{"id":2653,"date":"2026-07-24T11:52:53","date_gmt":"2026-07-24T03:52:53","guid":{"rendered":"http:\/\/0"},"modified":"2026-07-24T17:40:20","modified_gmt":"2026-07-24T09:40:20","slug":"high-precision-custom-plastic-battery-housings-for-ev","status":"publish","type":"post","link":"https:\/\/www.jcinjectionmolding.com\/ja\/design-guides\/high-precision-custom-plastic-battery-housings-for-ev\/","title":{"rendered":"EV\u5411\u3051\u9ad8\u7cbe\u5ea6\u30ab\u30b9\u30bf\u30e0\u30d7\u30e9\u30b9\u30c1\u30c3\u30af\u30d0\u30c3\u30c6\u30ea\u30fc\u30cf\u30a6\u30b8\u30f3\u30b0"},"content":{"rendered":"<article style=\", roboto, helvetica, arial, sans-serif;color: #333333;width: 100%\">\n<section style=\"margin-bottom: 30px\">\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">\u96fb\u6c17\u81ea\u52d5\u8eca\uff08EV\uff09\u306e\u30d0\u30c3\u30c6\u30ea\u30fc\u30d1\u30c3\u30af\u306b\u306f\u3001\u5805\u7262\u306a\u71b1\u7ba1\u7406\u3001\u96fb\u6c17\u7d76\u7e01\u3001\u8010\u885d\u6483\u6027\u306e\u3042\u308b\u69cb\u9020\u304c\u6c42\u3081\u3089\u308c\u307e\u3059\u3002.<br \/>\n\u91cd\u3044\u91d1\u5c5e\u88fd\u30a8\u30f3\u30af\u30ed\u30fc\u30b8\u30e3\u304b\u3089\u9ad8\u5f37\u5ea6\u30a8\u30f3\u30b8\u30cb\u30a2\u30ea\u30f3\u30b0\u30d7\u30e9\u30b9\u30c1\u30c3\u30af\u3078\u306e\u79fb\u884c\u306f\u3001\u81ea\u52d5\u8eca\u30d1\u30c3\u30af\u8a2d\u8a08\u306b\u304a\u3051\u308b\u5927\u304d\u306a\u9032\u5316\u3092\u8868\u3057\u3066\u3044\u307e\u3059\u3002.<br \/>\n\u3053\u306e\u6280\u8853\u30ac\u30a4\u30c9\u3067\u306f\u3001\u4fe1\u983c\u6027\u306e\u9ad8\u3044\u30a8\u30f3\u30af\u30ed\u30fc\u30b8\u30e3\u3092\u88fd\u9020\u3059\u308b\u305f\u3081\u306b\u4e0d\u53ef\u6b20\u306a\u91d1\u578b\u8a2d\u8a08\u3001DfM\uff08\u8a2d\u8a08\u88fd\u9020\u6027\uff09\u306e\u8003\u616e\u4e8b\u9805\u3001\u304a\u3088\u3073\u9ad8\u5ea6\u306a\u30dd\u30ea\u30de\u30fc\u52a0\u5de5\u6280\u8853\u306b\u3064\u3044\u3066\u8a73\u3057\u304f\u8aac\u660e\u3057\u307e\u3059\u3002.<\/p>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\"><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-2656\" src=\"https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/precision-molded-ev-battery-cover.webp\" alt=\"precision-molded-ev-battery-cover\" width=\"1376\" height=\"768\" srcset=\"https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/precision-molded-ev-battery-cover.webp 1376w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/precision-molded-ev-battery-cover-300x167.webp 300w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/precision-molded-ev-battery-cover-1024x572.webp 1024w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/precision-molded-ev-battery-cover-768x429.webp 768w\" sizes=\"auto, (max-width: 1376px) 100vw, 1376px\" \/><br \/>\nJUCHENG\u5c04\u51fa\u6210\u5f62\u306f\u3001\u30ab\u30b9\u30bf\u30e0\u91d1\u578b\u3068\u7cbe\u5bc6\u30d7\u30e9\u30b9\u30c1\u30c3\u30af\u6210\u5f62\u3092\u5c02\u9580\u3068\u3059\u308b\u9ad8\u7d1a\u30ab\u30b9\u30bf\u30e0\u53d7\u8a17\u88fd\u9020\u65bd\u8a2d\u3068\u3057\u3066\u904b\u55b6\u3055\u308c\u3066\u3044\u307e\u3059\u3002.<br \/>\n\u5f53\u793e\u306f\u6a19\u6e96\u54c1\u3084\u65e2\u88fd\u306e\u30d0\u30c3\u30c6\u30ea\u30fc\u30dc\u30c3\u30af\u30b9\u3092\u5c0f\u58f2\u308a\u3057\u3066\u304a\u308a\u307e\u305b\u3093\u3002\u3059\u3079\u3066\u306e\u30b3\u30f3\u30dd\u30fc\u30cd\u30f3\u30c8\u306f\u3001\u304a\u5ba2\u69d8\u304b\u3089\u63d0\u4f9b\u3055\u308c\u305f3D CAD\u30e2\u30c7\u30eb\u304b\u3089\u8a2d\u8a08\u3055\u308c\u3001\u53b3\u3057\u3044\u6027\u80fd\u4ed5\u69d8\u3092\u6e80\u305f\u3059\u3088\u3046\u306b\u4f5c\u3089\u308c\u3066\u3044\u307e\u3059\u3002.<br \/>\n\u8a66\u4f5c\u6bb5\u968e\u304b\u3089\u591a\u30ad\u30e3\u30d3\u30c6\u30a3\u306e\u91cf\u7523\u3078\u306e\u79fb\u884c\u307e\u3067\u3001\u5f53\u65bd\u8a2d\u306fIATF 16949\u304a\u3088\u3073ISO 13485\u8a8d\u8a3c\u306b\u88cf\u6253\u3061\u3055\u308c\u305f\u30ab\u30b9\u30bf\u30de\u30a4\u30ba\u3055\u308c\u305f\u88fd\u9020\u30b5\u30dd\u30fc\u30c8\u3092\u63d0\u4f9b\u3057\u307e\u3059\u3002.<\/p>\n<\/section>\n<p><!