Removable Battery Cooling Manifold With Serviceable Integrated Seals
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Solution Overview
Problem
Existing cooling systems for battery modules in electric vehicles are not serviceable, limiting the ability to perform in-line rework or maintenance.
Innovation Solution
A removable cooling system manifold with integrated seals is designed to supply and remove coolant from temperature regulating components in battery modules, allowing for easy attachment and detachment with removable fasteners and alignment pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If seals are integrated into ribbons or cooling plates, then cooling effectiveness is improved, but serviceability deteriorates
Solution Approach 1:
The manifold is divided into separate sections (first portion and second portion) that can be detached from each other. The seal is integrated into one portion but can be replaced by detaching the manifold sections, allowing serviceability while maintaining cooling effectiveness. This segmentation enables the seal to remain integrated with a component structure while still being replaceable through manifold disassembly.
2Reliability
If cooling system components are permanently attached, then thermal management effectiveness is improved, but maintenance complexity increases
Solution Approach 1:
The manifold attachment system transitions from a permanent fixed state to a dynamic state where the manifold can be attached and detached. The first and second portions can be separated and reattached, providing the benefits of secure attachment during operation while enabling maintenance when needed. This dynamic capability reduces maintenance complexity without compromising thermal management effectiveness during normal operation.
3Reliability
If seals are integrated into cooling components, then sealing reliability is improved, but in-line rework capability deteriorates
Solution Approach 1:
The manifold is segmented into detachable portions, allowing the seal to remain integrated with one portion while enabling replacement by separating the manifold sections. This segmentation provides both sealing reliability (through integrated seals) and in-line rework capability (through detachable sections that allow access and replacement during maintenance operations).
Solution Approach 2:
The seal is extracted from the overall assembly context and integrated specifically into the manifold structure rather than being a separate component. This allows the seal to be taken out with the manifold portion during replacement, maintaining sealing reliability while enabling easy rework. The seal remains integrated during operation but can be extracted/replaced by removing the entire manifold portion.
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
The solution enables efficient coolant management and allows for serviceability of the cooling system, reducing maintenance complexities and extending the lifespan of battery modules.
Implementation Method 1
heat transfer fluid is circulated to and from temperature regulating components... heat transfer fluid flow for a cooled battery module
Data Source
AI summary
A cooling system manifold for a battery module having at least one battery cell and at least one temperature regulating component having a flow path with a feed port and return port to receive and discharge coolant. The cooling system manifold being removably attachable to the battery module for supplying and/or removing coolant to the temperature regulating component and being separately formed with first and second portions that are joined together and form internal coolant flow channels. The first portion having an access feature for removing coolant from or directing coolant into the coolant flow channel and a second portion having engagement openings that provide coolant flow paths between the coolant flow channel and the temperature regulating component. The manifold having integrated seals that seal against the engagement openings and temperature regulating component, counter bores that inhibit removal, and back stops that limit movement of the seals.