Foldable One-Piece Battery Housing Seal for Leak-Free Assembly
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Solution Overview
Problem
The production of frame-like seals for high-voltage battery housings is costly due to the need for large production tools, and assembling seals from multiple parts can lead to leaks at transitions between parts.
Innovation Solution
A one-piece, frame-like seal ring made of elastic plastic, with fold regions that allow the seal to change dimensions from a compact production position to a larger installation position, and positioning and fixing elements for secure placement on the battery housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a frame-like seal is manufactured from one piece, then reliability is improved (no leaks at transitions), but production cost increases due to the need for large production tools
Solution Approach 1:
The seal body incorporates foldable regions that allow it to dynamically change its dimensions. During production, the seal is folded to a compact size that fits within standard production tools. During installation, the seal is unfolded to expand to its full sealing dimensions. This dynamic transformation enables one-piece manufacturing with conventional tools while maintaining the reliability benefits of a seamless seal structure.
Solution Approach 2:
The seal body is designed to nest within itself through folding, where portions of the seal are contained within the overall structure in a compacted state. This nesting allows the large seal to be produced using smaller production tools, as the seal fits within a reduced envelope dimension during manufacturing, then expands to full size during installation.
2Ease of manufacture
If a seal is manufactured from several individual parts, then production cost decreases, but reliability deteriorates due to leaks at transitions between parts
Solution Approach 1:
The seal body is segmented into functional regions (seal body, positioning elements, fixing elements) that are integrated into a single piece. The foldable regions create natural segmentation points that allow compacting without creating actual joints or transitions where leaks could occur. This maintains the one-piece integrity while enabling cost-effective production.
3Ease of manufacture
If the seal is made with fold regions, then ease of manufacture is improved (compact production), but device complexity increases
Solution Approach 1:
The seal body utilizes the flexibility of elastomeric material to create foldable regions. The material properties allow the seal to be folded during production and then expanded during installation without compromising sealing performance. This flexible shell approach simplifies the structure compared to rigid folding mechanisms while achieving the same compact-production benefit.
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 seal can be produced in a space-saving manner, reducing production costs, and provides reliable sealing of the battery housing without joining points that could cause leaks.
Implementation Method 1
The seal body (2) is configured in the form of a one-part, frame-like seal ring composed of an elastic plastic
Data Source
AI summary
A seal can be moved from a production position for a production tool into an installation position for a battery housing. The seal has a seal body to be arranged between a housing flange of a lower housing part and a housing cover of the battery housing, and has positioning elements and fixing elements for positioning and fixing the seal body on the housing flange. The seal body is designed as a one-piece, frame-like sealing ring made of a resilient plastic and has a seal body portion, which is reversibly variable in length, with fold regions. The seal body portion in the folded state of the fold regions provides the production position and in the unfolded state of the fold regions provides the installation position. Positioning regions and fixing regions in which the positioning elements and fixing elements are arranged have a greater width than the fold regions.