Hybrid Frame Seal Structure for Large Housing Gap Assembly
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Solution Overview
Problem
Conventional seals for large housing gaps, such as those in battery boxes, face challenges with security and assembly complexity due to the flexibility of elastomer seals and the difficulty in manufacturing large-format metal or plastic carriers with rubber sealing lips, leading to incorrect positioning and high material waste.
Innovation Solution
A seal comprising rigid and flexible sealing layer portions connected by a flexible sealing layer portion with support elements, allowing for easy assembly and reliable sealing, and enabling large-format seals to be produced and transported efficiently by folding, thus simplifying logistics and reducing material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pure elastomer seals are used for large housing gaps, then flexibility and deformability are improved, but positioning accuracy and assembly security deteriorate due to incorrect positioning and slipping
Solution Approach 1:
The seal is divided into a hybrid structure combining rigid sealing layer portions (for positioning accuracy) and flexible sealing layer portions (for adaptability). This segmentation allows each part to fulfill its specific function: rigid parts ensure correct positioning while flexible parts provide deformability for sealing.
Solution Approach 2:
The seal uses composite materials combining rigid materials (for structural stability and positioning) and flexible elastomer materials (for sealing adaptability). This composite approach resolves the contradiction by integrating the advantages of both material types into a single functional seal structure.
2Strength
If conventional single-part frame seals with continuous metal or plastic carriers are used, then structural integrity is improved, but manufacturing complexity and material waste increase due to large moulds and difficult production
Solution Approach 1:
The carrier is segmented into multiple separate carrier elements instead of a single continuous structure. This allows each carrier element to be manufactured independently using standard-sized moulds, reducing manufacturing complexity and material waste while maintaining structural integrity through the interconnected flexible sealing portions.
Solution Approach 2:
The seal design transitions from a two-dimensional continuous carrier to a multi-dimensional modular structure where separate carrier elements are connected through flexible sealing portions, enabling easier manufacturing and assembly while maintaining overall structural strength.
3Reliability
If large-format seals are manufactured as single pieces, then sealing continuity is improved, but transport and assembly complexity increase due to size constraints
Solution Approach 1:
The large-format seal is segmented into multiple smaller carrier elements that can be transported and handled more easily. These segments are then assembled by connecting them with flexible sealing portions, maintaining sealing continuity while reducing transport and assembly complexity.
Solution Approach 2:
The flexible sealing portions provide dynamic adaptability during assembly, allowing the segmented seal to conform to the housing gap while being assembled. This dynamic characteristic ensures sealing continuity is maintained despite the segmented structure.
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 robust, reliable, and easy-to-assemble seal with improved sealing performance and reduced complexity in manufacturing and transportation, while maintaining flexibility and durability, even for large-format seals.
Implementation Method 1
The flexible sealing layer portion comprises or consists of, at least in part, i.e. in part or entirely, an elastomer
Data Source
AI summary
The present disclosure relates to a seal, such as a gasket, for sealing a gap in a housing, said gap extending around an inner chamber of the housing, and thus for sealing the inner chamber from an exterior of the housing, comprising at least one sealing layer. The present disclosure further relates to a frame seal that provides sealing between at least two components of the housing, for example a bottom part and a top part of the housing, for example of a motor vehicle battery housing or motor vehicle battery box housing.