-- Table of Contents with local anchor links --><\/p>\n<section style=\"background-color: #f8f9fa;border-left: 4px solid #0056b3;padding: 24px;border-radius: 6px;margin: 40px 0\">\n<h3 style=\"font-size: 22px;font-weight: bold;line-height: 1.5em;margin-top: 0;margin-bottom: 16px;color: #111111\">\u76ee\u6b21<\/h3>\n<ul style=\"list-style-type: none;padding-left: 0;margin: 0\">\n<li style=\"margin-bottom: 12px\"><a style=\"color: #0056b3;text-decoration: none;font-size: 17px;font-weight: 500\" href=\"#why-injection-molding\">1. EV\u30d0\u30c3\u30c6\u30ea\u30fc\u30a8\u30f3\u30af\u30ed\u30fc\u30b8\u30e3\u306b\u30ab\u30b9\u30bf\u30e0\u5c04\u51fa\u6210\u5f62\u304c\u91cd\u8981\u306a\u7406\u7531<\/a><\/li>\n<li style=\"margin-bottom: 12px\"><a style=\"color: #0056b3;text-decoration: none;font-size: 17px;font-weight: 500\" href=\"#materials-and-flame-retardancy\">2. \u6750\u6599\u3068\u96e3\u71c3\u6027\u898f\u683c\uff08UL94 V-0\uff09<\/a><\/li>\n<li style=\"margin-bottom: 12px\"><a style=\"color: #0056b3;text-decoration: none;font-size: 17px;font-weight: 500\" href=\"#advanced-tooling\">3. \u8907\u96d1\u306a\u30d0\u30c3\u30c6\u30ea\u30fc\u5f62\u72b6\u306b\u5bfe\u5fdc\u3059\u308b\u9ad8\u5ea6\u306a\u91d1\u578b\u6280\u8853<\/a><\/li>\n<li style=\"margin-bottom: 12px\"><a style=\"color: #0056b3;text-decoration: none;font-size: 17px;font-weight: 500\" href=\"#dfm-analysis\">4. DfM\u89e3\u6790\u3068\u5b8c\u5168\u306a\u30bf\u30fc\u30f3\u30ad\u30fc\u30b5\u30fc\u30d3\u30b9<\/a><\/li>\n<li style=\"margin-bottom: 0\"><a style=\"color: #0056b3;text-decoration: none;font-size: 17px;font-weight: 500\" href=\"#faq\">5. \u3088\u304f\u3042\u308b\u8cea\u554f\uff08FAQ\uff09<\/a><\/li>\n<\/ul>\n<\/section>\n<p><!-- Section 1 --><\/p>\n<section id=\"why-injection-molding\" style=\"margin-bottom: 50px\">\n<h2 style=\"font-size: 28px;line-height: 1.5em;font-weight: bold;margin-top: 40px;margin-bottom: 24px;color: #111111;border-bottom: 1px solid #eaeaea;padding-bottom: 8px\">EV\u30d0\u30c3\u30c6\u30ea\u30fc\u30a8\u30f3\u30af\u30ed\u30fc\u30b8\u30e3\u306b\u30ab\u30b9\u30bf\u30e0\u5c04\u51fa\u6210\u5f62\u304c\u91cd\u8981\u306a\u7406\u7531<\/h2>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-2654\" src=\"https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/injection-molded-versus-thermoformed-plastic.webp\" alt=\"injection-molded-versus-thermoformed-plastic\" width=\"1376\" height=\"768\" srcset=\"https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/injection-molded-versus-thermoformed-plastic.webp 1376w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/injection-molded-versus-thermoformed-plastic-300x167.webp 300w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/injection-molded-versus-thermoformed-plastic-1024x572.webp 1024w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/injection-molded-versus-thermoformed-plastic-768x429.webp 768w\" sizes=\"auto, (max-width: 1376px) 100vw, 1376px\" \/><\/p>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">\u5805\u7262\u306a\u30a8\u30f3\u30b8\u30cb\u30a2\u30ea\u30f3\u30b0 <strong>\u30ab\u30b9\u30bf\u30e0EV\u7528\u30d7\u30e9\u30b9\u30c1\u30c3\u30af\u30d0\u30c3\u30c6\u30ea\u30fc\u30cf\u30a6\u30b8\u30f3\u30b0<\/strong> requires an understanding of structural integration and tight tolerance control.<br \/>\nTraditional metallic casings are heavy and require secondary insulation liners to prevent short circuits.<br \/>\nBy utilizing high-performance polymers, engineers can mold complex geometries, internal features, and functional mounts directly into a single unified part.<br \/>\nConsolidating components in this manner reduces bill-of-materials costs, eliminates secondary assembly steps, and shaves critical weight off the vehicle chassis.<\/p>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">Integrating internal components is crucial for protecting individual lithium-ion cells from thermal runaway propagation.<br \/>\nSeamless integration of <strong>\u96fb\u6c17\u81ea\u52d5\u8eca\u30d0\u30c3\u30c6\u30ea\u30fc\u30bb\u30eb\u30db\u30eb\u30c0\u30fc<\/strong> directly within the structural walls of the main housing prevents vibrational wear on cell terminals.