Parallel Cooling Channels in Injection Molds
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Solution Overview
Problem
Current injection molding technologies face inefficiencies in heat dissipation and pressure loss due to serial cooling concepts, leading to prolonged cycle times, distortion, and maintenance issues in producing medical containers like syringe nests.
Innovation Solution
A parallel cooling concept is implemented, where temperature-control channels are arranged in parallel to minimize pressure losses and maximize heat removal, using a network of channel portions connected to reduce the volume flow and enhance dirt resistance, thereby improving the efficiency and uniformity of the cooling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a serial cooling concept is used, then the temperature-control medium can be transported through the cooling channels, but the pressure loss is very high and the cooling efficiency is reduced
Solution Approach 1:
The cooling system is segmented into multiple parallel cooling circuits instead of a single serial path. Each circuit has its own temperature-control medium connection, allowing independent flow paths that reduce cumulative pressure loss while maintaining effective cooling across all cores
Solution Approach 2:
The patent applies hydraulic principles by optimizing the flow distribution of the temperature-control medium through parallel channels. The system uses fluid dynamics to balance the volume flow across multiple circuits, ensuring efficient heat removal while minimizing pressure losses through proper channel design and arrangement
2Productivity
If the volume flow is increased to improve cooling efficiency, then heat removal is enhanced, but the risk of blockages from dirt particles increases
Solution Approach 1:
By dividing the cooling system into multiple parallel circuits, the volume flow through each individual channel is reduced compared to a single serial path. This lower flow velocity in each channel decreases the likelihood of dirt particle deposition and blockages, while the combined effect of all channels maintains high overall cooling efficiency
Solution Approach 2:
The system changes the flow parameters by distributing the total volume flow across multiple parallel paths. This parameter adjustment allows each channel to operate at optimal flow conditions that prevent blockage while collectively achieving the required heat removal rate
3Loss of energy
If conformal cooling is realised to remove heat effectively from areas with low surface-to-volume ratio, then heat removal is improved, but the distortion behaviour of the workpiece is strongly pronounced
Solution Approach 1:
The cooling system is divided into multiple independent parallel circuits, each capable of being temperature-controlled separately. This segmentation allows for balanced heat removal across different regions of the workpiece, preventing excessive thermal gradients that cause distortion while maintaining effective conformal cooling in critical areas
Solution Approach 2:
Different parallel cooling circuits can be optimized for local cooling requirements. Areas with low surface-to-volume ratio receive enhanced cooling where needed, while other areas are cooled appropriately for their specific thermal characteristics, preventing uniform overheating and reducing overall distortion
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 cycle times, minimizes distortion, and lowers maintenance costs by increasing the volume flow and reducing the need for extensive tubing, enhancing the overall efficiency and quality of the injection molding process.
Implementation Method 1
the amount of heat which is produced must be removed as efficiently as possible... the temperature-control medium should have a higher temperature for heating... the temperature-control medium (usually water or oil) is transported successively through the cooling channel portions
Implementation Method 2
the temperature-control medium is transported successively through the cooling channel portions and thereby successively through the individual cores
Data Source
AI summary
An injection mold having a cavity for receiving a plastics melt and having a temperature-control system. The cavity comprises a plate-shaped first part and a plurality of hollow cylindrical second parts arranged next to one another perpendicularly to the first part. The temperature-control system comprises temperature-control channels divided into channel portions for transporting a temperature-control medium and a first and a second temperature-control medium connection, with at least one first channel portion arranged in parallel with the first part. Second channel portions are connected by a first end to the first channel portion and by a second end to a first end of a third channel portion. Third channel portions are connected by a second end to a fourth channel portion. One of the second channel portions and the connected third channel portion are surrounded at least in part by one of the second parts of the cavity.