In today's world, power sources are increasingly used, but power source housings, as a key component, are often overlooked. What exactly are they? Why are they worthy of our attention? And how are they manufactured?
II. "What is it" - Overview of Power Source Housings
1. Definition and Classification
1.1 Definition
Power source housings are the external structures that enclose and protect power source-related components (such as batteries and circuit boards), providing physical protection, heat dissipation, and electromagnetic shielding.
1.2 Classification
Electric Vehicle Battery Housings:
Mostly large rectangular or irregular shapes to accommodate chassis installation and battery layout.
They focus on heat dissipation and high-strength protection, often made of aluminum alloys with features such as cooling fins.
Power Bank Housings:
Compact and portable, available in a variety of shapes.
They emphasize aesthetics and feel, often made of engineering plastics such as ABS and PC, which are low-cost and easy to process.
Solar Panel Module Housing:
Depending on the shape and installation method of the solar panel, common shapes include flat and curved.
High weather resistance is required, and highly weather-resistant materials are often used. Sealing is important to prevent external factors from affecting panel efficiency.
2. Material Composition
2.1 Engineering Plastics
ABS Plastic:
Features: Excellent strength, toughness, and processability, aesthetically pleasing appearance, and low cost.
Applications: Power banks, small household solar panel housings, etc.
PC Plastic:
Features: Excellent transparency, impact resistance, and heat resistance.
Applications: Housings for power products requiring transparency or impact resistance.
2.2 Metal Materials
Aluminum Alloy:
Features: Lightweight, good heat dissipation, and high strength.
Applications: Housings for electric vehicle batteries and some outdoor portable power supplies.
Steel:
Features: High strength and excellent protection, but poor heat dissipation and relatively heavy.
Applications: Housings for high-power industrial power products.
III. "Why" - Reasons to Pay Attention to Power Supply Enclosures
1. The Importance of Protection
Preventing External Intrusion: Power supply components are sensitive, and enclosures protect against intrusion such as dust, moisture, and foreign matter, preventing short circuits and corrosion that could affect product operation.
Physical Protection: Products are subject to external forces, such as impact and compression. The enclosure withstands these forces, protecting internal components from deformation and damage, ensuring normal operation.
2. Heat Dissipation Requirements
The Importance of Heat Generation and Heat Dissipation: Power supply components generate heat during operation. If heat is not dissipated promptly, performance degradation, lifespan reduction, and safety hazards can result.
Coordination of the Enclosure's Heat Dissipation Design with the Internal Cooling System: For example, in computer power supplies and electric vehicle battery enclosures, the heat dissipation design coordinates with the internal cooling system, effectively dissipating heat through vents, fins, and other means.
3. Electromagnetic Compatibility Considerations
Electromagnetic Compatibility Requirements: Some power supply products must meet electromagnetic compatibility requirements because they generate electromagnetic radiation and are susceptible to external interference during operation.
The role of the housing as an electromagnetic shield: It reduces the impact of internal electromagnetic radiation on external components and prevents external interference from affecting internal components, maintaining product stability and reliability.
IV. "How It's Made" - The Electric Energy Housing Manufacturing Process
1. Design Phase
1.1 Teamwork: The design team works closely with the Electric Energy product R&D team to determine the housing shape, structure, and functional layout based on product function, size, and appearance requirements.
1.2 Key Elements
Parting Surface Selection: The parting surface is selected based on the housing shape to ensure smooth demolding and no noticeable surface marks.
Gate Positioning: The gate position is determined based on the housing shape, thickness, and plastic flowability to ensure uniform plastic filling of the mold cavity.
Reinforcement Rib Design: Reinforcement ribs are designed based on the housing's load bearing capacity and internal component layout to enhance strength while ensuring portability or installation adaptability.
2. Mold Manufacturing
2.1 Injection Mold Key: The injection mold is the core of manufacturing, determining housing molding quality and production efficiency.
2.2 Materials
P20 Steel: Offers excellent machining properties and moderate hardness, suitable for small and medium-sized molds.
718H Steel: Offers high strength and hardness, suitable for large molds or molds requiring high strength.
2.3 Processing
CNC Machining: Precision machining of mold components. Multi-axis linkage improves efficiency and minimizes errors.
Electrodischarge Machining: Suitable for complex shapes difficult to CNC machine, removing material to create shapes.
Wire Cutting: High-precision, high-speed machining of electrodes, inserts, and other components.
Precision Control: Dimensional accuracy of cavities and cores must reach micron levels. Coordinate measuring machines are used to monitor and correct deviations.
3. Injection Molding
3.1 Basic Process: Raw Material Heating - Injection into Mold - Holding Pressure - Cooling - Demolding
3.2 Parameter Control
Injection Pressure: Adjust the pressure to suit the mold, material, and other factors. Too high a pressure can cause flash, while too low a pressure can lead to underfilling.
Injection Temperature: Ensure the plastic is within its suitable temperature range. Too high a pressure can cause decomposition, while too low a pressure can affect melting. Injection Time: This includes filling, holding, and cooling times, and should be determined based on various factors to avoid defects.
3.3 Common Problems and Solutions
Shrinkage: Caused by cooling shrinkage, increase the holding time and pressure, and optimize the cooling system.
Flow Marks: Caused by uneven melt flow, adjust the pressure and speed, and check the exhaust system.
Flash: Caused by melt overflow, reduce the injection pressure, and check mold clamping accuracy.
In short, electrical energy housings play a critical role in electrical energy products. Understanding their "what" will clarify their diverse forms and material composition; understanding "why" they are of concern will help us understand the importance of protection, heat dissipation, and electromagnetic compatibility; and understanding "how" they are made will help us understand the key aspects of each manufacturing and mold making process. Mastering these principles will help promote the development and application of electrical energy products.
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