Battery Terminal Insert Molding to Prevent Resin Burrs
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Solution Overview
Problem
The existing method for producing power storage devices, such as batteries, results in the formation of resin burrs on terminal top surfaces due to variations in terminal dimensions during the insert-molding process, leading to inconsistent clearance and burr formation.
Innovation Solution
A method involving the use of a first mold with a flat top-face contact portion and a second mold with a contact portion to compress and elastically deform the terminal member, ensuring the terminal top surface is tightly contacted and reducing resin flow between the mold and terminal, thereby preventing burr formation regardless of terminal dimension variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If insert-molding is performed without pre-compression of the terminal member, then the molding process is simple, but resin burrs form on the terminal top surface due to dimensional variations
Solution Approach 1:
The terminal member is pre-compressed in the molding direction before resin injection to eliminate clearance between the terminal top surface and mold. This preliminary action ensures that dimensional variations in terminal members do not result in burr formation, while maintaining a relatively simple overall molding process.
Solution Approach 2:
The compression amount is set to 1-5% of the terminal member's length in the molding direction. By controlling this parameter within a specific range, the terminal top surface is sufficiently compressed to prevent burr formation, while avoiding excessive compression that could cause deformation or damage to the terminal member.
2Manufacturing precision
If the terminal member is compressed to eliminate clearance, then resin burr formation is prevented, but the terminal member may deform
Solution Approach 1:
The compression amount is precisely controlled to be 1-5% of the terminal member's length in the molding direction. This parameter optimization ensures sufficient compression to eliminate clearance and prevent burr formation, while remaining below the threshold that would cause permanent deformation or damage to the terminal member structure.
Solution Approach 2:
Instead of completely eliminating all clearance through excessive compression, the patent applies a controlled partial compression (1-5%) that is sufficient to prevent burr formation without causing deformation. This balanced approach achieves the necessary precision while maintaining structural integrity.
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 ensures consistent contact and reduces resin burr formation on terminal surfaces, maintaining surface integrity and assembly precision across varying terminal dimensions.
Implementation Method 1
a deformed portion of the terminal member positioned between the terminal top surface and the to-be-contacted portion is compressed and elastically deformed in the orthogonal direction to press and tightly contact with the terminal top surface on the top-face contact portion
Data Source
AI summary
A method for producing a power storage device includes a process of insert-molding. This process is to relatively move a first mold and a second mold to press a terminal top surface of a terminal member by a top-face close-contact portion of the first mold to a second-mold side and to press a to-be-contacted portion of the terminal member by a contact portion of the second mold to a first-mold side so that a deformed portion of the terminal member is elastically deformed. A resin member is thus insert-molded while the terminal top surface is pressed and tightly contacted with the top-face contact portion.