Electrochemical Cell Terminal Potting for Gap-Free Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrochemical cells are difficult to manufacture and have a limited service life.
Innovation Solution
The electrochemical cell design includes a housing with a cover element connected via form-fit, force-fit, and material-fit connections, using resin materials for potting elements to secure contact elements, and incorporates insulating elements with positioning projections for precise assembly, along with sealing elements to enhance sealing and prevent gap formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If traditional manufacturing methods are used for electrochemical cells, then manufacturing complexity is reduced, but service life is limited and manufacturing difficulty increases
Solution Approach 1:
The housing is divided into multiple components (cover element, base element, sealing elements) that can be manufactured separately and assembled through form-fit connections. This segmentation allows each component to be optimized for its specific function while simplifying the overall manufacturing process and enabling modular replacement, thereby extending service life.
Solution Approach 2:
Positioning projections and recesses are pre-formed on housing components during manufacturing. These preliminary structural features enable precise alignment and secure assembly without requiring complex adjustment tools during final assembly, reducing manufacturing difficulty while ensuring long-lasting reliable connections.
2Productivity
If injection molding of thermoplastic material is used, then manufacturing speed increases, but gap formation occurs that reduces sealing quality
Solution Approach 1:
The sealing system uses composite construction with thermoplastic sealing elements combined with thermosetting resin materials. The thermosetting resin fills gaps and bonds surfaces together, compensating for the gap formation inherent in injection molding processes while maintaining high manufacturing speed. This composite approach achieves both productivity and sealing quality.
Solution Approach 2:
Thermosetting resin material acts as an intermediary substance between thermoplastic housing components and metal elements (such as cap or base). The resin fills gaps, bonds surfaces, and creates a reliable seal, mediating between the molded components and ensuring high sealing quality without sacrificing manufacturing efficiency.
3Ease of manufacture
If tool-free terminal feedthrough is implemented, then manufacturing simplicity increases, but connection reliability may be compromised
Solution Approach 1:
The connection method transitions from mechanical tool-based fastening to chemical bonding using thermosetting resin materials. The resin cures to form strong, reliable bonds between terminals and housing components, achieving connection reliability comparable to or exceeding traditional methods while eliminating the need for additional tools and simplifying the manufacturing process.
4Reliability
If resin materials are used for potting elements, then sealing effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The potting element integrates multiple functions into a single component: electrical insulation, mechanical anchoring of terminals, and sealing against electrolyte ingress. By combining these functions into one resin-based element, the design achieves superior sealing effectiveness without proportionally increasing complexity, as the resin material simultaneously provides all required properties.
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 design simplifies manufacturing, enhances sealing, and extends the cell's service life by preventing gap formation and ensuring reliable electrical connections.
Implementation Method 1
The use of the first resin material and/or the second resin material can, in particular, prevent or reduce gap formation, which can occur, for example, when injection molding a thermoplastic material. This preferably optimizes the sealing effect of the first potting element and/or the second potting element.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The aim of the invention is to provide an electrochemical cell which can be produced as simply as possible and has a long service life. This is achieved in that the electrochemical cell comprises a first contact element which connects a first cell terminal to a first connection conductor and which is fixed to a cover element of the electrochemical cell by means of a first potting element in a first connection region, said first potting element being made of a first polymer material which comprises or is made of a first resin material, and/or the electrochemical cell comprises a second contact element which connects a second cell terminal to a second connection conductor and which is fixed to the cover element by means of a second potting element in a second connection region, said second potting element being made of a second polymer material which comprises or is made of a second resin material.