Injection Mold Temperature Control via Spray Welding

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Solution Overview

Problem

Existing molds for injection molding face limitations in shape and structural strength due to the placement and shape of heating and cooling elements, which restricts their heating and heat dissipation effects.

Innovation Solution

A method of manufacturing a mold for injection molding that involves covering a temperature control element, such as a heat or cool tube, with a material like copper or aluminum through spray welding or casting, allowing the element to be formed into various shapes and integrated into a mold body with a heat insulating layer and a flat surface, enhancing heating and cooling efficiency while maintaining structural strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If heating and cooling elements are disposed in the mold by drilling, then the mold can be manufactured with temperature control, but the disposition places and shapes of the elements are limited and structural strength is compromised

Engineering Contradiction:

Improvetemperature control effectVSAvoidstructural strength

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The temperature control elements (heating and cooling channels) are merged with the mold body through spray welding, creating an integrated structure. This eliminates the need for separate drilling operations and maintains the structural integrity of the mold while incorporating temperature control functionality throughout the mold body.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The heating and cooling elements are prepared in advance as separate components with predetermined shapes and positions, then attached to the mold body before the final molding process. This preliminary preparation allows for optimized element design without compromising the mold's structural strength during assembly.

Inventive Principle:

Principle #10Preliminary action

2Temperature

If heating and cooling elements are disposed in the mold by drilling, then the mold can be manufactured with temperature control, but the shapes of the elements are limited

Engineering Contradiction:

Improveheating and heat dissipating effectVSAvoidshape of temperature control element

Core Design Contradiction:

TemperatureVSShape

Solution Approach 1:

The invention changes the manufacturing parameter from drilling (which constrains shape) to spray welding (which allows flexible shaping). This enables the temperature control elements to be formed into various complex shapes including curved channels, varying cross-sections, and optimized flow paths that would be impossible to achieve through drilling alone.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The temperature control elements can now be designed with dynamic, varying shapes rather than fixed cylindrical drill holes. The channels can change diameter, direction, and distribution throughout the mold body to optimize thermal management for different regions, adapting to the specific heating and cooling requirements of each area.

Inventive Principle:

Principle #15Dynamics

3Temperature

If temperature control elements are shaped flexibly, then heating and cooling efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveheating and cooling efficiencyVSAvoidmanufacturing difficulty

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The invention replaces the traditional mechanical drilling system with a spray welding process. This substitution allows for the creation of complex, optimized temperature control element shapes without increasing manufacturing difficulty, as the spray welding process can accommodate various geometries more easily than drilling operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 allows for improved heating and cooling effects without structural compromise, enabling more flexible mold designs and efficient temperature control by allowing the temperature control elements to be shaped as needed and integrating a heat insulating layer to optimize performance.

Implementation Method 1

the temperature of the molding materials is greater than the temperature of the mold. To prevent the molding materials from cooling too fast due to the lower temperature of the mold, a heating element such as a heat plate or a heat tube may be disposed in the mold to preheat the mold

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The heat insulating layer corresponds to the temperature control element and is formed on the mold body

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS8322397B2Mold for injection molding and method of manufacturing thereof

Publication Date: 2012.12.04 PEGATRON

AI summary

This invention provides a mold for injection molding and a method of manufacturing thereof. The method of manufacturing a mold for injection molding includes the following steps. At least one temperature control element is provided. The temperature control element is covered with a first material. The first material is mechanically processed to form a mold body with a cavity. The mold for injection molding includes a mold body, a temperature control element, and a heat insulating layer.