Introduction
With the surge in battery-powered electronics, the need for advanced protection methods has become more critical than ever. Battery technology has evolved significantly over the years, leading to the proliferation of devices that rely on batteries for power. As these devices become more sophisticated, the challenge of protecting both the electronics and the batteries themselves has grown. A common question that arises in this context is: can batteries be overmolded?
In this article, we explore the feasibility, benefits, and process of overmolding batteries, with a particular focus on low pressure molding (LPM).
First off, let’s dive into some frequently asked questions about overmolding batteries:
Can you overmold batteries?
Yes, you can overmold batteries. Overmolding batteries provides them with additional protection and insulation, ensuring their longevity and reliability. The process involves encapsulating the battery within a protective material, which safeguards it from environmental factors and mechanical shocks.
Can capacitors and energy storage devices be overmolded?
Yes, like batteries, capacitors and other energy storage devices can be overmolded on a board assembly. This process provides these components with enhanced protection and insulation, contributing to the overall reliability and performance of the electronic assembly. At Cavist, we have numerous examples of successfully overmolded parts with capacitors and energy storage components. Some of these parts are shown at the end of this article
What Type of Batteries Can You Overmold?
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Lithium-Ion Batteries
Commonly used in consumer electronics, medical devices, wearables, and power tools, lithium-ion batteries require protection and insulation, making them ideal candidates for overmolding.
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Lithium Polymer Batteries
These are used in applications where lightweight and high energy density are crucial.
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Coin Cell Batteriess
Often found in small electronics, coin cell batteries benefit from overmolding for enhanced protection.
How We Do It – Low Pressure Molding for Batteries
Low pressure molding (LPM) is a specialized overmolding process particularly suited for delicate components like batteries. It is similar to the traditional injection molding process, but with key differences that make it ideal for sensitive electronics. In LPM, material is injected at low temperature and pressure, which minimizes the risk of damaging the components. The materials used in LPM have great adhesive properties, ensuring a strong bond to the electronics.
Gentle Process – Low Temperature & Pressure
LPM utilizes significantly lower pressure and temperature compared to traditional injection molding. This gentler approach reduces the risk of damaging sensitive battery components during the molding process. The material temperature typically ranges between 350°F to 450°F. The material quickly dissipates heat as it encapsulates the board, and the heat escapes through the tooling. The graph below shows the temperature profile of the material as it flows into the tool and touches the board. The injection temp was 445°F, but the temperature in the cavity was lower by 193°F.
Great Adhesion
The materials used in LPM offer excellent adhesion and sealing properties. This enhances protection against environmental factors such as moisture, dust, and mechanical shocks, which are essential for the longevity and safety of batteries.
The Future of Overmolding Batteries
Overmolding batteries, especially through low pressure molding, provides numerous advantages that enhance the performance, durability, and safety of battery-operated devices. Whether it’s lithium-ion batteries for electronics or coin cell batteries, the overmolding process ensures that these power sources are well-protected and optimized for their specific applications. As technology continues to evolve, overmolding will play an increasingly vital role in the development of innovative and reliable battery solutions.
References
“The Advantages of Low Pressure Molding”
– Cavist Technical Documentation
“Overmolding, A Multifaceted Medical Device Technology”
– Medical Device and Diagnostic Industry
“How To Care for The Battery”
– Battery University
Reach out to Cavist for more information about low pressure molding for batteries, electronics, wearables, and other applications. We are dedicated to helping you design a protective solution tailored to your needs.
