Liquid Silicone Rubber Over-molding PPO+30GF Connector Fox Mold
Over-molding connector is also widely used in battery pack cell carrier. The special feature of this kind of connector is that it usually contained hard plastic, soft plastic and metal limiter, in this case the hard plastic is PPO+GF30, soft plastic is liquid silicone rubber.
Our customers are often faced with a challenge: how to over molding liquid silicone rubber parts with hard plastic with glass fiber, but ensuring the bonding is good, will not separate with heat or other extremely condition.
Product Introduction
The design of the battery's waterproof structure is very important, and the waterproof level must reach IP67 or above.
Liquid silicone rubber over molding is to combine with metal or hard plastic through secondary injection molding. Secondary injection molding can combine the parts into one, which is not easy to fall off during assembly and has strong reliability. The outer shell sealing ring of the power battery can be replaced by liquid silicone secondary injection molding (that is, liquid silicone rubber over molding). This method can greatly improve productivity, ensure the consistency of parts and large-capacity molding, and can very well ensure the quality and stability of the product.
For batteries with a waterproof level of IP67 and above, this method is more stable than the sealing ring, but the cost is relatively higher.
Overview and Connector Profile:
Fox mold's main supply was the over molding mold and over-molding bulk parts, assembly with Spriol limiter. The PPO+GF30 geometry must be bonded well with liquid silicone rubber geometry, no falling off, over-molded parts production in strong reliability.
Project Timeline/Project Address:
April 2021/Dongguan, GuangDong, China.
PPO and LSR Injection mold/PPO&LSR overmolded connectors we offer:
Fox mold provided injection molds of PPO+GF30 an Liquid silicone rubber, do the over- molding production for the client's mutiple battery module. In order to ensure the accuracy and bonding, we invest lot of time to do Mold flow analysis with support of raw material supplier Sabic.
Application Scope:
Battery Module, carrier and connectors
Service We offer:
Learing raw material. Doing mold flow analysis to review raw material with hot runner to predict part filling situation, get the best injection molding parameter, analysis mold sulution 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
This product contains two different materials. The main material is plastic PPO+GF30, and liquid silicone rubber, although liquid silicone rubber accounts for a small proportion, it needs to meet its sealing function, so the bonding requirements for liquid silicone and plastic are very high.
Solution
In order to meet customer needs, we conducted a comprehensive DFM analysis, mold flow analysis, and detailed mold 3D/2D design for this product. In the mold design of this product:
1. A multi-point valve hot runner injection on PPO+GF30 injection mold and Cold deck system was used in the liquid silicone rubber over-molding mold to prevent producing runner waste. Both the plastic hot runner and liquid silicone cold deck design solutions do not produce runner waste, saving product costs.
2. Total demand for this product is not very large, in order to save the total cost of the mold, we adopted the overmolding process, that is, first producing the PPO+GF30 product, then transferring the molded plastic product to the LSR injection machine and mold for a second overmolding, and finally completing the entire product processing.
Completion Final
The mold is finally manufactured and mass production is achieved to meet customer needs. If the product demand is very large, we can also design a two-color injection mold to complete the injection molding and encapsulation process on the same set of equipment, but this requires a relatively high investment in molds and equipment. Generally, for small and medium batches (such as monthly demand less than 100K ), we still recommend that customers use 2 sets of molds and separate 2 sets of equipment for over molding.