<br \/>\nFurthermore, incorporating thin, high-insulation <strong>\u96fb\u6c17\u81ea\u52d5\u8eca\u30d0\u30c3\u30c6\u30ea\u30fc\u30b9\u30da\u30fc\u30b5\u30fc<\/strong> prevents thermal runaway from leaping between pouch or prismatic cell modules.<br \/>\nSuch configurations optimize space utilization inside the battery pack, allowing higher energy density while maintaining structural integrity during mechanical impacts.<\/p>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">Compared to alternative processing methods like sheet metal stamping or thermoforming, injection molding provides superior repeatability and dimensional accuracy.<br \/>\nHigh-pressure injection molding forces molten plastic into precision-machined cavities, producing parts with zero draft variations and highly consolidated molecular structures.<br \/>\nThis is especially crucial for molding elastomeric sealing channels and perimeter tongue-and-groove joints that prevent moisture and dust from breaching the battery module.<br \/>\n\u7d4c\u9a13\u8c4a\u5bcc\u306a\u88fd\u9020\u5c02\u9580\u5bb6\u3068\u63d0\u643a\u3059\u308b\u3053\u3068\u3067\u3001\u30ab\u30b9\u30bf\u30e0\u90e8\u54c1\u304c\u53b3\u683c\u306a\u81ea\u52d5\u8eca\u5b89\u5168\u57fa\u6e96\u306b\u9069\u5408\u3059\u308b\u3053\u3068\u304c\u4fdd\u8a3c\u3055\u308c\u307e\u3059\u3002.<\/p>\n<\/section>\n<p><!-- Section 2 --><\/p>\n<section id=\"materials-and-flame-retardancy\" style=\"margin-bottom: 50px\">\n<h2 style=\"font-size: 28px;line-height: 1.5em;font-weight: bold;margin-top: 40px;margin-bottom: 24px;color: #111111;border-bottom: 1px solid #eaeaea;padding-bottom: 8px\">\u6750\u6599\u3068\u96e3\u71c3\u6027\u57fa\u6e96\uff08UL94 V-0\uff09<\/h2>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-2659\" src=\"https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/flame-retardant-plastic-flammability-test.webp\" alt=\"flame-retardant-plastic-flammability-test\" width=\"1376\" height=\"768\" srcset=\"https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/flame-retardant-plastic-flammability-test.webp 1376w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/flame-retardant-plastic-flammability-test-300x167.webp 300w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/flame-retardant-plastic-flammability-test-1024x572.webp 1024w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/flame-retardant-plastic-flammability-test-768x429.webp 768w\" sizes=\"auto, (max-width: 1376px) 100vw, 1376px\" \/><\/p>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">\u7279\u6b8a\u306a\u958b\u767a <strong>\u30ab\u30b9\u30bf\u30e0EV\u7528\u30d7\u30e9\u30b9\u30c1\u30c3\u30af\u30d0\u30c3\u30c6\u30ea\u30fc\u30cf\u30a6\u30b8\u30f3\u30b0<\/strong> \u9ad8\u6027\u80fd\u71b1\u53ef\u5851\u6027\u30d7\u30e9\u30b9\u30c1\u30c3\u30af\u306b\u4f9d\u5b58\u3057\u3066\u3044\u307e\u3059\u3002.<br \/>\n\u30a8\u30f3\u30b8\u30cb\u30a2\u306f\u3001\u885d\u6483\u5f37\u5ea6\u3001\u30d0\u30c3\u30c6\u30ea\u30fc\u96fb\u89e3\u6db2\u306b\u5bfe\u3059\u308b\u8010\u85ac\u54c1\u6027\u3001\u71b1\u5909\u5f62\u6e29\u5ea6\u3001\u9577\u671f\u30af\u30ea\u30fc\u30d7\u8010\u6027\u306e\u30d0\u30e9\u30f3\u30b9\u3092\u53d6\u308b\u5fc5\u8981\u304c\u3042\u308a\u307e\u3059\u3002.<br \/>\n\u3057\u305f\u304c\u3063\u3066\u3001 <strong>EV\u30d0\u30c3\u30c6\u30ea\u30fc\u30e2\u30b8\u30e5\u30fc\u30eb\u7528\u306e\u5c04\u51fa\u6210\u5f62Bayblend FR3010<\/strong> \u3092\u4f7f\u7528\u3059\u308b\u3053\u3068\u3067\u3001-30\u00b0C\u307e\u3067\u306e\u512a\u308c\u305f\u885d\u6483\u6027\u80fd\u3092\u78ba\u4fdd\u3057\u30011.5mm\u539a\u3067UL94 V-0\u96e3\u71c3\u6027\u5b9a\u683c\u3092\u9054\u6210\u3057\u307e\u3059\u3002.<br \/>\n\u3053\u306e\u975e\u6676\u6027\u30dd\u30ea\u30ab\u30fc\u30dc\u30cd\u30fc\u30c8\u3068\u30a2\u30af\u30ea\u30ed\u30cb\u30c8\u30ea\u30eb\u30fb\u30d6\u30bf\u30b8\u30a8\u30f3\u30fb\u30b9\u30c1\u30ec\u30f3\u306e\u30d6\u30ec\u30f3\u30c9\u306f\u3001\u4e88\u6e2c\u53ef\u80fd\u306a\u53ce\u7e2e\u7387\u7279\u6027\u3092\u63d0\u4f9b\u3057\u3001\u5e73\u5766\u3067\u53cd\u308a\u306e\u306a\u3044\u30ab\u30d0\u30fc\u306e\u88fd\u9020\u3092\u5bb9\u6613\u306b\u3057\u307e\u3059\u3002.