Two Color Electrical Battery Cover Mold

Detail information of Two Color Electrical Battery Cover Mold

Two Color Electrical Battery Cover Mold

Mold Cavity: 1+1

Mold Steel：XPM with 36-40 HRC

Mold Injection System：1tip valve gate to cold runner

The Technical Challenge of Dual-Material Electrical Covers

In the modern electronics and electrical appliance industries, components like battery covers require a sophisticated balance of rigid structural protection and flexible tactile sealing. Achieving this efficiently demands advanced multi-component injection molding.

As a premier two color mold maker, Focare Mould recently executed a highly specialized tooling project for an electrical Battery Cover. This case study breaks down the precision engineering, material science, and tooling configurations required to deliver a flawless, high-volume dual-material component.

Material Synergy: PA6+GF Hard Substrate & Soft TPE Encapsulation

Achieving a perfect molecular bond between two distinct polymers is the cornerstone of successful 2K molding. For this electrical cover, the design utilizes two radically different materials:

Hard Substrate (First Shot): PA6 + 20% GF (Glass Fiber). This formulation provides high mechanical strength, thermal stability, and impact resistance required to protect internal electrical components.

Soft Layer (Second Shot): TPE 60A. This soft thermoplastic elastomer provides an ergonomic grip, sealing capabilities, and shock absorption around the perimeter of the cover.

Advanced Surface Texturing & Aesthetic Specifications:

To meet strict commercial aesthetics, a leading China mold maker must handle texture transitions with extreme precision. For this project:

Hard Plastic Surface: Finished with high-definition CJ-10118 texture for a premium matte appearance.

Soft TPE Surface: Finished with a specialized EDM spark texture to enhance tactile grip and prevent visual weld lines.

Mold Engineering & Gating Architecture

Built by our dedicated China mold making factory, the tooling design leverages a 1+1 Cavity configuration engineered for maximum tool life and optimized cycle balance.

1. High-Performance Mold Steel Selection

To withstand the abrasive nature of 20% glass-filled polyamide (PA6+GF), the core and cavity inserts are crafted from premium XPM Steel (Hardness: HRC 36~30). This premium steel offers exceptional wear resistance and dimensional stability under continuous high-pressure cycles.

2. Hybrid Gating & Runner System

The mold incorporates an advanced hybrid runner mechanism: a 1-Point Needle Valve Hot Runner system that transitions into a Cold Runner . This architecture ensures precise volumetric filling of the first-shot rigid housing while maintaining zero drooling and sharp thermal separation during the second-shot TPE molding phase.

Why choosing Focare Mould as your work partner?

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