Mold Feed Channel Layout for Mixed-Pressure Encapsulation
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Solution Overview
Problem
Existing methods for producing mold modules, such as those involving low-pressure pouring and separate shells, are time-consuming and costly, and fail to effectively protect pressure-sensitive components from excessive mold pressure.
Innovation Solution
A mold device with a cavity divided into low-pressure and high-pressure subspaces by a separating web, using injection channels of different cross-sectional areas to control mold pressure, allowing for the production of mold bodies with varying pressures in a single process step, and incorporating pressure sensors and flow detection to manage pressure and prevent damage to sensitive components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single mold tool is used for both low-pressure and high-pressure molding, then productivity is improved by producing different mold bodies in one process step, but device complexity increases due to the need for separating webs and multiple injection channels with different cross-sections
Solution Approach 1:
The mold cavity is segmented into multiple sub-chambers (first sub-chamber and second sub-chamber) by separating webs, allowing different molding conditions to be applied to different components simultaneously. This enables production of both pressure-sensitive and pressure-insensitive mold bodies in one cycle, improving productivity while managing complexity through functional segmentation.
Solution Approach 2:
Different regions of the mold cavity are assigned different pressure characteristics through separately controllable injection channels with different cross-sectional areas. The first injection channel has a smaller cross-section for low-pressure molding of pressure-sensitive components, while the second injection channel has a larger cross-section for high-pressure molding of pressure-insensitive components, allowing local optimization of molding conditions.
2Reliability
If low-pressure molding is used for pressure-sensitive components, then reliability is improved by protecting components from damage, but production time increases due to separate molding processes
Solution Approach 1:
The mold tool merges multiple molding functions into a single device, enabling simultaneous low-pressure molding of pressure-sensitive components in the first sub-chamber and high-pressure molding of pressure-insensitive components in the second sub-chamber. This eliminates the need for separate molding processes, reducing production time while maintaining component protection through dedicated low-pressure zones.
Solution Approach 2:
Pressure-sensitive components are positioned and protected in advance within the first sub-chamber before the high-pressure molding cycle begins. The separating webs and injection channel design pre-establish pressure barriers that prevent damage during the molding process, ensuring component reliability without requiring additional protective steps or sequential processing.
3Manufacturing precision
If the low-pressure injection channel has a smaller cross-section, then manufacturing precision is improved by enabling controlled solidification and pressure blocking, but device complexity increases due to narrowed channel design
Solution Approach 1:
The injection channel cross-sectional area is varied along its length, with a narrowed section designed to control the solidification process. This geometric parameter change enables the channel to transition from a flow path to a pressure barrier as the molding compound solidifies, providing precise pressure control for protecting pressure-sensitive components without requiring complex active control systems.
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
Enables the production of mold modules with pressure-sensitive components protected from excessive pressure and pressure-insensitive components embedded in high-pressure regions, achieving efficient underfilling and reducing production time and costs by utilizing a single mold tool for different pressure processes.
Implementation Method 1
The low-pressure injection channel is designed to become pressure-tightly blocked by hardening of the molding compound
Implementation Method 2
a common pressing device designed to allow the mold pressure to act on both the low-pressure injection channel and the high-pressure injection channel
Data Source
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AI summary
The invention relates to a mould device comprising a tool part and another tool part, said tool part and the other tool part surrounding a cavity together, with at least one of said tool parts, or only one tool part, having at least one separator; the separator is designed and arranged to divide the cavity into at least two, or only two sub-spaces, namely a low-pressure sub-space and a high-pressure sub-space; the tool part has at least two feed channels, of which a low-pressure feed channel feeds into the low-pressure sub-space, and has a smaller cross-section at least on a longitudinal section than a high-pressure feed channel feeding into the high-pressure sub-space; the low-pressure feed channel is designed such that it is plugged in a pressure-tight manner by solidifying the moulding mass, in particular after a predetermined time interval has elapsed or during said time interval; and the high-pressure feed channel is designed such that, in the meantime, it directs a mould pressure into the cavity for a longer time, in particular a longer time interval, than the low-pressure feed channel.