Precise Injection Molding Solutions
2025-06-13 15:15High-Precision Injection Molding for Electric Vehicle Battery Storage Components
Part Name: Electric Vehicle Battery Storage
Material: PA66 (BASELL) – High-temperature, flame-retardant nylon for superior mechanical and thermal stability
Mold Type: Insert Molding / Injection Molding (Multi-Cavity Production)
Cavity & Core: H13 Tool Steel (Hardened to 48-52 HRC for extended mold life)
Mold Base: LKM Standard (DME-compatible for global serviceability)
Hot Runner System: Moldmaster 4-Point Hot Nozzle (Precision temperature control for consistent fill)
Tolerance: ±0.2mm (Critical for battery sealing surfaces)
Technical Challenges & Solutions
1. Ultra-Thin Wall Molding (0.7mm Grid Structure)
Challenge: Flow hesitation risks in PA66 due to high aspect ratio (depth-to-thickness > 15:1)
Solution:
Moldflow® simulation-optimized gate locations
High-speed injection (800mm/sec) with variable pressure profiling
Beryllium copper inserts (thermal conductivity 105 W/m·K vs. 24 W/m·K for H13)
2. Gas Trapping Prevention
Challenge: Deep ribs (up to 12mm) create blind pockets during filling
Countermeasures:
Vacuum venting channels (0.03mm depth) at last-to-fill areas
Modular ejector pins with micro-venting grooves
Scientific molding DOE to optimize pack/hold parameters
3. Warpage Control for BYD Battery Compartment
Critical Factors:
Differential cooling between thick mounting bosses (3.2mm) and thin walls
Fiber orientation effects in glass-filled PA66
Mold Engineering:
Conformal cooling channels following rib geometry
Post-molding fixture aging (85°C/4hrs) to relieve internal stresses
Process Validation
| Parameter | Target | Measurement Method |
|---|---|---|
| Flash | 0mm | Optical comparator |
| Sink marks | Class A (<0.05mm) | Laser scanning |
| Puller pin height | 12.00±0.10mm | CMM (Zeiss CONTURA G2) |
Quality Assurance:
100% inline dimensional checks with Keyence CV-X series vision system
CT scanning for internal porosity analysis (≤0.3% void ratio requirement)
Industry-Specific Advantages
For EV Battery Systems:
UL94 V-0 compliance for fire safety
Chemical resistance to coolant exposure
EMI shielding compatibility (metalized plating-ready surface)
Production Capacity:
16-cavity mold with 45-second cycle time
300,000+ part lifespan before tool refurbishment
Supply Chain Integration:
IATF 16949-certified production
Just-in-time delivery with RFID-tracked packaging