<\/p>\n<p><!-- Bulleted List (\u5c0f\u5706\u70b9\u533a\u5206\u5206\u7c7b) --><\/p>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 16px\">\u9ad8\u96fb\u5727\u30d0\u30c3\u30c6\u30ea\u30fc\u30a8\u30f3\u30af\u30ed\u30fc\u30b8\u30e3\u306e\u30b3\u30a2\u6750\u6599\u6027\u80fd\u8981\u4ef6\u306b\u306f\u4ee5\u4e0b\u304c\u542b\u307e\u308c\u307e\u3059\uff1a<\/p>\n<ul style=\"font-size: 18px;line-height: 1.8em;margin-bottom: 24px;padding-left: 24px;list-style-type: disc\">\n<li style=\"margin-bottom: 12px;text-align: left\"><strong>\u71b1\u5b89\u5b9a\u6027<\/strong>\u2014\u30a8\u30f3\u30b8\u30cb\u30a2\u30ea\u30f3\u30b0\u30d7\u30e9\u30b9\u30c1\u30c3\u30af\u306f\u3001100\u00b0C\u3092\u8d85\u3048\u308b\u9023\u7d9a\u52d5\u4f5c\u6e29\u5ea6\u4e0b\u3067\u69cb\u9020\u7684\u5b8c\u5168\u6027\u3092\u7dad\u6301\u3059\u308b\u5fc5\u8981\u304c\u3042\u308a\u307e\u3059\u3002.<\/li>\n<li style=\"margin-bottom: 12px;text-align: left\"><strong>\u96e3\u71c3\u6027<\/strong>\u2014\u53b3\u683c\u306aUL94 V-0\u5b9a\u683c\u3092\u9054\u6210\u3059\u308b\u3053\u3068\u3067\u3001\u706b\u707d\u306e\u4f1d\u64ad\u3092\u9632\u304e\u3001\u30d7\u30e9\u30b9\u30c1\u30c3\u30af\u90e8\u54c1\u3092\u6570\u79d2\u4ee5\u5185\u306b\u81ea\u5df1\u6d88\u706b\u3055\u305b\u307e\u3059\u3002.<\/li>\n<li style=\"margin-bottom: 12px;text-align: left\"><strong>\u7d76\u7e01\u8010\u529b<\/strong>\u2014High volume resistivity prevents electrical arcing between battery cells and the outer chassis.<\/li>\n<li style=\"margin-bottom: 12px;text-align: left\"><strong>\u8010\u885d\u6483\u6027<\/strong>\u2014Robust physical properties safeguard the delicate lithium cell matrix from debris puncture during dynamic driving.<\/li>\n<\/ul>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">Similarly, manufacturing <strong>\u96e3\u71c3\u6027PC ABS\u30d0\u30c3\u30c6\u30ea\u30fc\u7b50\u4f53<\/strong> ensures structural rigidity while providing reliable electrical insulation.<br \/>\nWhen high mechanical rigidity is required to withstand extreme drop tests, glass-fiber reinforced polymers represent the optimal choice.<br \/>\nFor instance, choosing <strong>\u5c04\u51fa\u6210\u5f62Lexan 940A\u30d0\u30c3\u30c6\u30ea\u30fc\u30d5\u30ec\u30fc\u30e0<\/strong> offers exceptional flame retardancy coupled with the dimensional stability required for interlocking prismatic cell matrices.<br \/>\nThis polycarbonate resin maintains its physical properties under constant thermal loads, preventing cell migration during rapid charging and discharging cycles.<\/p>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">Safety compliance remains non-negotiable for all high-voltage automotive components.<br \/>\nTherefore, specifying <strong>UL94 V-0 flame retardant plastic cell carrier injection molding<\/strong> guarantees that the polymer will self-extinguish within 10 seconds of a flame application, preventing catastrophic thermal fire propagation.<br \/>\nStructural trays also demand extreme load-bearing capabilities.<br \/>\nIndeed, handling <strong>\u30ac\u30e9\u30b9\u7e4a\u7dad\u5f37\u5316\u30dd\u30ea\u30a2\u30df\u30c9\u88fd\u30d0\u30c3\u30c6\u30ea\u30fc\u30c8\u30ec\u30a4\u306e\u88fd\u9020<\/strong> presents challenges with warpage due to the differential shrinkage between the transverse and parallel glass fiber orientations.<br \/>\nOur mold design team overcomes this by optimizing gate locations and using balanced hot runner systems to distribute fiber alignment evenly across the mold cavity.<\/p>\n<p><!