Description

JONVER offers a variety of products,such as insert over-molding for busbars,electric vehicle connection parts and plastic tray for Cell Contact System.

We also provide detail DFM & Design suggestions.Customized injection molding services can seamlessly bridge the gap from prototype design to high-quality production. Our solutions accelerate product development cycles and ensure the delivery of high-quality injection molded parts, simplifying the process from concept to market.

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cell contacting system services

STEP 1: Understand the Project Requirements
• Gather the project’s background information.
• Obtain the customer’s 2D and 3D drawings for review.

STEP 2: Design Feasibility Review (DFM)
• JONVER reviews the provided drawings and submits a Design for Manufacturability (DFM) report.
• The DFM includes key details such as parting line placement, gate design, draft angle considerations, ejector layout, and other mold design elements.
• Suggestions for improvement are provided to enhance production efficiency and quality.

STEP 3: Customer Discussions and Alignment
• Collaboration with the customer is crucial during this phase.
• JONVER explains its understanding of the drawings and addresses any production challenges or risk points.
• Special attention is given to critical aspects such as dimensional tolerances, ensuring all potential issues are resolved before proceeding.

STEP 4: Process Simulation and Risk Mitigation
• For additional processes like nut torque, dispensing, or welding, JONVER conducts simulation experiments to verify feasibility and address any customer concerns.

STEP 5: Contract Confirmation and Mold Production
• Upon customer approval, a formal contract is signed.
• JONVER prepares a mold flow analysis report and begins mold production, which typically takes 45-60 days.

STEP 6: Sample Production and Inspection
• The first batch of samples is produced.
• A Full-Size Inspection Report (FAI) is provided to the customer, ensuring all specifications are met before mass production begins.

Key Advantage of JONVER's Plastic Injection

1. Ensuring Copper Part Dimensional Stability:
Maintaining consistent dimensional tolerances for the copper component is paramount. If the dimensions are close to the upper or lower tolerance limits, it is critical to stabilize these measurements before proceeding with the detailed mold design. Even minor deviations in copper tolerances can lead to significant issues in the final product, affecting both functionality and aesthetics.

2. Sensitivity of the Injection Molding Process:
The selection of the injection solution (material, process parameters, and injection pressure) requires careful consideration. The high pressure involved in the injection molding process can induce deformation in the copper part if not properly controlled. Ensuring that the copper component is protected from such distortion requires careful monitoring of the injection parameters to maintain part integrity.

3. Strategic Gate Placement:
The positioning of the injection gate is a critical factor in minimizing distortion. Improper gate placement can lead to uneven pressure distribution, causing the copper part to warp or distort during the injection process. It is essential to carefully analyze and select the optimal gate location to achieve uniform filling and pressure balance, particularly around the copper areas, to prevent undesirable deformations.

4. Differential Shrinkage Rates:
The plastic and copper components exhibit significantly different shrinkage rates during cooling. The areas of the part in direct contact with the copper tend to shrink at a different rate than those farther away, which can lead to dimensional instability. This shrinkage disparity must be carefully accounted for in the mold design, with appropriate compensation for material behavior to prevent warping, misalignment, or other defects.

5. Role of Mold Flow Analysis:
In projects involving copper and plastic materials, the role of traditional mold flow analysis is somewhat limited. While this analysis is invaluable in many injection molding scenarios, in copper-plastic assemblies, the process relies more heavily on the mold designer’s experience. An in-depth understanding of the interaction between copper and plastic during the molding process, informed by past experience, is crucial for anticipating material behavior and achieving the desired results.

By focusing on these critical aspects and drawing on experienced-based insights, the injection molding process for copper-plastic assemblies can be optimized, ensuring the production of high-quality, dimensionally stable components with minimal risk of defects

cell contact system supplier
cell contact system solutions
cell contact system services
JONVER cell contact system
cell contact system

Strength

  • Diversification

    Diversification

  • Automation

    Automation

  • Standardization

    Standardization

JONVER offers customized services.