Power Storage Resin Molding With Nested Inserts to Prevent Burrs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing resin molding methods for power storage devices face challenges such as molding failures due to nest interference and resin leakage, which occur when the mold dimensions are not accurately matched to the nest dimensions, leading to burrs and inefficient resin distribution.
Innovation Solution
A method involving a nested structure where a nest is first molded with a first resin, then inserted into a second mold with identical concave portion dimensions to produce a resin member, ensuring precise positioning and minimizing resin leakage, using resins with different melting points to enhance the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the dimensions of the concave portion of the mold are set larger than the dimensions of the nest to prevent interference, then the nest is protected from breaking, but resin may leak through the gap during molding causing burrs
Solution Approach 1:
The patent applies nesting by placing the nest (insert) inside the concave portion of the mold, and then molding the resin member around it. The nest is subsequently removed to form a through hole. This nested structure allows precise positioning while preventing resin leakage that would cause burrs.
Solution Approach 2:
The nest is prepared and positioned in the concave portion of the mold before the resin molding process begins. This preliminary positioning ensures that the nest is securely in place to prevent resin leakage during molding, while its pre-positioned geometry prevents interference with the molding process.
2Ease of operation
If the dimensions of the concave portion of the mold are set relatively larger in the width direction to accommodate nest displacement, then the nest can be inserted, but molding failure such as burr is more likely to occur
Solution Approach 1:
The patent addresses asymmetric nest displacement in the width direction by designing the concave portion dimensions to be larger in that specific direction. This asymmetric dimensioning accommodates the directional displacement while maintaining precise control to prevent resin leakage and burr formation.
3Device complexity
If a single resin molding process is used to form both the nest and resin member, then the process is simplified, but accurate resin distribution and positioning are difficult to achieve
Solution Approach 1:
The patent segments the molding process into two distinct steps: first molding the nest (insert) with controlled resin distribution, then removing the nest and molding the resin member in a second process. This segmentation allows precise control of resin distribution in each step, achieving high manufacturing precision while maintaining reasonable process complexity.
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 method effectively reduces molding failures by ensuring accurate resin distribution and preventing burrs, resulting in a high-quality resin member for power storage devices.
Implementation Method 1
a first molding step of molding a resin portion by feeding a first resin between the nest A and the first concave portion
Implementation Method 2
a second molding step of molding a resin member by feeding a second resin between the stacked member and the second mold
Data Source
AI summary
A main object of the present disclosure is to provide a method for producing a power storage device wherein a molding failure hardly occurs when molding a resin member. The present disclosure achieves the object by providing a method for producing a power storage device, the method comprising: a preparing step of preparing a predetermined stacked member; a first placing step of placing a predetermined first mold; a first molding step of obtaining a predetermined nest B; a second placing step of placing a predetermined second mold; and a second molding step of molding a predetermined resin member.