Hot Stamping Method for Channel Formation
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Solution Overview
Problem
Current methods for creating channels in components, such as mechanical machining and injection molding, face challenges including complex programming, inadequate surface quality, high costs, and core misalignment, which hinder efficient and cost-effective production with high surface quality.
Innovation Solution
A method involving a preform with a recess, where a channel implementation element is heated above the melting temperature of the preform material and moved into the recess to displace the preform material, allowing for the creation of channels with high surface quality and precision, enabling the implementation of channels with varying cross sections and internal contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If mechanical machining (milling) is used to create channels with variable cross sections, then complex shapes and undercuts can be implemented, but the surface quality is inadequate and requires additional smoothing steps
Solution Approach 1:
The patent utilizes the phase transition of material from solid to liquid and back to solid. A heated implementation element (above melting temperature) is inserted into the preform, melting the material locally. The molten material is then displaced to form the channel, and upon cooling, solidifies to create a smooth channel surface without machining grooves.
2Productivity
If injection molding is used to create channels, then channels can be formed during molding, but core misalignment occurs with long cores resulting in different wall thicknesses
Solution Approach 1:
The patent performs preliminary action by creating a recess in the preform before channel implementation. This recess serves as a receptacle that guides the implementation element and contains the molten material during displacement, ensuring uniform wall thicknesses and preventing misalignment issues.
3Adaptability or versatility
If injection molding with long cores is used, then channels can be formed, but core misalignment occurs resulting in different wall thicknesses
Solution Approach 1:
The patent segments the channel implementation process into distinct steps: first creating a recess in the preform, then separately inserting the heated implementation element to melt and displace material. This segmentation eliminates the need for long, alignment-critical cores while achieving precise channel formation.
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 results in channels with high surface quality and precision, minimizing material shrinkage and demolding issues, allowing for constant cross sections and wall thicknesses, and enabling the creation of channels in a single process step, reducing costs and effort.
Implementation Method 1
heating a channel implementation element (30) to a temperature greater than a melting temperature of a material of the preform
Implementation Method 2
the material of the preform is at least partially melted in a region around the recess
Data Source
AI summary
A method for implementing a channel (56) includes providing a preform (20) having a recess (22) therein and heating a channel implementation element (30′) to a temperature greater than a melting temperature of a material of the preform (20). An external contour of the channel implementation element (30′) at least regionally corresponds to an internal contour of the channel (56) to be implemented. The method then moves the heated channel implementation and/or the preform (20) in relation to one another so that the heated channel implementation element (56) at least regionally moves into the recess (22) in a moving-in direction. The material of the preform (20) is at least partially melted in a region around the recess (20) and is at least partially displaced by the channel implementation element (30′), wherein at least a part of the channel (56) to be implemented is thus implemented.