Integrated Fastener Gasket Compression for Battery Sealing

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Solution Overview

Problem

The existing battery watertightness structures for electric vehicles, relying on gaskets and metal bushes, face issues with secure fixation, leading to increased cycle time, production costs, and quality problems due to manual fitting and repeated deformation of the gasket, resulting in compromised compression and potential moisture ingress.

Innovation Solution

A battery watertightness structure that integrates a gasket between two members with assembly hardware, where the height of the hardware supports gasket compression, eliminating the need for a separate bush and enhancing the gasket's compression limit against axial forces, thus ensuring consistent sealing without bush-related deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate bush is coupled to the gasket to support axial force, then the gasket can maintain compression, but the assembly process becomes more complex and time-consuming

Engineering Contradiction:

Improvegasket compression maintenanceVSAvoidassembly structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention integrates the bush function directly into the assembly hardware (bolt or nut) by forming an integrated structure where the fastening component also serves as the axial force support. This eliminates the need for a separate bush component while maintaining the ability to support axial forces and maintain gasket compression.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The assembly hardware is designed to perform multiple functions simultaneously: fastening the battery cover to the battery body, supporting axial forces, and maintaining gasket compression. This multi-functional design replaces the traditional separate bush component.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a separate bush is manually fitted to the gasket, then axial force support is improved, but production cycle time increases

Engineering Contradiction:

Improveaxial force supportVSAvoidassembly cycle time

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The bush function is merged with the assembly hardware into a single integrated component. This eliminates the manual fitting process of a separate bush and reduces assembly steps, thereby decreasing production cycle time while maintaining axial force support capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The axial force support structure is pre-integrated into the assembly hardware during manufacturing, so no additional action is needed during assembly. The component is ready to support axial forces immediately upon installation.

Inventive Principle:

Principle #10Preliminary action

3Ease of operation

If assembly hardware is tightened and loosened repeatedly, then maintenance and adjustment are facilitated, but the bush flange bends causing gasket deformation

Engineering Contradiction:

Improvemaintenance accessibilityVSAvoidgasket sealing quality

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The assembly hardware and axial force support structure are integrated into a single robust component designed to withstand repeated tightening and loosening cycles without deformation. This integrated structure maintains its geometric precision and continues to support the gasket uniformly throughout its service life.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated assembly hardware features a rounded head geometry that distributes stress more evenly during tightening and loosening operations, preventing localized stress concentrations that could cause deformation of the support structure or gasket.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Reliability

If a bush is used to support axial force, then gasket compression is maintained, but production costs increase

Engineering Contradiction:

Improvecompression maintenanceVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention combines the fastening function and axial force support function into a single assembly hardware component. This reduces the total part count, eliminates the need for separate bush manufacturing and assembly, and lowers production costs while maintaining reliable gasket compression.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The assembly hardware is designed as a multi-functional component that performs both fastening and axial force support, replacing the traditional separate bush component and reducing manufacturing complexity and cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20220285767A1Battery watertightness structure and method

Publication Date: 2022.09.08 HYUNDAI MOBIS CO LTD

AI summary

A battery watertightness structure includes a first member, a second member that covers the first member, a gasket located between the first member and the second member, assembly hardware fixed to a hole formed in the first member, and counterpart assembly hardware that is assembled with the assembly hardware through a hole formed in the second member and fastens the first member and the second member and the gasket therebetween. A height of a portion of the assembly hardware, which is located between the first member and the second member, is configured to support a compression limit of the gasket against an axial force when the counterpart assembly hardware is assembled between the first member and the second member.