-- Material Comparison Table --><\/p>\n<div style=\"margin: 32px 0\">\n<table style=\"width: 100%;border-collapse: collapse;font-size: 16px;text-align: left;min-width: 600px\">\n<thead>\n<tr style=\"background-color: #f8f9fa;border-bottom: 2px solid #dee2e6\">\n<th style=\"padding: 16px;border: 1px solid #dee2e6;font-weight: 600;color: #111111\">\u6750\u6599\u30b0\u30ec\u30fc\u30c9<\/th>\n<th style=\"padding: 16px;border: 1px solid #dee2e6;font-weight: 600;color: #111111\">\u30dd\u30ea\u30de\u30fc\u30bf\u30a4\u30d7<\/th>\n<th style=\"padding: 16px;border: 1px solid #dee2e6;font-weight: 600;color: #111111\">\u5f15\u5f35\u5f37\u3055 (MPa)<\/th>\n<th style=\"padding: 16px;border: 1px solid #dee2e6;font-weight: 600;color: #111111\">HDT @ 1.82 MPa\uff08\u00b0C\uff09<\/th>\n<th style=\"padding: 16px;border: 1px solid #dee2e6;font-weight: 600;color: #111111\">\u96e3\u71c3\u6027\u7b49\u7d1a<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr style=\"border-bottom: 1px solid #dee2e6\">\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">Bayblend FR3010<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">PC + ABS \u30d6\u30ec\u30f3\u30c9<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">60<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">110<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">UL94 V-0<\/td>\n<\/tr>\n<tr style=\"border-bottom: 1px solid #dee2e6\">\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">Lexan 940A<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">\u30dd\u30ea\u30ab\u30fc\u30dc\u30cd\u30fc\u30c8\uff08PC\uff09<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">65<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">125<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">UL94 V-0<\/td>\n<\/tr>\n<tr style=\"border-bottom: 1px solid #dee2e6\">\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">PA66-GF30 (FR)<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">\u30dd\u30ea\u30a2\u30df\u30c966 + 30% GF<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">150<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">240<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">UL94 V-0<\/td>\n<\/tr>\n<tr style=\"border-bottom: 1px solid #dee2e6\">\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">TPV (70A-40D)<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">\u71b1\u53ef\u5851\u6027\u52a0\u786b\u30b4\u30e0<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">8 \u2013 15<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">\u8a72\u5f53\u306a\u3057 (\u30a8\u30e9\u30b9\u30c8\u30de\u30fc)<\/td>\n<td style=\"padding: 16px;border: 1px solid #dee2e6;color: #333333\">UL94 HB \/ V-0<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/div>\n<\/section>\n<p><!-- Section 3 --><\/p>\n<section id=\"advanced-tooling\" style=\"margin-bottom: 50px\">\n<h2 style=\"font-size: 28px;line-height: 1.5em;font-weight: bold;margin-top: 40px;margin-bottom: 24px;color: #111111;border-bottom: 1px solid #eaeaea;padding-bottom: 8px\">\u8907\u96d1\u306a\u30d0\u30c3\u30c6\u30ea\u30fc\u5f62\u72b6\u306b\u5bfe\u5fdc\u3059\u308b\u9ad8\u5ea6\u306a\u91d1\u578b\u52a0\u5de5\u80fd\u529b<\/h2>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-2655\" src=\"https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/milling-hardened-steel-mold-cavity.webp\" alt=\"milling-hardened-steel-mold-cavity\" width=\"1376\" height=\"768\" srcset=\"https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/milling-hardened-steel-mold-cavity.webp 1376w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/milling-hardened-steel-mold-cavity-300x167.webp 300w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/milling-hardened-steel-mold-cavity-1024x572.webp 1024w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/milling-hardened-steel-mold-cavity-768x429.webp 768w\" sizes=\"auto, (max-width: 1376px) 100vw, 1376px\" \/><\/p>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">\u91d1\u578b\u8a2d\u8a08\u306f\u3001\u30ab\u30b9\u30bf\u30e0\u90e8\u54c1\u306e\u9577\u671f\u7684\u306a\u54c1\u8cea\u3001\u5e73\u5766\u5ea6\u3001\u304a\u3088\u3073\u69cb\u9020\u7684\u4fe1\u983c\u6027\u306b\u76f4\u63a5\u5f71\u97ff\u3092\u4e0e\u3048\u307e\u3059\u3002.<br \/>\n\u5f53\u793e\u306e\u4e8c\u91cd\u8a8d\u8a3c\u65bd\u8a2d\u3067\u306f\u3001\u793e\u5185\u306e5\u8ef8CNC\u5de5\u4f5c\u6a5f\u68b025\u53f0\u4ee5\u4e0a\u3092\u6d3b\u7528\u3057\u3001\u713c\u5165\u308c\u3055\u308c\u305fH13\u307e\u305f\u306fS136\u5de5\u5177\u92fc\u304b\u3089\u7cbe\u5bc6\u306a\u91d1\u578b\u30b3\u30a2\u3092\u5207\u524a\u52a0\u5de5\u3057\u307e\u3059\u3002.