Vehicle Battery Receiving Chamber Sealing With Intermediary Ring
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Solution Overview
Problem
Existing motor vehicle shells face challenges in consistently sealing the receiving chamber for electrical energy stores due to joints and steps between longitudinal and crossmembers, which can compromise the quality of the seal, especially in serial production.
Innovation Solution
An annular intermediary element, formed separately from the frame structure and cover, is introduced to bridge these joints and steps, providing a firmly bonded, liquid-tight connection to the frame structure and sealing surface, ensuring a high-quality seal by supporting a sealing element between the intermediary element and the cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the frame structure is formed by separate crossmembers and longitudinal members connected at joints, then the structural assembly is easier to manufacture, but the sealing quality of the receiving chamber deteriorates due to joints and steps between members
Solution Approach 1:
A sealing element is introduced as an intermediary component between the frame structure and the cover. This sealing element bridges the gaps and steps created by joints between crossmembers and longitudinal members, providing a continuous sealing surface that compensates for assembly tolerances while maintaining the modular advantage of separate frame members
Solution Approach 2:
The sealing element is designed as a flexible component that can deform to accommodate irregularities in the frame structure surface. This flexibility allows the sealing element to conform to the actual geometry of the frame, including steps and joints, ensuring consistent sealing quality regardless of minor variations in frame member positioning
2Device complexity
If separate longitudinal and crossmembers are used to form the frame structure, then the device complexity is reduced and assembly is simplified, but the consistency of the seal quality deteriorates in serial production
Solution Approach 1:
The sealing element acts as a mediator that decouples the seal quality from the precision of frame member connections. By placing the sealing function in a separate, dedicated component, the system maintains reliable sealing even when frame members are assembled with typical tolerances in serial production
Solution Approach 2:
The sealing element is designed with specific material properties and geometric parameters that allow it to compensate for dimensional variations. The material selection and cross-sectional dimensions are optimized to ensure that the sealing element can bridge gaps and accommodate steps while maintaining consistent sealing pressure and contact
3Manufacturing precision
If joints between longitudinal members and crossmembers are minimized, then the frame structure becomes more complex and harder to assemble, but the sealing quality improves
Solution Approach 1:
Rather than modifying the frame structure to eliminate joints, the sealing element is positioned to specifically address the sealing challenge at joint locations. This approach preserves the simple, modular frame construction while providing targeted sealing enhancement where it is most needed
Solution Approach 2:
The sealing function is segmented from the structural function. The frame members maintain their simple, separate construction for ease of assembly, while the sealing element provides the specialized sealing function. This segmentation allows each component to be optimized for its primary purpose without compromising the other
Data Source
AI summary
A motor vehicle shell of a motor vehicle includes a frame structure that is formed by crossmembers and by longitudinal members. The frame structure is closed peripherally and protrudes downwardly in a vertical direction of the motor vehicle from a base element. A receiving chamber for receiving an electrical energy store is delimited by the frame structure. A cover is formed separately from the frame structure and is disposed opposite the base element. The receiving chamber is closed downwardly in the vertical direction of the motor vehicle by the cover. An annular and dimensionally stable intermediary element is formed separately from the frame structure and separately from the cover. The intermediary element is disposed between the frame structure and the cover and the intermediary element is fixed at least in a liquid-tight manner on the frame structure by a firmly bonded connection.