Foldable One-Piece Battery Casing Seal for Leak-Free HV Packs
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Solution Overview
Problem
The high manufacturing costs and potential leaks at transitions between individual parts of frame-shaped seals for high-voltage battery housings pose challenges in creating a reliable and cost-effective sealing solution for large external dimensions.
Innovation Solution
A one-piece, frame-shaped sealing ring made of elastic plastic with folding areas, positioning elements, and fixing elements that can be transformed from a compact manufacturing position to a larger installation position, ensuring a tight seal without joints or connection points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a frame-shaped seal is manufactured from a single piece for large external dimensions, then sealing reliability is improved by eliminating joints, but manufacturing costs increase due to the requirement of large manufacturing tools
Solution Approach 1:
The seal is folded into a compact configuration during manufacturing, nesting the large seal structure into a smaller form factor that can be produced with standard-sized tools. The folded seal contains multiple layers and sections nested within each other, reducing the tooling size requirement while maintaining the capability to form a complete seal when deployed.
Solution Approach 2:
The seal transitions from a static compact manufactured form to a dynamic deployed form through unfolding and expansion. The seal structure includes flexible sections that can be mechanically activated to transform from the compact manufacturing position to the expanded installation position, allowing the same seal to serve both manufacturing and operational requirements.
2Ease of manufacture
If a frame-shaped seal is manufactured from several individual parts, then manufacturing costs are reduced by avoiding large tools, but sealing reliability deteriorates due to potential leaks at transition areas between parts
Solution Approach 1:
Multiple seal sections that would traditionally be separate parts are merged into a single piece construction. The seal includes continuous sealing surfaces and integrated transition areas that eliminate gaps and potential leak paths between separate components, while still allowing the overall seal structure to be folded for compact manufacturing.
3Area of stationary object
If the seal is manufactured in a compact position, then the manufacturing tool size is reduced, but the seal must be transformed to a larger installation position requiring additional complexity
Solution Approach 1:
The seal is divided into distinct functional sections including folding sections for compacting, positioning elements for alignment, and fixing elements for securing. Each section has a specific function in the transformation process, making the overall complex transformation manageable through modular functional breakdown.
Solution Approach 2:
The seal structure includes self-positioning features such as positioning elements that automatically align the seal with the housing flange during installation, and self-fixing mechanisms that secure the seal in its deployed position. This reduces the complexity of external transformation mechanisms by utilizing the seal's own structure to facilitate its own installation.
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 reliable, cost-effective seal for high-voltage battery housings by eliminating manufacturing costs associated with large tools and minimizing leaks, ensuring effective sealing of the battery housing from environmental influences.
Implementation Method 1
The sealing body (2) is designed as a one-piece, frame-shaped sealing ring made of an elastic plastic
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a seal (1), which - can be moved from a production position provided for a production tool into an installation position provided for a battery housing, - has a seal body (2) to be arranged between a housing flange of a lower housing part and a housing cover of the battery housing, and - has positioning elements (8) and fixing elements (9) for positioning and fixing the seal body (2) on the housing flange, - the seal body (2) being designed as a one-piece, frame-like sealing ring made of a resilient plastic and having at least one seal body portion (6), which is reversibly variable in length, with fold regions (3), - the at least one seal body portion (6) in the folded state of the fold regions (3) provides the production position and in the unfolded state of the fold regions (3) provides the installation position, and - positioning regions (4) and fixing regions (5) in which the positioning elements (8) and fixing elements (9) are arranged are designed with a greater width (B1) than the fold regions (3). The invention also relates to a method, a battery housing, a high-voltage battery and a motor vehicle.