<br \/>\n\u713c\u5165\u308c\u92fc\u306f\u3001\u8150\u98df\u6027\u306e\u9ad8\u3044\u96e3\u71c3\u5264\u3084\u7814\u78e8\u6027\u306e\u9ad8\u3044\u30ac\u30e9\u30b9\u7e4a\u7dad\u3092\u6271\u3046\u969b\u306b\u3001\u30d4\u30c3\u30c1\u30f3\u30b0\u3084\u6025\u901f\u306a\u5bf8\u6cd5\u6469\u8017\u3092\u8d77\u3053\u3055\u305a\u306b\u5bfe\u5fdc\u3059\u308b\u305f\u3081\u306b\u5fc5\u9808\u3067\u3059\u3002.<br \/>\n\u6210\u5f62\u30d7\u30ed\u30bb\u30b9\u4e2d\u3001\u91d1\u578b\u92fc\u306b\u7d71\u5408\u3055\u308c\u305f\u6700\u9069\u5316\u3055\u308c\u305f\u30b3\u30f3\u30d5\u30a9\u30fc\u30de\u30eb\u51b7\u5374\u30c1\u30e3\u30cd\u30eb\u306b\u3088\u308a\u3001\u30b5\u30a4\u30af\u30eb\u30bf\u30a4\u30e0\u3092\u6700\u592730%\u77ed\u7e2e\u3057\u3001\u5747\u4e00\u306a\u653e\u71b1\u3092\u78ba\u4fdd\u3057\u3066\u3001\u6210\u5f62\u5f8c\u306e\u53cd\u308a\u3092\u9632\u304e\u307e\u3059\u3002.<\/p>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">One prominent technique involves overmolding high-voltage conductive elements directly inside the structural shell.<br \/>\nSpecifically, employing <strong>insert molding busbars in EV battery covers<\/strong> minimizes assembly errors and prevents environmental moisture from leaking into critical high-voltage contact areas.<br \/>\nThis requires incredibly tight tooling shut-off tolerances to prevent plastic flash from flowing onto the active contact surfaces of copper or aluminum busbars.<br \/>\nOur precise tooling designs utilize spring-loaded core pins and real-time cavity pressure sensors to prevent crushing the metal inserts during mold clamp-up.<\/p>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">Moisture and dust ingress must be prevented to avoid short-circuiting expensive lithium cell modules.<br \/>\nThus, performing <strong>\u30ab\u30b9\u30bf\u30e0\u6210\u5f62\u71b1\u53ef\u5851\u6027\u52a0\u786b\u30b4\u30e0TPV\u30d0\u30c3\u30c6\u30ea\u30fc\u30ac\u30b9\u30b1\u30c3\u30c8<\/strong> ensures that our <strong>\u30ab\u30b9\u30bf\u30e0EV\u7528\u30d7\u30e9\u30b9\u30c1\u30c3\u30af\u30d0\u30c3\u30c6\u30ea\u30fc\u30cf\u30a6\u30b8\u30f3\u30b0<\/strong> achieve dynamic sealing profiles directly integrated onto the rigid PC\/ABS cover.<br \/>\nAchieving this dual-material integration is possible through advanced multi-shot injection molding or custom overmolding processes, completely eliminating the labor-intensive hand-application of adhesive foam strips.<br \/>\nSuch multi-material integrations remain a hallmark of automotive-grade manufacturing, providing robust protection against IP67 and IP69K moisture standards.<\/p>\n<\/section>\n<p><!-- Section 4 --><\/p>\n<section id=\"dfm-analysis\" style=\"margin-bottom: 50px\">\n<h2 style=\"font-size: 28px;line-height: 1.5em;font-weight: bold;margin-top: 40px;margin-bottom: 24px;color: #111111;border-bottom: 1px solid #eaeaea;padding-bottom: 8px\">DfM Analysis &amp; Complete Turnkey Services<\/h2>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"alignnone size-full wp-image-2657\" src=\"https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/battery-box-mold-flow-analysis.webp\" alt=\"battery-box-mold-flow-analysis\" width=\"1376\" height=\"768\" srcset=\"https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/battery-box-mold-flow-analysis.webp 1376w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/battery-box-mold-flow-analysis-300x167.webp 300w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/battery-box-mold-flow-analysis-1024x572.webp 1024w, https:\/\/www.jcinjectionmolding.com\/wp-content\/uploads\/2026\/07\/battery-box-mold-flow-analysis-768x429.webp 768w\" sizes=\"auto, (max-width: 1376px) 100vw, 1376px\" \/><\/p>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">Optimizing structural geometries for <strong>\u30ab\u30b9\u30bf\u30e0EV\u7528\u30d7\u30e9\u30b9\u30c1\u30c3\u30af\u30d0\u30c3\u30c6\u30ea\u30fc\u30cf\u30a6\u30b8\u30f3\u30b0<\/strong> prevents defects and lowers production costs.<br \/>\nDraft angles of at least 1.5 to 2 degrees must be incorporated on all vertical ribs and side walls to permit clean ejection without part distortion.