Battery Cooling Fin Coupling With O-Ring Seals
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Solution Overview
Problem
Existing battery cell assemblies face challenges in effectively coupling cooling fins to manifolds to achieve fluid-tight seals, which is crucial for efficient heat transfer and battery performance.
Innovation Solution
The use of cylindrical coupling members with O-ring gaskets provides a fluid-tight seal between the cooling fins and manifolds, ensuring efficient heat transfer by removably coupling the inlet and outlet tube portions to the cylindrical coupling members, which are brazed to the metal plate and coupled to the manifolds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coupling methods are used to attach cooling fins to manifolds, then the structural simplicity is maintained, but fluid-tight seals cannot be reliably achieved
Solution Approach 1:
The patent introduces cylindrical coupling members as intermediary components between the cooling fins and manifolds. These coupling members feature circumferential grooves that receive O-ring gaskets, creating a mediator structure that reliably forms fluid-tight seals while maintaining modular assembly. The intermediary coupling member resolves the contradiction by providing a dedicated sealing interface without requiring direct complex integration between the fin and manifold.
Solution Approach 2:
The coupling structure is segmented into distinct functional components: cylindrical coupling members, O-ring gaskets, inlet tube portions, and outlet tube portions. This segmentation allows each component to perform its specific function (structural support, sealing, fluid connection) independently, enabling reliable fluid-tight seals through the specialized O-ring interfaces while keeping the overall device complexity manageable through modular design.
2Ease of repair
If removable coupling is used to allow assembly and disassembly, then ease of maintenance is improved, but seal reliability may be compromised
Solution Approach 1:
The coupling structure employs dynamic characteristics through removable cylindrical coupling members that can be assembled and disassembled from the manifolds. The O-ring gaskets in circumferential grooves provide flexible sealing that maintains fluid-tight integrity during assembly and disassembly operations. This dynamic design allows for maintenance and replacement while preserving seal reliability through the resilient O-ring interfaces.
Solution Approach 2:
The O-ring gaskets serve as beforehand cushioning elements that compensate for potential sealing issues during assembly and disassembly. The elastomeric O-rings are pre-positioned in circumferential grooves to create a protective sealing barrier that maintains fluid-tight integrity even during repeated assembly cycles, cushioning against dimensional variations and assembly tolerances.
3Reliability
If multiple O-ring gaskets are used per coupling member, then seal reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The sealing system is segmented with multiple O-ring gaskets positioned in separate circumferential grooves on each cylindrical coupling member. This segmentation provides multiple independent sealing interfaces, where the first and second O-ring gaskets on each coupling member create redundant fluid-tight barriers. While this increases the number of components, each O-ring is a simple elastomeric ring that can be manufactured using standard processes, keeping individual manufacturing complexity low.
Solution Approach 2:
The patent uses homogeneous O-ring gaskets made from elastomeric material for all sealing interfaces. This homogeneity simplifies manufacturing by using a single material type and sealing geometry (circumferential grooves) throughout the assembly, despite having multiple O-rings per coupling member. The consistent design across all sealing points reduces manufacturing variability and simplifies the fabrication process.
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 configuration ensures reliable fluid-tight seals, enhancing the cooling efficiency of battery cells by effectively transferring heat from the cells to the cooling manifolds, thereby improving battery performance and longevity.
Implementation Method 1
first and second O-ring gaskets are disposed in the first and second circumferential grooves, respectively, such that the first and second O-ring gaskets are removably coupled to the first cylindrical coupling member
Data Source
AI summary
A battery cell assembly having a cooling fin with a tube, a substantially rectangular-shaped metal plate, first and second cylindrical coupling members, and first and second O-ring gaskets is provided. The tube has an inlet tube portion and an outlet tube portion. The tube is coupled to a peripheral region of the metal plate. The first cylindrical coupling member has a first aperture extending therethrough, and first and second circumferential grooves. The inlet tube portion is disposed in the first aperture and coupled to the first cylindrical coupling member. The first and second O-ring gaskets are disposed in the first and second circumferential grooves, respectively. The outlet tube portion is disposed in the second aperture and is coupled to the second cylindrical coupling member.