IGBT Module Insert Molding Connector Housing Fox Mold
The IGBT module housing molded by special plastic PPS, has considerable heat resistance, dimensional stability, and excellent heat cycle resistance.
For the copper inserts, we designed and formulated a special process route to ensure smooth connection between each process; got strong support from our supplier of stamping, electroplating, cleaning, heat treatment.
IGBT is the main equipment of large-capacity inverters. In the new energy vehicle industry, the commonly used IGBT product voltage is 600V-1200V, and it accounts for a high proportion. This puts forward new requirements for the performance of the IGBT shell. The IGBT housing molded by special plastic PPS injection molding has considerable heat resistance, dimensional stability, and excellent heat cycle resistance.
Few hundreds of IGBT module will be required to run testing. Fox Mold was honor to be supplier of revisions of IGBT module housing, cover and cooper insert since 2019, to produce prototype mold and provide low volume production for the test. Our task is producing few hundreds of these insert molding prototypes in competitive price but the accuracy must be ensured.
Project Overview and Connector Profile
Fox mold's main supply was the injection mold of PPS housing, copper insert stamping tool and insert molding bulk parts. This copper insert processing is complicated and including metal stamping, bending, nickel-plating, heat treatment and cleaning. Fox Mold has complete supplier management system to ensure the outsourced copper insert are made in good quality and meet client's time line.
Project Timeline/Project Address:
March 2019/Dongguan, GuangDong, China.
PPS IGBT housing injection mold/Copper insert we offer
Fox mold provided the injection molds an insert molding parts for the client's mutiple revision IGBT module projects. In order to ensure the accuracy and time line, we invest lot of time to do Mold flow analysis and DFM with support from our Germany client.
Application Scope
Electric bus, Electric car
Service We offer:
Learing raw material. Doing mold flow analysis to review raw material with hot runner to predict part filling and pressure situation, 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, FAI measurment and support part mass production.
Challenge
When using PPS for IGBT injection molding, PPS itself is hard and easy to crack, and it is easily affected by internal stress and produces stress lines.
The copper insert are need to be produced by complex process. The whole demand of parts is low volume quantity but high quality ccuracy requirements;
This product contains two materials, plastic and copper insert, of which copper needs to be partially electroplated and annealed to control hardness.
Solution
IIn the early stage of product mold design, DFM mold flow analysis should be fully done to help eliminate residual stress and prepare for melt fluidity during injection molding.
Designed and formulated a special processing route to ensure smooth connection between each process.
Final Completion
With the strong support of our stamping, electroplating, cleaning, heat treatment and other suppliers, we successfully completed this project, carried out multiple small batch productions, and successfully delivered qualified products to our customers.