EV Battery Leadframe Double Sealing System
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Solution Overview
Problem
Existing battery apparatuses for electric vehicles face challenges in maintaining leak-tightness, particularly in the abutment regions between the battery frame and cell modules, leading to potential coolant leaks and suboptimal cooling effects, which require high structural precision and costly sealing measures.
Innovation Solution
A leadframe with an encircling frame section and separating sections that create module receptacles, featuring a double sealing system comprising inner and outer sealing means to prevent coolant escape, along with tolerance sections for temperature compensation and fastening sections for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical separation and sealing measures are implemented to prevent coolant leaks, then leak protection is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent implements a double sealing system where an inner sealing means is nested within an outer sealing means. The inner sealing means is arranged between the frame section and the cell module, while the outer sealing means is arranged between the frame section and the leadframe. This nested configuration provides redundant leak protection without requiring completely separate sealing systems, thereby improving reliability while controlling device complexity.
Solution Approach 2:
The sealing system is segmented into distinct functional zones: the inner sealing means handles sealing at the cell module interface, while the outer sealing means handles sealing at the leadframe interface. This segmentation allows each sealing means to be optimized for its specific location and function, improving overall leak protection while enabling independent selection of sealing materials and methods for each zone.
2Reliability
If very precise production is required in abutment regions, then leak risk is reduced, but manufacturing cost and production time increase
Solution Approach 1:
The patent employs flexible sealing means (such as sealing rings, sealing films, or elastomeric materials) in both the inner and outer sealing configurations. These flexible elements can accommodate minor dimensional variations and misalignments in the abutment regions between the frame section, cell modules, and leadframe. By using compliant sealing materials, the system achieves reliable leak protection without requiring extremely tight manufacturing tolerances, thereby reducing manufacturing precision requirements while maintaining leak prevention effectiveness.
Data Source
AI summary
A leadframe (10) for a battery apparatus (100) of an electric vehicle, having an encircling frame section (20) and at least one separating section (30) that subdivides the frame section (20) into at least two module receptacles (40) for receiving in each case one cell module (120). The encircling frame section (20) has an encircling outer seal (50) for sealing off against the passage of liquid. Additionally, the at least one separating section (30), together with the frame section (20), has an inner seal (60) that encircles each module receptacle (40) for sealing off against the passage of liquid.