In the field of new energy, good compatibility between new energy plastic prototype parts and metal connectors is crucial to product performance, reliability and safety.
First of all, material selection and surface treatment are the basis. For new energy plastic prototype parts, plastic materials with good affinity to metals, such as certain engineering plastics, should be selected. At the same time, pretreatment of the plastic surface, such as plasma treatment or chemical etching, can increase its surface roughness and active groups, thereby improving the bonding force with metal connectors. Metal connectors can also be treated with galvanizing, chrome plating, etc., on the one hand to prevent metal rust and corrosion, and on the other hand to improve its contact interface characteristics with plastics.
Secondly, the right connection method is the key. Mechanical connection methods such as riveting and bolting are more commonly used, but the strength and toughness of the plastic must be considered, and a reasonable connection structure must be designed to avoid damage to plastic parts due to stress concentration. For example, when bolting, gaskets can be added to disperse the pressure. In addition, bonding connection is also an effective means. A special high-strength adhesive is selected to ensure that it can form a strong chemical bond between plastic and metal.
In the design stage, the difference in thermal expansion coefficients between the two should be fully considered. Since the thermal expansion coefficients of metals and plastics are usually different, internal stress is easily generated when the temperature changes. Therefore, when designing the matching dimensions of the prototype parts and the connectors, a certain gap should be reserved or an elastic structure should be used to adapt to the changes in thermal expansion and contraction to prevent the connection from failing due to thermal stress.
The optimization of the manufacturing process should not be ignored. During the injection molding process of the new energy plastic prototype parts, the parameters such as injection temperature, pressure and speed should be controlled to ensure that the internal structure of the plastic parts is uniform and defect-free, thereby improving the stability of its combination with the metal connectors. For the processing of metal connectors, ensure that their dimensional accuracy and surface quality meet the requirements and reduce assembly errors.
In addition, environmental adaptability testing is an important step to ensure compatibility. Simulate the temperature, humidity, vibration and other environmental conditions of new energy products in actual use, conduct long-term tests on the combination of new energy plastic prototype parts and metal connectors, observe the performance changes of the connection parts, and promptly discover potential problems and make improvements.
Sealing and protective measures are also critical. Use sealants or sealing gaskets at the connection parts to prevent the intrusion of impurities such as moisture and dust, and avoid compatibility due to corrosion or short circuits. At the same time, for some special application scenarios, the connection parts can be insulated to ensure electrical safety.
Through comprehensive measures such as material selection and surface treatment, connection method optimization, design considerations, process improvements, environmental testing, and sealing protection, the compatibility of new energy plastic prototype parts and metal connectors can be effectively enhanced to meet the strict requirements of the new energy field.
