Cooling Plate Port Cover for Clean Coolant Tube Assembly
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Solution Overview
Problem
Existing coolant systems for batteries require complex assembly processes that expose the cooling plate's internal channels to dust and contaminants, which can lead to contamination and inefficiencies.
Innovation Solution
A method and system where a cover is used to seal the cooling plate's ports during assembly, allowing the coolant tube to pierce and connect without removing the cover, using a water-soluble material that dissolves in coolant fluid, ensuring contamination prevention and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the cover is removed before connecting the coolant tube, then the connection process is simpler, but dust or contaminants may enter the internal channel of the cooling plate
Solution Approach 1:
The cover is pre-installed on the cooling plate port before assembly, providing preliminary protection against contamination. The cover remains in place during transport and assembly, and only the necessary portion is removed during connection, maintaining protection until the moment of need.
Solution Approach 2:
The cover is designed to be selectively removed only at the connection point where the coolant tube needs to access the internal channel. This extraction of the protective cover only where and when needed allows both protection during assembly and connection capability when required.
2Ease of operation
If the cover is made removable to allow coolant tube connection, then connection is enabled, but assembly complexity increases
Solution Approach 1:
The cover is segmented into a removable portion and a remaining portion. The removable portion is pierced by the coolant tube to enable connection, while the remaining portion stays attached to provide ongoing protection. This segmentation allows connection capability without requiring complete removal or complex assembly steps.
3Object-affected harmful factors
If the cover completely seals the port, then contamination prevention is maximized, but coolant flow access is blocked
Solution Approach 1:
The cover provides complete sealing during transport and assembly as a preliminary protective measure. The opening for coolant flow is created only when needed during connection, allowing maximum protection during vulnerable phases and full flow capability when operational.
Solution Approach 2:
The necessary opening for coolant flow is extracted from the sealed cover at the moment of connection. The coolant tube pierces the cover to create the required aperture, maintaining sealing during transport while enabling flow during operation.
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 effectively prevents contamination of the cooling plate's internal channels while simplifying the assembly process, maintaining system integrity and efficiency.
Implementation Method 1
using a water-soluble material that dissolves in coolant fluid
Data Source
AI summary
A vehicle, a coolant system for a vehicle, and a method for assembling a coolant system are provided. A method includes providing a cooling plate formed with an external surface surrounding a port, and with an internal channel in communication with the port, wherein a plate engagement surface defines the internal channel adjacent to the port; sealing the port of the cooling plate with a cover; piercing the cover with a distal end of a coolant tube; inserting the distal end into the port to engage a tube engagement surface of the coolant tube with the plate engagement surface; and pushing a removed portion of the cover into the port, while a remaining portion of the cover remains around the port.