Double Busbar Gasket Molding to Prevent Liquid Creep
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Solution Overview
Problem
Existing methods for sealing double busbars in electric vehicles fail to effectively prevent liquid creep and require additional bushings at transition points, complicating the design and increasing the risk of corrosion.
Innovation Solution
A method where a gasket is cast onto both busbars of a double busbar, allowing them to be guided into a housing through a common feedthrough, using a mold cavity filled with a sealing material that solidifies to form a permanent, elastic bond with the busbars and housing, eliminating the need for separate bushings and enhancing sealing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate bushings are used at transition points to seal double busbars, then sealing effectiveness is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple separate sealing bushings into a single integrated gasket that seals around both busbars simultaneously. The gasket is molded as one piece with continuous sealing material that wraps around both conductors, eliminating the need for separate bushings at each transition point while maintaining comprehensive sealing effectiveness.
Solution Approach 2:
The single gasket performs multiple sealing functions that would otherwise require separate components. It seals both busbars at their transition points, prevents liquid creep along both conductors, and provides mechanical support for both busbars entering the housing through a common feedthrough, thereby reducing overall device complexity.
2Reliability
If additional bushings are installed at transition points, then protection against liquid creep is improved, but manufacturing time increases
Solution Approach 1:
The gasket is pre-molded as a complete integrated component before installation. The sealing material is already positioned and shaped to accommodate both busbars, eliminating the need for on-site assembly of multiple bushings and reducing manufacturing time during the busbar assembly process.
Solution Approach 2:
By combining multiple sealing functions into one pre-manufactured gasket component, the installation process is simplified to a single assembly step rather than requiring sequential installation of multiple separate bushings, thereby improving productivity without compromising liquid creep protection.
3Device complexity
If a common gasket is cast onto both busbars, then device complexity is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The sealing material is provided in a liquid or paste-like state that can flow and adapt to the contours of both busbars before solidifying. This parameter change from solid to liquid state during molding allows the material to conform precisely to the busbar surfaces and transition points, achieving high sealing precision through the molding process rather than requiring pre-formed precision components.
Solution Approach 2:
The sealing material undergoes a phase transition from liquid/paste-like state during injection to solid state after setting. This phase transition enables the material to fill the mold cavity completely, conform to complex geometries of both busbars, and then lock into place, achieving high manufacturing precision through the phase change process itself.
4Adaptability or versatility
If separate bushings are used for each busbar, then adaptability to different configurations is improved, but loss of substance increases
Solution Approach 1:
The single integrated gasket is designed to accommodate both busbars in a unified structure, reducing the total amount of sealing material required compared to using separate bushings for each conductor. The continuous sealing material efficiently covers all transition points without the redundant material that would be present in multiple separate components.
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 approach reliably prevents liquid creep and simplifies the design by integrating the gasket directly onto the busbars, ensuring effective sealing without additional bushings and enhancing protection against environmental influences.
Implementation Method 1
the sealing material flowing around the flat conductors, adhering to the flat conductors and solidifying in the mold cavity to form the gasket molded onto the double current bar
Implementation Method 2
The sealing material may be provided and/or processed in a liquid or paste-like state. The liquid or paste-like sealing material then at least partially or preferably completely fills the mold cavity and thereby assumes a contour of the mold cavity. The sealing material solidifies, cross-links or otherwise subsequently solidifies in this contour.
Implementation Method 3
The sealing material may be mixed from at least two components such that the mixture solidifies, in particular crosslink, after mixing. In a solidified or cross-linked state, the sealing material may be permanently elastic.
Data Source
AI summary
A method of manufacturing a gasket for a double busbar is disclosed. The double busbar may be composed of two separate electrically insulated flat conductors. The conductors may be arranged one above the other. The double busbar may be placed in a mold cavity for molding the gasket. The mold cavity may be closed around the double busbar and filled with a sealing material. The introduced sealing material flows around the flat conductors, adhering to the flat conductors, and solidifying in the mold cavity to form a gasket molded to the double busbar.