Mold Coating Embedded Temperature Control
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Solution Overview
Problem
Existing molds for producing large fiber-reinforced plastic components, such as those used in aerospace and automotive industries, face inefficiencies due to energy-intensive heating and cooling processes, long heat transport distances, and heavy, cumbersome metal tools that require extensive energy and complex manufacturing processes.
Innovation Solution
A mold manufacturing method involving a base body coated with a temperature control device embedded between the base body and a sprayed coating, utilizing lightweight materials like foamed plastic, ceramic, or fiber-reinforced plastic, with integrated heating and cooling channels or electrical heating elements, allowing for near-surface temperature control and efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat is supplied from outside the mold using conventional heating devices, then the mold can be heated, but the heating-up and cooling phases become long and energy consumption increases due to long heat transport distances through the entire metal block
Solution Approach 1:
The mold is divided into a base body made of lightweight material and a separate coating layer made of metal or metal foam. The temperature control device is integrated into the base body, allowing heat to be generated and applied directly at the mold surface rather than transporting heat through the entire mold structure from outside.
Solution Approach 2:
The coating layer acts as an intermediary between the temperature control device in the base body and the plastic molding process. This coating provides the necessary thermal properties and surface characteristics while the lightweight base body provides structural support with minimal thermal mass.
2Temperature
If heat is supplied from outside the mold, then the mold can be heated, but the heating and cooling processes require extensive energy due to the need to heat the entire metal block
Solution Approach 1:
The mold structure is segmented into a lightweight base body and a thin coating layer. This segmentation reduces the overall thermal mass that needs to be heated and cooled, significantly reducing energy losses during temperature control cycles.
Solution Approach 2:
The invention changes the material parameters of the mold by using lightweight materials (plastic, foamed plastic, ceramic, or fiber-reinforced plastic) for the base body instead of traditional solid metal. This parameter change reduces thermal mass and associated energy losses while maintaining functional performance through the metal or metal foam coating.
3Strength
If traditional metal molds are used, then the molds provide structural strength, but they have high specific weight and dead mass that must be heated or cooled, leading to high energy losses
Solution Approach 1:
The mold is constructed as a composite structure with a lightweight base body made of plastic, foamed plastic, ceramic, or fiber-reinforced plastic combined with a coating layer of metal or metal foam. This composite structure provides the necessary structural strength while minimizing weight and thermal mass.
Solution Approach 2:
The invention fundamentally changes the material parameters by replacing solid metal with lightweight materials for the base body. This parameter change reduces weight and thermal mass by a significant factor while the coating layer maintains the necessary surface properties and structural integrity.
4Weight of moving object
If plastic molds are used, then the molds are lighter, but heat flow to the tool surface is made more difficult by the insulating properties of the plastic
Solution Approach 1:
The composite structure combines the advantages of both plastic and metal: the plastic or foam base body provides lightweight construction while the metal or metal foam coating layer provides excellent thermal conductivity for efficient heat flow to the mold surface.
Solution Approach 2:
Different parts of the mold have different material properties optimized for their specific functions: the base body uses lightweight insulating material for structural support and weight reduction, while the coating layer uses thermally conductive metal material for efficient heat transfer at the mold surface.
5Manufacturing precision
If molds are made by machining from a solid block or complex casting processes, then the molds achieve required precision, but the manufacturing process becomes time-consuming and cost-intensive
Solution Approach 1:
The base body is pre-formed using molding or foaming processes to achieve the basic shape and integrate the temperature control device. This preliminary action eliminates the need for time-consuming machining from solid blocks, while the subsequent coating process achieves the required surface precision.
Solution Approach 2:
The composite construction allows the base body to be manufactured using efficient molding or foaming processes, while the coating layer is applied using thermal spraying or similar processes. This combination of manufacturing methods is both time-efficient and cost-effective while achieving the required precision.
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 reduces energy consumption and production time by enabling selective heating and cooling, increasing the production rate and allowing for the use of lightweight, easily machined tools with improved heat transfer and design flexibility, suitable for large components like aircraft and wind turbine parts.
Implementation Method 1
electrical heating conductors
Implementation Method 2
The second material is sprayed onto the base body in a spraying process. The spraying process is advantageously a thermal spraying process.
Data Source
AI summary
The invention relates to a mold (10) for producing in particular fiber-reinforced plastic molded parts, comprising a main body (12) made of a first material, which main body is provided with a coating (24) made of a second material on a molding surface (14), wherein a temperature-control apparatus (18) is provided in a boundary region between the main body (12) and the coating (24), said temperature-control apparatus being embedded between the first material and the second material. The invention further relates to a production device for producing fiber-reinforced plastic molded parts that is provided with the mold and to a mold production method for producing the mold.