Integrated Battery Cooling Manifold With Leak Drain Detection
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Solution Overview
Problem
Existing battery systems face challenges with coolant leakage from external cooling manifolds, which can lead to short circuits and hazardous conditions, requiring additional space and preventing compact integration, while also necessitating cumbersome replacement procedures for defective parts.
Innovation Solution
An integrated cooling manifold within the battery housing, enclosed by a leakage protection member that directs leaked coolant to a detection unit at the bottom, preventing contact with high-voltage components and enabling easy detection of leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If an external cooling manifold is used, then coolant leakage can be contained externally, but additional space is required and compact integration is prevented
Solution Approach 1:
The cooling manifold is integrated directly into the housing structure, merging the cooling function with the structural enclosure. This eliminates the need for separate external cooling manifolds and reduces overall space occupation while maintaining cooling effectiveness.
Solution Approach 2:
The cooling manifold channels are nested within the housing structure itself, with the manifold forming an integral part of the housing walls. This nested integration allows the cooling system to occupy minimal additional space while the housing provides both structural and cooling functions.
2Difficulty of detecting and measuring
If coolant leakage is allowed to contact high-voltage components, then detection is simpler, but short circuits and hazardous conditions occur
Solution Approach 1:
A leakage detection sensor is introduced as an intermediary element positioned at the bottom of the housing to detect coolant leakage before it can contact high-voltage components. The sensor acts as an early warning system, enabling detection without allowing harmful contact.
Solution Approach 2:
The system takes preliminary action by detecting coolant leakage at the earliest stage through sensors positioned to detect leaked coolant. This preliminary detection enables the control unit to activate warning signals or shut down the cooling system before hazardous conditions can develop.
3Strength
If replacement of defective battery modules requires dismounting the entire battery system, then structural integrity is maintained, but maintenance becomes cumbersome
Solution Approach 1:
The battery system is segmented into modular battery modules that can be independently accessed and replaced. The housing structure is designed to allow individual module removal without dismounting the entire system, maintaining structural integrity while enabling convenient maintenance.
Data Source
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AI summary
The present disclosure refers to a battery system (100) a plurality of accommodation chambers (26) disposed on top each other in a housing (20) with a plurality of side portions (21, 22, 23), wherein each accommodation chamber (26) includes a plurality of battery cells (29) and a cooling plate (28). A cooling manifold (30) is provided inside the housing (20) and including a vertically extending portion (32) which vertically extends along a side portion (21, ..., 23) of the housing (20), wherein the cooling manifold (30) is connected to each of the plurality of cooling plates (28). The battery system (100) further includes a leakage protection member (40) enclosing at least a portion of the cooling manifold (30), wherein the leakage protection member (40) extends toward a bottom portion (24) of the housing (20) along the cooling manifold (30) such that coolant that is leaked from the cooling manifold (30) is drained toward the bottom portion (24) of the housing (20). Further, a detection unit (50) includes at least one leakage sensor (60) positioned at the bottom portion (24) of the housing (20) and configured to detect coolant drained toward the bottom portion (24) by the leakage protection member (40).