach 1:
The first section with sharp features provides precise geometric definition for the moulded object surface. The sharp edges and corners in this region ensure high-fidelity reproduction of the cavity geometry, achieving excellent geometrical conformity in critical areas.
4Ease of manufacture
If a conventional mould surface is used, then the surface is clean initially, but residue accumulates quickly requiring frequent maintenance
Solution Approach 1:
The second section with rounded features creates a self-cleaning effect during demoulding. The rounded geometry prevents material adhesion and facilitates complete object removal, minimizing residue accumulation on the mould surface and reducing maintenance frequency.
Data Source
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AI summary
A method of manufacturing a mould and a mould arranged for manufacturing an object, preferably a mould for injection moulding an object comprising a plastic material, the mould comprising: - a first mould section arranged for, during use, delimiting a part of a cavity for manufacturing the object; - a surface structure provided at a side of the first mould section facing, during use, the cavity, wherein the surface structure comprises: - a first section provided with first features; - a second section provided with second features, wherein the first features are sharper than the second features; and wherein the first section is provided at a side of the second section facing away, during use, from the cavity.