Clinched Metal Part Overmolding for Low-Waste Busbar Assembly
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Solution Overview
Problem
The existing methods for producing busbars for electric vehicles often result in significant waste due to complex geometries and require multiple tools and processes, which are inefficient and costly.
Innovation Solution
Integration of a clinching device with a punch and die into an injection molding tool allows for the simultaneous clinching and overmolding of metal parts, reducing waste and the number of tools needed by combining the processes of mechanical connection and plastic encapsulation within a single manufacturing step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If busbars are made from a single sheet of metal, then manufacturing simplicity is improved, but material waste increases due to complex geometries
Solution Approach 1:
The busbar is divided into multiple individual metal parts that are connected through clinching, allowing each part to be optimized for its specific function while reducing overall material waste compared to cutting complex geometries from a single sheet
2Loss of substance
If busbars are assembled from several smaller individual parts, then material waste is reduced, but the number of tools and processes increases
Solution Approach 1:
The injection molding tool is integrated with a clinching device, merging the plastic encapsulation process and mechanical connection process into a single integrated tool system, thereby reducing the number of separate tools and processes needed
Solution Approach 2:
The injection molding tool is designed to perform multiple functions: it provides plastic encapsulation for electrical insulation and simultaneously houses the clinching device for mechanical connection of metal parts, making the tool multi-functional
3Ease of manufacture
If clinching and overmolding are performed as separate processes, then process simplicity is improved, but productivity decreases due to multiple steps
Solution Approach 1:
The clinching device and injection molding process are combined into a single integrated system, allowing both the mechanical connection of metal parts and the plastic encapsulation to be performed simultaneously in one operation, thereby increasing productivity without significantly complicating the overall process
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 waste, and lowers production costs by enabling the efficient connection and encapsulation of metal parts in a single operation, enhancing the production efficiency and reducing the complexity of the manufacturing process.
Implementation Method 1
The plasticized synthetic material can be provided at high pressure by an extruder of an injection molding machine in liquid or fluid form
Implementation Method 2
When filled, the plastic material can take on or mold the contour of the mold cavity and solidify into the plastic component in the mold cavity. In particular, the plastic material can be a thermoplastic that solidifies when cooled within the mold cavity
Implementation Method 3
The injection molding tool can be cooled for this purpose
Data Source
AI summary
An injection molding tool and method are used to create a connection between at least two metal parts. The metal parts are inserted into the injection molding tool. Using a clinching device of the injection molding tool, the metal parts are mechanically connected to one another by clinching and are encapsulated with a plastic material using an extruder connected to the injection molding tool so as to, at least partially, enclose the metal parts with overmolding or casting.