FRP Battery Enclosure With Integrated Seal for Precise Sealing
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Solution Overview
Problem
Current motor vehicle battery enclosures rely on adhesives, fasteners, and gaskets for sealing, which can lead to inaccurate seal placement, increased part complexity, and longer manufacturing times, while lacking the flexibility and durability needed for modern electric and hybrid vehicles.
Innovation Solution
Integration of an elastomeric seal stitched onto a fiber preform within a fiber-reinforced polymer (FRP) composite component, using resin transfer molding to create a unitary structure that eliminates the need for adhesives and fasteners, ensuring accurate seal placement and reduced part complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adhesives, fasteners, and gaskets are used for sealing battery enclosures, then sealing function is achieved, but seal placement accuracy decreases and part complexity increases
Solution Approach 1:
The elastomeric seal is integrated directly into the FRP composite component during the molding process, merging the seal function with the structural component. This eliminates separate sealing elements and their associated fasteners or adhesives, achieving accurate seal placement while reducing overall system complexity
Solution Approach 2:
The elastomeric seal is pre-positioned and embedded within the FRP composite component before final assembly. This preliminary integration ensures precise seal placement is achieved during manufacturing rather than requiring adjustment during assembly, while eliminating the need for separate sealing systems
2Productivity
If adhesives, fasteners, and gaskets are used for sealing battery enclosures, then sealing function is achieved, but manufacturing time increases
Solution Approach 1:
The seal and structural component are manufactured as a single integrated unit through resin transfer molding, combining multiple manufacturing steps into one process. This eliminates sequential operations such as applying adhesives, installing fasteners, or fitting gaskets, thereby reducing total manufacturing time and improving productivity
Solution Approach 2:
The elastomeric seal is pre-integrated into the composite component during the molding process itself, rather than being added as a separate post-processing step. This preliminary action consolidates manufacturing operations and reduces the time required for final assembly and sealing
3Reliability
If traditional sealing methods are used, then sealing is achieved, but durability and flexibility are insufficient
Solution Approach 1:
The sealing system utilizes a composite structure combining FRP (fiber-reinforced polymer) for structural strength and durability with an elastomeric material for flexibility and sealing performance. This composite approach allows the seal to simultaneously achieve high durability from the rigid composite and adaptability from the elastic polymer
Solution Approach 2:
The FRP composite component incorporates the elastomeric seal with different local properties: the FRP provides rigid structural support and durability, while the embedded elastomeric portion provides flexible sealing capability. Each material is positioned where its specific properties are most needed, achieving both durability and flexibility in the overall sealing system
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 integrated elastomeric seal provides a durable, flexible, and accurately positioned sealing solution that reduces manufacturing time and costs, while enhancing the durability and watertightness of battery enclosures in electric and hybrid vehicles.
Implementation Method 1
a polymer-matrix encapsulant (e.g., fast-curing epoxy resin) is injected into the mold cavity and cured to create a single-piece, rigid composite component
Data Source
AI summary
Presented are fiber-reinforced polymer (FRP) composite components with integrated polymer parts, methods for making/using such FRP composite components, and vehicles equipped with battery packs sealed inside FRP battery enclosures by integrated elastomeric seals. An FRP composite component, such as a rigid battery tray basin, includes a component body that is formed with a polymer matrix material, such as a fast-curing epoxy resin. A fiber preform, such as a multiaxial-fiber fabric sheet, is encapsulated within the component body and formed with a cluster of fibers bound together in a predefined formation. A polymer seal, such as an elastomeric bulb seal, includes a seal head and a mounting base. The seal's mounting base is stitched to the fiber preform and at least partially encapsulated within the component body. The seal head protrudes from the fiber preform and extends through an aperture in the component body.