Cap Assembly Mold Insert Injection Molding
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Solution Overview
Problem
Conventional secondary battery manufacturing processes are time-consuming, prone to defects, and risk electrical short circuits, deformation, and explosion due to complex assembly steps and high-temperature molding, which complicates the integration of protection circuit boards and cap assemblies.
Innovation Solution
A cap assembly mold is developed where the protection circuit board, safety element, and cap housing are integrally formed through insert injection molding, allowing for a single assembly step and precise component positioning, eliminating the need for separate electrical connections and reducing the risk of short circuits by exposing connection terminals for direct electrical connection to the battery cell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional multi-step assembly process is used to connect protection circuit board, safety element, and cap housing separately, then electrical connections can be made, but the assembly process becomes time-consuming and prone to defects
Solution Approach 1:
The patent combines the protection circuit board, safety element, and cap housing into a single integrated cap assembly mold. This merging eliminates multiple separate assembly steps, reducing assembly time and complexity while maintaining all necessary electrical connection functions through the integrated structure.
2Strength
If high-temperature and high-pressure molding is applied to integrate components, then component coupling is strengthened, but electrical short circuits and component deformation occur
Solution Approach 1:
The patent changes the molding parameters from high-temperature and high-pressure conditions to low-temperature and low-pressure conditions. This parameter modification allows the cap assembly mold to be integrated without subjecting electrical components to damaging conditions, preventing short circuits and deformation while still achieving strong component coupling.
3Manufacturing precision
If battery cell is subjected to physical pressure during molding, then component positioning is improved, but battery cell deformation occurs
Solution Approach 1:
The patent performs preliminary positioning of the battery cell and cap assembly mold components before the molding process. By pre-positioning components accurately, the need for high physical pressure during molding is eliminated, preventing battery cell deformation while maintaining precise component positioning.
4Reliability
If multiple assembly steps are used to connect components, then electrical connections can be established, but defective ratio increases
Solution Approach 1:
The patent merges all electrical connection components (protection circuit board, safety element, connection terminals) and structural components (cap housing) into a single integrated cap assembly mold. This eliminates multiple separate connection steps, reducing the defective ratio by minimizing handling and connection points while maintaining reliable electrical connections.
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 simplifies the manufacturing process, reduces defective products, ensures secure component coupling, and prevents electrical damage by avoiding high-temperature and high-pressure molding, allowing for easy separation and remanufacturing of the cap assembly mold, thereby increasing productivity and stability.
Implementation Method 1
the cap assembly mold is manufactured by integrally forming a protection circuit board, a safety element, connection terminals, and a cap housing by insert injection molding
Data Source
AI summary
Disclosed herein is a cap assembly mold mounted to a battery cell, in which an electrode assembly including cathodes/separators/anodes is disposed, wherein the cap assembly mold is manufactured by integrally forming a protection circuit board, a safety element, connection terminals, and a cap housing by insert injection molding, and, when the insert injection molding is carried out, the connection terminals are partially exposed from the lower end surface of the cap assembly mold such that the connection terminals can be electrically connected to electrode terminals of the battery cell. According to the present invention, the cap assembly mold is formed by insert injection molding in the state that the protection circuit and the battery are not connected with each other. Consequently, the molding process is carried out using normally available resins, the cap assembly mold is electrically stable, the coating process for preventing electrical short circuits is not necessary, and the possibility of electrical damage to the protection circuit is eliminated.