<br \/>\nWall thickness must remain as uniform as possible, ideally ranging from 2.5mm to 3.5mm, to prevent differential shrinkage and sink marks.<br \/>\nFlow simulation analysis prevents problematic knit lines, especially around the molded insert zones where molten plastic splits and recombines around cold metal busbars.<\/p>\n<p><!-- Numbered List (\u5e8f\u53f7\u533a\u5206\u6d41\u7a0b) --><\/p>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 16px\">Our end-to-end custom tooling and manufacturing workflow typically follows this path:<\/p>\n<ol style=\"font-size: 18px;line-height: 1.8em;margin-bottom: 24px;padding-left: 24px;list-style-type: decimal\">\n<li style=\"margin-bottom: 12px;text-align: left\"><strong>Design evaluation (DfM)<\/strong>\u2014Providing a detailed manufacturability review, assessing draft angles, gate locations, and predicting potential knit lines within 24 hours.<\/li>\n<li style=\"margin-bottom: 12px;text-align: left\"><strong>Tooling fabrication<\/strong>\u2014Milling high-precision mold cavities from hardened H13\/S136 steel using our in-house 5-axis high-speed CNC machining centers.<\/li>\n<li style=\"margin-bottom: 12px;text-align: left\"><strong>Trial molding (T0\/T1)<\/strong>\u2014Conducting trial runs to optimize injection pressure, melt temperature, and holding times, yielding initial physical samples for dimensional checks.<\/li>\n<li style=\"margin-bottom: 12px;text-align: left\"><strong>Quality verification<\/strong>\u2014Utilizing Zeiss coordinate measuring machines to scan critical part geometries and cell pocket concentricity, compiling precise dimensional reports.<\/li>\n<li style=\"margin-bottom: 12px;text-align: left\"><strong>Final production<\/strong>\u2014Executing low-to-high volume injection molding runs backed by IATF 16949-certified quality control and complete lot traceability.<\/li>\n<\/ol>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">For design validation, relying on <strong>low volume rapid tooling for EV battery prototypes<\/strong> accelerates validation times while limiting initial non-recurring engineering tooling expenses.<br \/>\nOur facility builds rapid mold structures utilizing P20 or Alumec 89 aluminum cores, permitting functional molded prototypes of <strong>\u30ab\u30b9\u30bf\u30e0EV\u7528\u30d7\u30e9\u30b9\u30c1\u30c3\u30af\u30d0\u30c3\u30c6\u30ea\u30fc\u30cf\u30a6\u30b8\u30f3\u30b0<\/strong> to be delivered in as fast as 10 to 12 business days.<br \/>\nThis bridge-to-production strategy allows automotive engineering teams to perform real-world environmental stress screening, drop testing, and vibration analysis before investing in mass-production, multi-cavity hardened steel tools.<br \/>\nOur team manages the entire project from initial design optimization to post-mold assembly under one roof.<\/p>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">Our in-house 5-axis CNC machining, ultrasonic plastic welding, thermal heat staking, and coordinate measuring machine inspections complete our comprehensive turnkey operations.<br \/>\nEvery production lot is fully traceable, and our quality control engineers verify critical-to-quality dimensions on every shipment.<br \/>\nWe sign non-disclosure agreements early in the design cycle, safeguarding proprietary intellectual property and ensuring confidential product launches.<\/p>\n<\/section>\n<p><!-- Section 5: FAQ --><\/p>\n<section id=\"faq\" style=\"margin-bottom: 40px\">\n<h2 style=\"font-size: 28px;line-height: 1.5em;font-weight: bold;margin-top: 40px;margin-bottom: 24px;color: #111111;border-bottom: 1px solid #eaeaea;padding-bottom: 8px\">\u3088\u304f\u3042\u308b\u8cea\u554f\uff08FAQ\uff09<\/h2>\n<div style=\"margin-bottom: 30px\">\n<h3 style=\"font-size: 22px;line-height: 1.5em;font-weight: bold;margin-top: 24px;margin-bottom: 12px;color: #111111\">How do you manage warpage in large, glass-filled battery trays?<\/h3>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">Shrinkage management involves balancing the fiber orientation in glass-filled polyamide materials.