Vehicle Battery Housing Seal via Intermediary Frame
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Solution Overview
Problem
Conventional battery assemblies for vehicles face issues with forming a good seal connection between the lower and upper housings due to bulges caused by the tightening force of bolts, which can lead to leaks and compromised sealing.
Innovation Solution
Incorporating frame elements with notches or slots that absorb the axial tightening force of bolts, allowing for an interference fit and preventing bulges, thus ensuring a secure and sealed connection between the housings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bolts are used to connect the lower housing and upper housing together, then the connection strength is improved, but the tightening force causes bulges in the flanges which deteriorates the seal connection quality
Solution Approach 1:
A seal member (gasket) is introduced as an intermediary element between the lower and upper housings. This seal member absorbs the bulging effect caused by bolt tightening forces, preventing direct transmission of these forces to the housing flanges. The seal member deforms elastically under compression to accommodate minor misalignments and bulges while maintaining effective sealing, thus resolving the contradiction between connection strength and seal quality.
Solution Approach 2:
The design changes the mechanical parameters of the connection system by using multiple bolts distributed across the flange interface. This distribution strategy reduces the localized tightening force on any single point, minimizing bulge formation. Additionally, the flange geometry is optimized with increased thickness and appropriate radius of curvature at critical areas to resist deformation under bolt loads, thereby maintaining both strong connection and good sealing.
2Manufacturing precision
If the flange thickness is increased to prevent bulging, then the seal connection quality is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
Rather than increasing flange thickness to prevent bulging, a seal member is introduced as a compliant intermediary layer. This seal member has optimized geometric parameters including thickness, radius of curvature, and material properties that allow it to accommodate bulging without requiring thicker housing flanges. This approach achieves the same sealing effect with simpler, thinner flange structures.
Solution Approach 2:
The sealing system uses a composite structure combining the rigid housing flanges with a compliant seal member made of elastomeric or polymeric material. This composite approach allows the rigid housings to maintain structural integrity while the compliant seal member absorbs deformation and maintains sealing under varying bolt loads, avoiding the need for overly thick or complex flange designs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution effectively prevents bulges and ensures a good seal connection between the housings, enhancing the sealing integrity and preventing leaks, which is crucial for maintaining the internal environment and preventing pollution.
Implementation Method 1
the at least one frame element bears and absorbs a tightening force of the bolts in an axial direction caused by screwing the nut onto the bolt
Data Source
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AI summary
An energy storage system for vehicle comprising a lower housing (3) and an upper housing (5) connecting with each other; and a plurality of battery modules connected in an internal space defined by the lower housing (3) and the upper housing (5), and connected in serial or in parallel to supply power to a battery-power driven motor of the vehicle. It is possible to establish a good seal connection between the lower housing (3) and the upper housing (5) of the energy storage system.