Coolant Distribution Interface with Testing Channel for Battery Modules
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Solution Overview
Problem
Existing coolant distribution interfaces in battery systems have a high number of sealing points, making proactive leak detection challenging and increasing the risk of leakage, as liquid cooling media can conduct electricity and react with battery cell compounds.
Innovation Solution
A coolant distribution interface with a dual sealing system, including an inner sealing element and a supporting sealing element, and a testing channel that allows for external detection of coolant leaks, enabling proactive leak detection and reducing the number of required sealing points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple sealing points are used in the coolant distribution interface, then the sealing reliability is improved, but the complexity of the system increases and leak detection becomes more difficult
Solution Approach 1:
The patent combines multiple sealing functions into a single integrated sealing structure. The sealing element is designed to simultaneously seal multiple coolant channels and mounting portions, reducing the number of separate sealing points while maintaining comprehensive sealing coverage. This merging approach simplifies the overall interface design while preserving reliability.
Solution Approach 2:
The sealing element is designed with multi-functional capabilities, serving as both a sealing component and a structural element that supports multiple coolant channels. This universal design allows a single component to perform multiple sealing functions across different mounting portions, reducing system complexity while maintaining reliable sealing.
2Reliability
If multiple sealing points are used in the coolant distribution interface, then the sealing coverage is improved, but the difficulty of detecting leaks increases
Solution Approach 1:
The patent introduces a testing channel as an intermediary element that provides direct access to the sealed interior space. This testing channel serves as a mediator between the sealed coolant channels and the external environment, enabling easy leak detection through pressure testing or visual inspection without needing to access multiple sealing points.
Solution Approach 2:
The testing channel extracts the leak detection function from the complex multi-sealing-point system. By providing a dedicated access path to the sealed interior, the testing channel separates the detection function from the sealing structure itself, making leak detection straightforward while maintaining comprehensive sealing coverage.
3Ease of operation
If a testing channel is added to enable leak detection, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The testing channel is integrated into the existing mounting portion structure, serving multiple functions: it provides leak detection access, structural support, and coolant distribution. This multi-functional integration allows the testing channel to improve ease of operation without proportionally increasing device complexity, as it combines several functions in a single structural element.
Data Source
AI summary
A coolant distribution interface for a battery system includes a battery module housing comprising a coolant channel, and at least one mounting portion located at an entrance of the coolant channel, wherein the mounting portion comprises a first sealing section and a second sealing section; a matching housing comprising a matching coolant channel, and at least one matching mounting portion located at an entrance of the matching coolant channel, wherein the matching mounting portion comprises a first matching sealing section and a second matching sealing section; a joint coolant channel configured to connect the coolant channel of the mounting portion and the matching coolant channel of the matching mounting portion; a shared sealing element locating between the second sealing section and the second matching sealing section; a channel sealing element sealing the first sealing section and first matching sealing section against the joint coolant channel; a security chamber configured to form by the mounting portion, the matching mounting portion, the shared sealing element and channel sealing element; and a testing channel connecting the security chamber with an outside of the battery module housing and the matching housing, wherein the test channel is penetrated at least one of the battery module housing and the matching housing.