Insert Molding Component With Heat Insulation For Battery Protection
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Solution Overview
Problem
In insert molding processes, built-in components, such as lithium-ion batteries, often degrade due to high temperatures and pressures during the resin molding process, which can lead to malfunction and safety issues.
Innovation Solution
The method involves creating a concave portion on a primary molding section to house the insert component, applying a heat-insulating component on top, and molding a secondary section that contacts the primary section, ensuring the insert component remains within a safe temperature range and is protected from excessive pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If insert molding process is used to build electronic components in resin molding, then product downsizing and manufacturing simplification are achieved, but built-in components are subjected to high temperature and high pressure causing property degradation
Solution Approach 1:
The molding process is divided into two separate stages: first molding the resin portion, then molding the cover portion. This segmentation allows the insert component to be protected from high temperature and pressure during the first molding, while still achieving integration of all components in the final product.
Solution Approach 2:
The resin portion is molded first, creating a protective structure before the insert component is exposed to high temperature and pressure. The heat-insulating component is also preliminarily positioned to protect the insert during subsequent molding operations.
2Manufacturing precision
If high temperature and high pressure are applied during resin molding, then molding quality is improved, but insert components such as lithium-ion batteries degrade and malfunction
Solution Approach 1:
A heat-insulating component is introduced as an intermediary between the insert component and the high temperature environment. This heat insulating member blocks thermal transmission, allowing high temperature molding of the cover portion without damaging the insert component.
Solution Approach 2:
The molding process is split into two stages: first molding the resin portion at lower temperature, then molding the cover portion at high temperature. This segmentation ensures that the insert component is only exposed to high temperature during the second stage when it is already protected by the resin portion and heat-insulating component.
3Adaptability or versatility
If insert components are built in during resin molding, then integration is achieved, but components are exposed to excessive pressure causing degradation
Solution Approach 1:
The molding process is divided into two stages: first molding the resin portion with the insert component at lower pressure, then molding the cover portion at high pressure. This segmentation ensures that the insert component is only exposed to high pressure during the second stage when it is already protected by the resin portion.
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 configuration prevents the degradation of insert components by maintaining the lithium-ion battery at a safe temperature and shielding it from high pressure, ensuring the integrity and safety of the insert molding component, suitable for applications like wearable electronics.
Implementation Method 1
a heat-insulating component (50) made of an olefin sheet
Data Source
AI summary
An insert molding component includes a primary molding section having a concave portion formed in one surface thereof, the concave portion including stepped lower and upper concave portions, an insert component disposed on a bottom surface of the lower concave portion, a heat-insulating component disposed in the upper concave portion above an opening of the lower concave portion in which the insert component is disposed, and a secondary molding section disposed in contact with the one surface of the primary molding section.