Power Storage Lid Insert Molding for Bubble-Free Resin Sealing
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Solution Overview
Problem
Existing methods for producing power storage devices result in air bubbles due to low resin pressure, or deformation of the case member due to high resin pressure during insert-molding, leading to incomplete resin distribution and structural issues.
Innovation Solution
The method involves insert-molding the resin member by positioning the insertion hole of the case member in front of the gate, allowing molten resin to flow through the insertion hole to an opposite space, ensuring complete cavity coverage without air bubbles and minimizing case deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If resin pressure is increased to prevent air bubbles, then air bubble generation is reduced, but case member deformation occurs
Solution Approach 1:
The cavity is divided into multiple regions (gate-side space and opposite gate-side space) with the insertion hole acting as a flow path separator. This segmentation allows controlled resin flow through the insertion hole, distributing pressure evenly and preventing both air bubbles and deformation
Solution Approach 2:
The insertion hole is pre-positioned in front of the gate before resin injection. This preliminary positioning ensures that resin flows through the insertion hole first, establishing a controlled flow path that prevents air bubble formation without requiring excessive pressure that would cause deformation
2Manufacturing precision
If resin pressure is decreased to prevent case deformation, then case member integrity is maintained, but air bubbles are generated in the resin member
Solution Approach 1:
The insertion hole acts as an intermediary flow path that guides resin from the gate-side space to the opposite gate-side space. This intermediary structure ensures complete cavity coverage at lower pressures by directing flow through a controlled path, preventing air bubble formation without compromising case integrity
3Object-generated harmful factors
If insertion hole size is reduced to minimize resin burrs, then resin burr formation is decreased, but resin flow control becomes more difficult
Solution Approach 1:
The solution addresses resin flow control not by changing insertion hole dimensions but by changing the spatial arrangement - positioning the insertion hole in front of the gate. This dimensional repositioning allows small insertion holes to effectively control resin flow direction and distribution, minimizing burrs while maintaining ease of manufacture
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 enables the formation of resin members without air bubbles and prevents case deformation, while allowing for reduced insertion hole size and minimized resin burrs, resulting in a high-quality power storage device.
Implementation Method 1
injecting the molten resin through the gate into the cavity, so that the molten resin flows, through the insertion hole, to an opposite gate-side space located on an opposite side from the gate relative to the case member, and spreads over the entire cavity
Data Source
AI summary
A method for producing a power storage device includes an insert-molding step of making a resin member by insert-molding with respect to a terminal member inserted in an insertion hole of a lid. In this insert-molding step, the insertion hole of the lid is placed in front of a gate, and a molten resin is injected through the gate to flow in an opposite gate-side space in a cavity through the insertion hole, allowing the molten resin to spread over the entire cavity, to form the resin member.