Battery Module Self-Sealing Connectors for Hot-Swap Cooling
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Solution Overview
Problem
The existing battery modules for vehicles, particularly aircraft, are complex and time-consuming to exchange due to the need to drain the thermal management system before installation or removal, posing safety and efficiency challenges.
Innovation Solution
The integration of self-sealing, dripless connectors for fluid inlet and outlet connections within the battery module housing allows for hot-swapping without draining the system, combined with a lightweight, structurally stable housing design and a thermal management system that can shut off fluid flow in case of thermal runaway.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional connectors are used for thermal management system connections, then the system can be connected, but the battery module exchange process becomes complicated and time-consuming requiring system drainage
Solution Approach 1:
The connector incorporates a self-sealing valve that automatically closes when the connector is disconnected, eliminating the need for manual system drainage. The valve seals itself upon disconnection, allowing rapid battery module exchange without complicated drainage procedures.
Solution Approach 2:
The self-sealing valve is pre-configured in the connector to be ready for immediate sealing action. When disconnection occurs, the valve automatically seals the fluid path before any significant fluid loss can occur, enabling hot-swap capability without preliminary system drainage.
2Productivity
If self-sealing connectors are used to enable hot-swap, then battery module exchange is simplified, but there is risk of heat transfer fluid leakage
Solution Approach 1:
The self-sealing valve automatically detects and responds to disconnection, sealing the fluid path without external intervention. This self-activating mechanism prevents fluid leakage by closing the valve immediately when the connector is removed, enabling hot-swap operation.
Solution Approach 2:
The valve is designed with a pre-positioned sealing element that is ready to close the fluid path. This preliminary preparation ensures that when disconnection occurs, the sealing action happens immediately, cushioning against any potential fluid loss before it can occur.
3Ease of manufacture
If fluid inlet and outlet connectors are oriented in parallel, then push-to-connect installation is simplified, but the connector design becomes more complex
Solution Approach 1:
The parallel orientation of fluid inlet and outlet connectors allows both connections to be made simultaneously in a single installation motion. By merging the connection actions into one push-to-connect operation, the installation process is simplified despite the complex parallel connector arrangement.
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
Enables simplified and safe exchange of battery modules by eliminating the need to drain the thermal management system, enhancing modularity and maintenance efficiency while ensuring safety through controlled pressure release and fluid management.
Implementation Method 1
a self-sealing connector incorporates a valve that automatically closes when the connector is disconnected from the corresponding counter-connector
Implementation Method 2
an internal channel system for a heat transfer fluid disposed in the housing
Implementation Method 3
Thermal management is an important issue in this field as the performance of rechargeable batteries is very sensitive to temperature
Data Source
AI summary
A battery module for a vehicle, in particular for an aircraft, comprises a housing, a cell stack accommodated in the housing, an internal channel system for heat transfer fluid disposed in the housing, a fluid inlet connector and a fluid outlet connector connected to the internal channel system and adapted to being connected to an external thermal management system, wherein the fluid inlet connector and the fluid outlet connector are self-sealing connectors molded into the housing, preferably self-sealing and dripless connectors.