GenZe Electric Transportation Battery Pack Gasket

Using a form-in-place gasket to create a reliable battery assembly that meets strict design standards of weight, performance, and safety.

 

Challenge

GenZe was challenged with producing an aesthetically-pleasing removable Li-Ion battery pack without compromising safety and reliability. 

Packaging state-of-the-art electronics with energy-dense Li-Ion battery cells presented some unique challenges and opportunities. Because the battery pack is removable, many design challenges had to be addressed. Weight, performance, and safety were top priorities. GenZe engineers pored over the designs for thousands of hours and those efforts resulted in a safe, aesthetically pleasing, yet extremely complex battery system. The question was, could it be mass-produced, and at the same time be serviceable? The manufacturing engineering team had to develop a process to assemble the system, while ensuring it could be disassembled and resealed reliably, time and time again. Countless trials of different options ranging from solid die cut gaskets to individual O-rings and liquid materials were run. None of the trials proved to be a solution that could provide the necessary sealing performance while being easy to apply.

Solution

The Dymax team recommended a form-in-place gasket to satisfy the needs of the application for sealing protection and manufacturability.

After visiting the GenZe production floor to assess the process, a Dymax team of marketing, application engineering, and sales personnel suggested a solution - GA-201 – a form-in-place gasket that would satisfy the needs of the application, not only in terms of sealing protection but also in terms of manufacturability.

In addition, this “dispensable” gasketing material demonstrated previously unseen flexibility to the product engineers. This was a breakthrough because the product’s styling and packaging would no longer be limited by its sealing requirements.

GA-201 is formulated for sealing plastic, glass, metal enclosures, and plated surfaces that require a soft, tack-free, flexible gasket. It acts as a moisture barrier and prevents absorption or penetration of air, dust, noise, liquids, gaseous substances, or dirt.

Results

The Dymax system solution enabled consistent production of GenZe battery assemblies that meet strict design standards of weight, performance, and safety. 

After running months of performance and validation testing, GA-201 proved to be the solution GenZe was searching for. The Dymax team not only brought their materials expertise to the table, but they also offered process application recommendations and assisted GenZe process engineers with the selection of the proper dispensing and UV curing systems. This shortened the equipment selection process significantly and added much - needed confidence in attempting to produce a product that had never been offered before. A complex manufacturing cell, which includes a 6-axis robot complete with precision dispensing equipment and a BlueWave® 200 curing unit, was installed. And in a very short time, battery assemblies that power the GenZe 2.0 scooter were in production and passing the rigorous in-process tests with flying colors.

More Case Studies

We offer more than products, we offer solutions. See how Dymax is helping customers solve their most challenging applications in various markets.

View all

Adhesive Replaces 2-Part Epoxy for Faster Optical Sensor Assembly

A case study about how a light-curable adhesive replaced a two-part epoxy for faster sensor assembly and improved the application process. ...

Aerospace Improving PCB Conformal Coating Process

 A case study on improving the PCB conformal coating process by increasing production output.  ...

Aerospace Improving PCB Masking Process

A case study on improving the PCB masking process for an aerospace and defense manufacturer.  ...

Aerospace Masking Process for Electroless Nickel Plating

A case study on the masking process for electroless nickel plating ...

Aerospace Printed Circuit Board Assembly

Increasing Production and Reducing Processing Time in PCB Assembly  ...

Automated Masking System Revolutionizes Surface Treatment Processing

A case study about how an automated masking line drastically reduced the processing times required for an aero engine component. ...

Bonding MLAs in Automotive Headlights

Adhesive for Bonding MLAs in Automotive Headlights Exhibits Low Discoloration Under High Temperatures ...

Cinch Gaming Controllers Get Enhanced Grip

Cinch Gaming, a national leader in custom professional video game controllers, was looking for a durable solution to provide a rubber grip coating to their ABS plastic controller shells. ...

Electrical Explosion Protection & Sensor Technology

A world leader in electrical explosion protection and sensor technology was looking to turn away from laser welding for an application that requires sealing two polycarbonates of their photoelectric ...

High Performance Solutions for EV Charging Stations

A case study on how light-curable conformal coatings and encapsulants helped improve EV smart charging station infrastructure PCB applications. ...

Light-Curing Conveyor Enables 100% Manufacturing Scale Up

A case study on how using Dymax UVCS Light-Curing Conveyor Systems helped to increase the production of nasal swabs.VIDEO:  Dymax Partners with 3D Printer Company on COVID-19 Test Swabs #InThisTogeth...

One Part, Optical Epoxy Using UV/Visible Light and Heat Cure

A case study on using ultraviolet and heat cure to secure a camera module holder to a PCB. ...

Ruggedizing Lens and Reflector Housings in Flashlights

A leading manufacturer of premium portable lighting wanted to ruggedize its safety flashlights used in the field by firefighters, police officers, and military troops. In their search for a fast-curi...

Ultra-Red Fluorescing Technology Provides Immediate Quality Check

A case study on how the use of patented Ultra-Red® fluorescing technology can aid in product verification. ...

Get In Touch

Interested in learning more or have questions? We want to hear from you.

Back to top