rubber inflatable seal7
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Case Study of Integral molded inflatable seal Project: A Complete Implementation Guide from Requirements Analysis to Implementation
Case Study 1: New Energy Vehicle Battery Pack Sealing Project (A Leading Automaker)
1. Project Background and Verification of Requirement Authenticity
Industry Pain Points: New energy vehicle battery packs must meet IP67 waterproof and dustproof standards, while also adapting to extreme temperature ranges from -40℃ to 85℃. Traditional seals are prone to failure due to thermal expansion and contraction, resulting in leakage rates exceeding industry requirements (≤0.05m³/(h·m²)).
Requirement Confirmation: Through the battery pack design drawings and operating condition simulation data provided by the client (e.g., vibration frequency 5Hz, pressure fluctuation ±0.2MPa), it was verified that their seal Inflatable requirements necessitate a customized solution with high elasticity, resistance to temperature changes, and low compression set.
2. Selection and Customized Design
Material Selection: A composite material of silicone (VMQ) and fluororubber (FKM) was used. The silicone layer provides low-temperature elasticity (maintaining flexibility even at -40℃), while the fluororubber layer is resistant to high temperatures (150℃) and chemical corrosion.
Structural Optimization: Based on compression molding technology, a double-layer hollow sealing structure is designed with dynamically adjustable internal inflation pressure (0.1-0.5MPa) to compensate for manufacturing errors and thermal deformation.
Verification Testing: Passing a 1000-hour high-temperature and high-humidity (85℃/85%RH) aging test, the seal's tensile strength retention rate is ≥90%, and the leakage rate is ≤0.02m³/(h·m²), meeting customer requirements.
3. Cooperation Model and Execution Process
Joint R&D: A dedicated team is established with the customer's technical team to iterate through three rounds of samples (each round lasting 15 days) until the final design is finalized.
Production Control: An SPC (Statistical Process Control) system is introduced to monitor parameters such as molding temperature (180±2℃) and pressure (15±0.5MPa) in real time, ensuring batch consistency.
Delivery and Installation: Pre-installation tools and operation videos for the seals are provided, with on-site installation guidance. The installation time for a single battery pack seal is reduced from 4 hours to 1.5 hours.
4. Implementation Results and Feedback
Performance Data: One year after mass production, the customer reported a 0% failure rate for the seals, and the battery pack's waterproof rating passed third-party testing (IP68). It also supports vehicle testing in extreme environments (such as low-temperature starts in Mohe and high-temperature exposure in Hainan).
Commercial Value: The customer has extended this Inflatable seal solution to all its vehicle models, with annual purchases exceeding 500,000 units, increasing the supplier's market share to 60%.
Summary: Core Logic of Project Validation
Requirement Authenticity: Third-party evidence, such as operating condition data and test reports provided by the customer, ensured the requirements were not fictitious.
Scientific Selection: Selection criteria were quantified based on material performance databases and structural simulations (such as CAE analysis).
Transparent Collaboration: A trust mechanism was established through joint R&D and risk-sharing models.
Controllable Execution: Tools such as SPC and on-site teams were introduced to ensure delivery quality and schedule.
Quantifiable Results: Product value was validated through comparative data (such as leakage rate and maintenance costs), forming a closed-loop feedback loop.
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