Master Mould Tool Insert with Solid Metallic Glass for Cooling Delay
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Solution Overview
Problem
Existing tool inserts for injection molding and die casting suffer from surface defects due to uneven mold wall temperatures, leading to issues like weld line notches, differences in gloss, and cloud formation, which are exacerbated by the high energy and investment costs associated with temperature control and the limited design flexibility of ceramic materials.
Innovation Solution
A tool insert with a thermal insulator made of solid metallic glass or a composite insulator, which has a lower thermal conductivity than the base body, allowing for controlled cooling delay and surface quality improvement while maintaining design flexibility, and can be integrated with a wear-resistant layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional electrical heating cartridges are arranged in recesses of the mold to increase mold wall temperature, then the flowability of plastic melt is improved, but additional energy costs and investment costs for heating elements and control units are incurred
Solution Approach 1:
The invention changes the thermal conductivity parameter of the mold wall by using a multi-layer structure with thermal insulators and tempering layers, replacing the conventional approach of adding heating elements. This parameter change allows the mold wall to retain heat more effectively, improving plastic melt flowability without requiring additional energy input from heating cartridges.
Solution Approach 2:
The invention employs composite material structures combining different layers with varying thermal conductivities - thermal insulators (low thermal conductivity) and tempering layers (higher thermal conductivity). This composite structure creates optimized thermal management in the mold wall, allowing localized temperature control and improved plastic flow without the need for additional heating elements and associated energy costs.
2Manufacturing precision
If ceramic tool inserts are used to delay cooling of plastic melt, then certain optical properties on the surface are improved, but the creation of high-gloss surfaces and structured surfaces is limited and requires significant technical and financial investment
Solution Approach 1:
The invention combines ceramic thermal insulators with metallic tempering layers to create a composite structure that overcomes the limitations of pure ceramic materials. The tempering layer provides the necessary design flexibility for creating high-gloss and structured surfaces, while the ceramic insulator layer maintains the cooling delay effect. This composite approach eliminates the need for significant additional investment while achieving both optical quality and design freedom.
Solution Approach 2:
The invention applies different material properties to different layers of the tool insert structure. The thermal insulator layer provides localized thermal management properties, while the tempering layer provides localized surface quality and design flexibility. This local differentiation of material qualities allows the system to achieve multiple functions simultaneously without requiring significant additional investment.
3Manufacturing precision
If the molding surface is spaced from the base body by a thermal insulator, then cooling of the plastic melt is delayed and surface quality is improved, but the structure becomes more complex and additional materials are required
Solution Approach 1:
The invention integrates multiple functional layers (thermal insulator layer and tempering layer) into a single composite tool insert structure. While this does increase structural complexity compared to a monolithic design, the layered composite structure provides multiple benefits simultaneously - thermal insulation for cooling delay, tempering for surface quality, and improved thermal management. The complexity is justified by the multiple functions achieved in a single integrated component.
Solution Approach 2:
The multi-layer tool insert structure serves multiple functions: the thermal insulator layer delays cooling to improve surface quality, the tempering layer provides enhanced thermal conductivity and surface properties, and the combination enables improved thermal management overall. This multi-functionality in a single integrated component reduces the need for separate parts and assemblies, making the increased structural complexity worthwhile.
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 use of solid metallic glass insulators in tool inserts achieves improved surface quality by delaying cooling, reduces energy costs, and allows for high-gloss and structured surfaces without additional investment, while minimizing thermal stress and extending tool life.
Implementation Method 1
a thermal insulator arranged on a base body, with a molding surface contacted by the molten material to be shaped, which is at least partially spaced from the base body of the tool insert by a thermal insulator
Implementation Method 2
the thermal insulator comprises a solid metallic glass
Data Source
Figure 1~2
Figure 3
AI summary
Described is a tool insert for a primary forming tool, comprising a thermal insulator arranged on a base body with a forming surface contacted by the molten material to be shaped, which is at least partially separated from the base body of the tool insert by a thermal insulator. The thermal insulator comprises solid metallic glass.