Foldable Frame Seal Structure for Large Housing Gap Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional seals for large housing gaps, such as those in battery boxes, face challenges with assembly security, material wastage, and manufacturing complexity due to their size and flexibility, leading to incorrect positioning and increased assembly effort.
Innovation Solution
A foldable seal design featuring hard components connected by a soft component, allowing for easier production and assembly, with a continuous sealing contour formed by merging partial sealing contours, enabling larger formats to be produced with smaller tools and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional one-part frame seals with continuous metal or plastic support are used, then sealing performance is maintained, but manufacturing becomes difficult for large dimensions requiring very large tools and causing significant material waste
Solution Approach 1:
The seal is divided into multiple hard components (support elements) that can be manufactured separately using smaller tools, then connected through soft components. This segmentation allows large-format seals to be produced without requiring very large manufacturing tools, reducing tooling costs and material waste while maintaining the structural integrity needed for sealing performance.
2Ease of operation
If pure elastomeric seals are used for large housing gaps, then assembly is simpler, but the assembly becomes insecure due to flexibility and deformability leading to incorrect positioning or slipping
Solution Approach 1:
The seal combines hard components (metal or plastic supports) with soft components (elastomeric sealing lips). The hard components provide structural rigidity and positioning stability to prevent incorrect placement and slipping, while the soft components maintain sealing functionality and ease of assembly. This composite structure resolves the contradiction between assembly simplicity and assembly security.
3Manufacturing precision
If traditional one-part frame seals are used for large dimensions, then sealing contour is continuous, but transport and assembly require great effort due to size and weight
Solution Approach 1:
The seal is segmented into multiple smaller hard components connected by soft components, making the overall structure more manageable for transport and assembly. The segmented design reduces the effort required to handle and install large-format seals while the connection mechanisms ensure the sealing contour remains effectively continuous when assembled.
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 design enhances assembly security, reduces material waste, and simplifies logistics by allowing for easier handling and reusability of large-format seals, while maintaining reliable sealing performance even upon deformation.
Implementation Method 1
at least two hard components (11a, 11b; 11c, 11d; 11e, 11f) which are connected by a connecting soft component (12a, 12b, 12c), which is soft in comparison to the hard components (11a-f)
Data Source
AI summary
A seal, in particular a gasket, for sealing with at least one sealing layer a gap in a housing that extends around an inner chamber of the housing. In particular, a frame seal which seals between a lower part and an upper part of the housing, for example a motor vehicle battery housing or a motor vehicle battery box housing.