<br \/>\nGlass fibers tend to align with the melt flow, causing the material to shrink less along the flow direction than across it.<br \/>\nWe use advanced mold-flow software to simulate gate placement, frequently utilizing valve-gated hot runner systems to control the flow front and balance orientation, minimizing structural warpage.<\/p>\n<\/div>\n<div style=\"margin-bottom: 30px\">\n<h3 style=\"font-size: 22px;line-height: 1.5em;font-weight: bold;margin-top: 24px;margin-bottom: 12px;color: #111111\">What is the typical mold lifespan for flame-retardant plastics?<\/h3>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">Mold lifespans vary depending on the tooling steel and polymer additives.<br \/>\nFlame-retardant agents release corrosive gasses at high temperatures, which degrade soft steels.<br \/>\nBy using premium hardened S136 or H13 stainless steels with specialized anti-corrosive coatings, our molds consistently achieve over 500,000 cycles, maintaining tight dimensional tolerances over high-volume production runs.<\/p>\n<\/div>\n<div style=\"margin-bottom: 0\">\n<h3 style=\"font-size: 22px;line-height: 1.5em;font-weight: bold;margin-top: 24px;margin-bottom: 12px;color: #111111\">Can you mold copper or aluminum busbars directly into battery covers?<\/h3>\n<p style=\"font-size: 18px;line-height: 1.8em;text-align: left;margin-bottom: 24px\">Insert molding requires precise clamping pressure and strict shut-off tolerances to prevent plastic flash.<br \/>\nOur robotic insert systems place busbars with sub-millimeter precision.<br \/>\nWe design custom sealing lands on the mold steel that firmly grip the metallic inserts, ensuring a leak-proof seal and preventing any flash onto the connection terminals.<\/p>\n<\/div>\n<\/section>\n<\/article>","protected":false},"excerpt":{"rendered":"<p>Electric vehicle (EV) battery packs demand robust thermal management, electrical isolation, and impact-resistant structures. Transitioning from heavy metal enclosures to high-strength engineering plastics represents a major evolution in automotive pack design. This technical guide details the mold engineering, DfM considerations, and advanced polymer processing technologies essential for producing reliable enclosures. JUCHENG Injection Molding operates as a high-end, custom-job contract manufacturing facility specializing in custom tooling and precision plastic molding. We do not retail standard or off-the-shelf battery boxes; every component is engineered from customer-supplied 3D CAD models to meet stringent performance specifications. Whether navigating prototype phases or transitioning to multi-cavity high-volume production, our facility delivers tailored manufacturing support backed by [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":2658,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[27],"tags":[],"class_list":["post-2653","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-design-guides"],"_links":{"self":[{"href":"https:\/\/www.jcinjectionmolding.com\/ja\/wp-json\/wp\/v2\/posts\/2653","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.jcinjectionmolding.com\/ja\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.jcinjectionmolding.com\/ja\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.jcinjectionmolding.com\/ja\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.jcinjectionmolding.com\/ja\/wp-json\/wp\/v2\/comments?post=2653"}],"version-history":[{"count":0,"href":"https:\/\/www.jcinjectionmolding.com\/ja\/wp-json\/wp\/v2\/posts\/2653\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.jcinjectionmolding.com\/ja\/wp-json\/wp\/v2\/media\/2658"}],"wp:attachment":[{"href":"https:\/\/www.jcinjectionmolding.com\/ja\/wp-json\/wp\/v2\/media?parent=2653"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.jcinjectionmolding.com\/ja\/wp-json\/wp\/v2\/categories?post=2653"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.jcinjectionmolding.com\/ja\/wp-json\/wp\/v2\/tags?post=2653"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}