Urethane Adhesive Battery Pack Sealing With Fewer Fasteners
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Solution Overview
Problem
Conventional electrified vehicle battery packs face challenges in securely sealing the enclosure assembly to prevent moisture ingress, often relying on gasket-type seals which can be costly and inefficient.
Innovation Solution
The use of a urethane-based adhesive is introduced between the tray and cover of the battery pack enclosure assembly, acting as both a fastener and seal, with a crossover design that overlaps by at least 80 mm and is augmented by fasteners positioned outboard of the adhesive, ensuring a secure and moisture-tight seal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gasket-type seals are used to seal the enclosure assembly, then moisture prevention is achieved, but cost and complexity increase
Solution Approach 1:
The patent combines the sealing function and fastening function into a single urethane-based adhesive system. The adhesive bead simultaneously seals the joint between tray and cover while providing structural fastening, eliminating the need for separate gasket-type seals and reducing the number of fasteners required.
Solution Approach 2:
The urethane-based adhesive performs multiple functions: it acts as a sealant to prevent moisture ingress, as a fastener to secure the enclosure assembly, and as a structural bonding agent. This multi-functionality replaces the need for separate sealing components and reduces overall system complexity.
2Strength
If multiple fasteners are used to secure the enclosure assembly, then structural strength is improved, but the number of components and assembly complexity increases
Solution Approach 1:
The patent merges the fastening function with the sealing adhesive. The urethane-based adhesive bead provides both structural bonding strength and sealing functionality, allowing the enclosure assembly to be secured with fewer fasteners while maintaining structural integrity.
Solution Approach 2:
The adhesive system serves as both the sealing mechanism and the fastening mechanism. This multi-functionality reduces the total number of components needed, simplifying the assembly while maintaining the required structural strength of the enclosure.
3Reliability
If gasket-type seals are used for sealing, then moisture sealing is achieved, but cost increases
Solution Approach 1:
The urethane-based adhesive performs both sealing and fastening functions in a single application, eliminating the need for separate expensive gasket-type seals. This multi-functional approach reduces material costs and simplifies the manufacturing process.
Solution Approach 2:
The patent uses a cost-effective urethane-based adhesive material that provides reliable sealing without the high cost associated with traditional gasket-type seals. The adhesive can be applied directly and cured to form a durable sealing joint.
4Reliability
If conventional sealing methods are used, then sealing is achieved, but adaptability to varying contour surfaces is reduced
Solution Approach 1:
The urethane-based adhesive exhibits viscoelastic properties that allow it to adapt to varying contour surfaces and irregular geometries. The adhesive can flow and conform to different surface profiles during application and curing, providing effective sealing on non-uniform surfaces where rigid gaskets would fail.
Solution Approach 2:
The adhesive forms a flexible sealing layer that can accommodate surface variations and contour irregularities between the tray and cover. This flexibility allows the seal to maintain contact and effectiveness across varying geometries, unlike rigid gasket-type seals.
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
This solution reduces the number of required fasteners, eliminates the need for expensive gasket-type seals, and provides an effective seal across varying contour surfaces, enhancing the reliability and durability of the battery pack.
Implementation Method 1
a urethane based adhesive disposed between the tray and the cover
Implementation Method 2
A first end portion of the urethane based adhesive overlaps a second end portion of the urethane based adhesive at a crossover location
Data Source
AI summary
This disclosure details exemplary battery pack designs for use in electrified vehicles. An exemplary battery pack may include a multi-piece enclosure assembly and an urethane based adhesive. The urethane based adhesive may function as both a fastener for securing the enclosure assembly components together and as a seal for blocking the ingress of moisture into the interior of the battery pack. Associated battery pack assembly methods are also disclosed.