Porous Electroformed Shell Pore Control via Fiber Implantation
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Solution Overview
Problem
Existing methods for manufacturing porous electroformed shells for patterning face challenges in efficiently and economically controlling the diameters, formation positions, and densities of fine pores on three-dimensional electroformed shells, leading to low productivity and economic efficiency, as well as complex and time-consuming processes.
Innovation Solution
A method involving fiber implantation into a patterned silicone cast, followed by epoxy mandrel formation, conductive thin film creation, fiber removal, and electroforming to generate fine pores, allowing precise control over pore diameters, positions, and densities, with the use of nickel, copper, or brass electrodeposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to manufacture porous electroformed shells, then the basic shell structure can be obtained, but the control over pore diameters, formation positions, and densities is complex and time-consuming
Solution Approach 1:
The invention applies preliminary action by pre-forming the pore structure through fiber implantation into the mold cavity before electroforming. The fibers are positioned in advance to define pore locations, and the electroformed shell grows around these pre-positioned fibers, automatically creating pores at the desired positions with controlled diameters when the fibers are removed.
Solution Approach 2:
The invention uses fibers as an intermediary element to control pore formation. The fibers serve as temporary placeholders that define pore positions and diameters during the electroforming process. After electroforming, the fibers are removed, leaving precisely controlled pores in the shell without requiring complex direct pore formation equipment.
2Productivity
If conventional methods are used to manufacture porous electroformed shells, then the shell can be produced, but the production efficiency and economic efficiency are low
Solution Approach 1:
The invention merges multiple operations into a single integrated process. Fiber implantation, shell electroforming, and pore formation are combined into one continuous manufacturing step. The shell is electroformed directly over the implanted fibers, and pore formation occurs automatically when fibers are removed, eliminating separate pore creation steps and reducing total manufacturing time.
Solution Approach 2:
The electroforming process itself serves to create the pores through the pre-positioned fibers. The shell material deposits around the fibers during electroforming, and the pores are self-formed when fibers are removed, without requiring additional post-processing equipment or operations for pore creation.
3Manufacturing precision
If conventional methods are used to create patterns on electroformed shells, then basic patterning can be achieved, but the overall formation positions, shapes, densities, and diameters of pores cannot be precisely controlled according to various curved shapes
Solution Approach 1:
The invention applies local quality by allowing different fiber types, sizes, and densities to be implanted in different regions of the mold cavity. This enables local control of pore characteristics - for example, higher fiber density in areas requiring finer pore patterns, or specific fiber arrangements to match local curvature requirements of the shell being formed.
Solution Approach 2:
The invention transitions from two-dimensional flat patterning to three-dimensional curved surface patterning by implanting fibers that conform to the mold cavity's curved geometry. The fibers are positioned in three-dimensional space to match the desired pore distribution on the curved shell surface, enabling precise pore control across complex three-dimensional shapes.
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 method enables the production of porous electroformed shells with high precision and regularity in pore distribution, enhancing the texture and pattern quality of injection molded products while reducing production costs and complexity.
Implementation Method 1
an electroforming step of forming an electrodeposited layer by electrodepositing an electroforming metal on the conductive thin film while generating and growing a fine pore at a position of a hole due to the removal of the fiber
Data Source
AI summary
Disclosed are a porous electroformed shell for forming a grain pattern and a manufacturing method thereof. The method includes the step of implanting a fiber into a patterned surface of a negative-type silicone cast; applying, laminating, and curing an epoxy resin on the patterned surface of the negative-type silicone cast, and transferring the fiber from the negative-type silicone cast to an epoxy mandrel during demolding of the epoxy mandrel; forming a conductive thin film on the patterned surface of the epoxy mandrel, and causing the patterned surface to be conductive; removing the fiber having the conductive thin film from a surface of the epoxy mandrel; forming an electrodeposited layer by electrodepositing an electroforming metal on the conductive thin film while generating and growing a fine pore at a position of a hole due to the removal of the fiber; and demolding the electrodeposited layer having the fine pore from the epoxy mandrel. Through the disclosed method, precise control on a diameter and distribution of a fine pore can be simply and efficiently can be carried out.