Method of manufacturing a mold body

Abstract

A method includes 3D printing a mold body from polycarbonate to form a cavity surface and 3D printing a permanent hydrophobic structure of polycarbonate on the cavity surface. The hydrophobic structure comprises a plurality of regularly shaped protrusions extending from and spaced 0 mm to 1.5 mm apart on the cavity surface. The patterned protrusions impart permanent hydrophobicity to the mold cavity surface.

Claims

1. A method, comprising: manufacturing a mold body having a cavity surface; and creating a permanent hydrophobic structure on the cavity surface, wherein the mold body and the hydrophobic structure are 3D printed, wherein the mold body or the hydrophobic structure are made of polycarbonate, wherein the hydrophobic structure comprises a plurality of regularly shaped protrusions, and wherein each protrusion is spaced from an adjacent protrusion at a distance of 0 mm to 1.5 mm.

2. The method according to claim 1, wherein the hydrophobic structure and the mold body are created simultaneously.

3. The method according to claim 1, wherein the mold body and the hydrophobic structure are made of polycarbonate.

4. The method according to claim 1, wherein the protrusions are formed as a shape selected from a list consisting of a hemisphere, a cone, a frustum, and a pyramid.

5. The method according to claim 1, wherein each protrusion has a quadratic base having an area of 0.25 mm.sup.2 to 1 mm.sup.2.

6. The method according to claim 1, wherein each protrusion has a tip.

7. The method according to claim 1, wherein the hydrophobic structure is created with a height of 0.1 mm to 1 mm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention is now described, by way of example with reference to the accompanying drawings, in which:

(2) FIG. 1 is an enlarged schematic illustration of a hydrophobic structure on a cavity surface of a mold body, according to an embodiment of the present disclosure; and

(3) FIG. 2 is an enlarged schematic illustration of a further hydrophobic structure on a cavity surface of a mold body, according to another embodiment of the present disclosure.

DETAILED DESCRIPTION

(4) FIG. 1 depicts an enlarged schematic view of a mold body 10 that is used to form a cavity in which polyurethane will contact a cavity surface 11 of the mold body 10 when producing a polyurethane product by injection molding or overmolding. A mold may be composed of at least one mold body and further components commonly forming a cavity for receiving the polyurethane material.

(5) As shown in FIG. 1, the cavity surface 11 of the mold body 10 is provided with a hydrophobic surface structure S.

(6) When manufacturing the injection mold body shown in FIG. 1, the hydrophobic structure S and the mold body 10 are created during the same manufacturing step, e.g. by 3D printing a polycarbonate based resin material that can be hardened by UV radiation. In other words, not only the mold body 10 but also the hydrophobic structure S may be 3D printed of the same material, e.g. in one process step.

(7) The hydrophobic structure S comprises a plurality of regularly shaped protrusions that may have various geometrical shapes to form a microstructure. In the embodiment shown in FIG. 1 the protrusions 12 have the shape of a pyramid having a sharp tip and a quadratic base with a length 14 between 0.5 and 1 mm. Of course, these dimensions may vary. Furthermore, each pyramid or protrusion 12 is spaced from an adjacent pyramid or protrusion at a distance that may be chosen between 0 and about 1.5 mm, e.g., as 0.5 or 1 mm. The hydrophobic structure S may be created with a height of about 0.1 to 1 mm, e.g. of 0.25 to 0.5 mm as measured perpendicular to the cavity surface 11.

(8) FIG. 2 shows a further embodiment of a mold body 10 having a cavity surface 11 with a hydrophobic surface structure S being created on the cavity surface 11. In this embodiment, the protrusions are shaped as hemispheres having a radius of e.g. about 1 mm and a distance to adjacent hemispheres of about 1 mm.

(9) As shown in FIG. 2, the protrusions of one row are shifted to the protrusions of an adjacent row such that one protrusion (having a circular ground area) is partly nested between two adjacent protrusions. Such arrangement minimizes the space between adjacent protrusions as compared to an arrangement in which four adjacent protrusions are located at the four corners of a square.

(10) A polyurethane injection mold body that has been manufactured according to a method as described above can advantageously be used for producing a polyurethane product without applying a release agent to the mold before injecting the polyurethane material. At least, the amount of release agent can be significantly reduced without negatively affecting the release properties and the shape and quality of the final product.

(11) Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled.

(12) As used herein, one or more includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.

(13) It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact. The terminology used in the description of the various described embodiments herein is for the purpose of describing embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term and/or as used herein refers to and encompasses all possible combinations of one or more of the associated listed items. It will be further understood that the terms includes, including, includes, and/or including, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

(14) As used herein, the term if is, optionally, construed to mean when or upon or in response to determining or in response to detecting, depending on the context. Similarly, the phrase if it is determined or if [a stated condition or event] is detected is, optionally, construed to mean upon determining or in response to determining or upon detecting [the stated condition or event] or in response to detecting [the stated condition or event], depending on the context.

(15) Additionally, while terms of ordinance or orientation may be used herein these elements should not be limited by these terms. All terms of ordinance or orientation, unless stated otherwise, are used for purposes distinguishing one element from another, and do not denote any order of arrangement, order of operations, direction or orientation unless stated otherwise.