With the increasing mileage of electric vehicle, energy density and energy consumption of batteries, the light weighting of power batteries has become a topic of great concern. It is urgent to achieve light weighting of batteries and improve the grouping efficiency of power batteries.
For irregular battery module, cylindrical batteries can make full use of space, which is more advantageous than square and soft packs. By reducing the cell spacing and light weighting the module, the module grouping efficiency can be greatly improved. In line with the requirements of lightweight battery packs, our customer optimized the design of the cell bracket and put forward higher tolerance requirements for the accuracy of all carrier components, this carrier back has extremely high tolerance requirements for flatness and length.
Fox mold’s main supply was the mold and molding bulk parts to meet Alpha and Beta test asap. This carrier end plate front is mating with other three carrier parts. Fox Mold is honored to have been trusted by client to supply all carrier parts and do the assembly for the pack.
The part is characterized by a long length close to 500mm and has high requirements for product flatness in ±0.1mm, If the injection pressure is unbalanced, it will cause the product to warp, or uneven thickness, or cloak problems in places with high pressure.
In order to meet the customer’s drawing tolerance, we conducted a comprehensive DFM analysis, mold flow analysis by hot runner and cold runer to compare, and detailed mold 3D/2D design for the product.
In the injection mold design of this product, we adopted a multi-point needle valve hot runner injection solution and followed the principle of runner balance to ensure that the pressure of each injection port is balanced during the filling process.
Learning raw material, doing mold flow analysis to review raw material with hot runner to predict part filling situation and part deformation get the best injection molding parameter.
Analysis mold solution and optimize mold cost and molding cost. DFM and mold design, developing injection mold, doing mold trail。
Provide all SQR document including FAI measurement and support part mass production.
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