Cross-linking Seal Wedging Electrochemical Generators
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Solution Overview
Problem
Existing methods for wedging electrochemical generators in batteries, such as using foam or elastomeric polymer rings, are inefficient and heavy, fail to provide rigid blocking, and do not accommodate safety systems or vibrations effectively.
Innovation Solution
A seal comprising two deformable shells with a sealing film that cross-links upon mechanical stress, forming a resilient resin to securely wedge electrochemical generators in a battery tray, allowing for robust and lightweight construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foam or resin is used to wedge electrochemical generators, then the generators are mechanically blocked, but the battery becomes heavier and requires more material
Solution Approach 1:
The seal is divided into multiple modular elements (first seal element, second seal element, third seal element) that can be independently positioned and function. Each seal element contacts specific portions of the generator container, providing distributed mechanical blocking without requiring excessive material throughout the entire battery tray.
Solution Approach 2:
The seal elements are constructed as flexible rings with cross-sections that can deform under compression. When compressed between the battery tray and generator container, these flexible rings expand radially to provide effective mechanical blocking, achieving reliable wedging with minimal material volume and reduced weight.
2Adaptability or versatility
If elastomeric polymer ring is used for wedging, then the structure remains flexible, but low frequency vibrational eigenmodes are induced which is a penalty for mechanical structure
Solution Approach 1:
The seal elements exhibit dynamic properties: they remain flexible during assembly and normal operation to accommodate positioning tolerances and thermal expansion, but under vibration or impact loads, they stiffen through elastic deformation to provide stable mechanical blocking, thus avoiding harmful low-frequency resonances while maintaining adaptability.
Solution Approach 2:
The mechanical properties of the seal elements change based on applied stress conditions. During assembly, the seals are soft and compliant for easy installation. During operation, particularly under vibration, the elastic material properties cause the seals to stiffen, providing the necessary mechanical stability without inducing problematic vibrational modes.
3Ease of manufacture
If attachment element is placed between electrochemical generators, then some portions are not in contact with container, but rigid wedging along radial and axial directions cannot be guaranteed
Solution Approach 1:
The seal elements are designed to perform multiple functions simultaneously: they provide mechanical blocking in both radial and axial directions, ensure electrical insulation between generators and tray, accommodate positioning variations, and distribute compression forces. This multi-functionality achieves reliable rigid wedging without complicating the assembly process.
4Adaptability or versatility
If curable filling material in hollow deformable attachment element is used, then expansion is possible, but the solution does not allow rigid wedging of generator both along radial and axial directions
Solution Approach 1:
The seal elements utilize three-dimensional elastic deformation of their ring structure with specific cross-sectional geometries. When compressed axially between the tray and generator, the rings expand radially to contact and block the generator container in both radial and axial directions simultaneously, achieving multi-directional rigid wedging through spatial transformation of the seal geometry.
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
The solution provides a lightweight, robust wedging mechanism that effectively withstands vibrations and impacts, ensuring secure positioning of electrochemical generators and accommodating safety systems, while reducing material usage and manufacturing time.
Implementation Method 1
the breaking of the sealing film by the action of a mechanical stress causes the components to be contacted
Implementation Method 2
causes cross-linking of the mixture of both components
Implementation Method 3
A seal comprising at least two deformable shells
Data Source
AI summary
Seal (3) comprising at least two deformable shells (1,1′), each one of the shells containing a component and comprising a membrane, characterized in that bringing the component contained in one shell (1) into contact with the component contained in another shell (1′) causes the mixture of the components to crosslink. Use of the seal for wedging electrochemical generators in position in a battery, particularly lithium generators.