Polymer Battery Pack Enclosure With Integrated Joint Sealing
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Solution Overview
Problem
Existing battery pack enclosures in electrified vehicles face challenges in sealing external joints, retaining internal components, and securing electrical and coolant lines effectively.
Innovation Solution
The use of a polymer-based enclosure assembly with a tray, mid-tray, and cover, featuring a tongue and groove connection sealed with tape and liquid seals, along with a foamed electrical subassembly and connectors with weld flanges for securing lines, addresses these challenges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing methods are used at external joints, then sealing effectiveness is insufficient, but adding complex sealing structures increases device complexity
Solution Approach 1:
The patent combines multiple sealing methods (tape seal and liquid seal) into a unified sealing system at the external joints. The tape seal provides primary sealing while the liquid seal fills gaps and provides secondary sealing, creating a composite sealing structure that achieves reliable sealing without requiring overly complex individual components
Solution Approach 2:
The patent employs composite sealing materials including adhesive tapes and liquid sealants that combine different material properties. The tape seal uses adhesive materials for bonding and sealing, while the liquid seal provides gap-filling and sealing capabilities, creating a composite sealing system that achieves effective sealing at external joints
2Reliability
If multiple sealing methods are applied at external seams, then sealing reliability is improved, but manufacturing process complexity increases
Solution Approach 1:
The tape seal is applied preliminarily to the external seams before final assembly, establishing a baseline sealing condition. This preliminary sealing action allows subsequent liquid seal application to focus on filling remaining gaps and reinforcing the seal, thereby improving sealing reliability while organizing the manufacturing process into manageable stages
3Strength
If polymer-based enclosure with tongue and groove connection is used, then structural integrity is improved, but manufacturing precision requirements increase
Solution Approach 1:
The tongue and groove connection features localized geometric shapes designed to guide alignment during assembly. The tongue protrusion and groove reception create a mechanical guide system that ensures proper alignment at the joint location, enabling the polymer-based enclosure to achieve high structural integrity while accommodating reasonable manufacturing tolerances
4Stability of the object's composition
If foam shell is used to fill gaps between components, then component retention is improved, but manufacturing complexity increases
Solution Approach 1:
The foam shell utilizes porous or cellular material structure to fill gaps between electrical subassembly components. This foam material provides mechanical retention by physically occupying and stabilizing the spaces between components, ensuring proper component positioning and retention while maintaining a relatively simple overall enclosure 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 effective sealing, retention, and secure connection of electrical and coolant lines, enhancing durability and reducing manufacturing complexity while maintaining a gapless arrangement for improved load distribution and energy absorption.
Implementation Method 1
the tape seal is secured in place with an adhesive
Data Source
AI summary
Battery pack designs for use in electrified vehicles may include a polymer-based enclosure having features for sealing external joints, retaining components inside the battery pack, securing electrical and coolant lines to the polymer-based enclosure, etc. The proposed designs reduce the number of overall parts in assembly, such as fasteners and brackets, and simplify the overall battery pack manufacturing and assembly processes.