Encapsulated Coolant Interconnector for Battery Pack Leakage
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Solution Overview
Problem
Existing battery pack designs face mechanical stability and coolant leakage issues, particularly in multi-level stacks, which can lead to heat dissipation inefficiencies and damage to battery modules and surrounding structures.
Innovation Solution
A battery pack design featuring a first and second battery module level with a heat exchange member, coolant distributor lines, and a coolant interconnector enclosed by an encapsulation element to prevent coolant leakage and enhance mechanical stability, ensuring efficient heat dissipation and protection against coolant exposure to battery cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If coolant distributor lines and interconnectors are arranged outside the heat exchange member, then ease of manufacture and assembly is improved, but mechanical stability and tightness are worsened
Solution Approach 1:
The patent merges the coolant distributor line and interconnector assembly into an integrated unit that is embedded within the heat exchange member. This combining approach allows the coolant distribution function to be maintained while simultaneously improving mechanical stability, as the integrated structure becomes a unified component rather than separate external parts.
Solution Approach 2:
The coolant distributor line and interconnector are nested within the heat exchange member structure. This nesting arrangement allows the coolant distribution system to be housed inside the heat exchange member, providing both mechanical protection and structural integration, thereby improving mechanical stability while maintaining ease of manufacture through modular design.
2Ease of manufacture
If coolant distributor lines and interconnectors are arranged outside the heat exchange member, then ease of assembly is improved, but tightness and leakage prevention are worsened
Solution Approach 1:
The patent combines the coolant distributor line and interconnector into an integrated assembly that is embedded within the heat exchange member. This merging creates a unified structure with fewer connection points, thereby improving tightness and leakage prevention while maintaining ease of assembly through the integrated design.
Solution Approach 2:
The coolant distribution components are nested within the heat exchange member, creating a protected internal arrangement. This nesting reduces exposure to external mechanical stresses and environmental factors that could cause leakage, thereby improving reliability and tightness while allowing for straightforward assembly of the nested components.
3Productivity
If multiple battery modules are stacked to increase energy density, then productivity and energy density are improved, but heat dissipation efficiency is worsened
Solution Approach 1:
The patent segments the coolant distribution system into multiple levels corresponding to each battery module stack. Each level has its own coolant distributor line and interconnector arrangement, allowing independent coolant flow paths through each module. This segmentation enables efficient heat dissipation from each stacked module while maintaining high energy density through the compact vertical arrangement.
Solution Approach 2:
The patent transitions from horizontal coolant distribution to vertical multi-level distribution, adding a vertical dimension to the coolant flow paths. This dimensional change allows coolant to efficiently reach and cool multiple stacked battery modules, improving heat dissipation efficiency while maintaining the high energy density achieved through vertical stacking.
4Device complexity
If coolant interconnector connects multiple battery module levels, then device complexity is reduced, but mechanical stability and leakage risk are worsened
Solution Approach 1:
The patent merges the interconnector function into an integrated assembly with the coolant distributor line and heat exchange member. This combining reduces the number of separate components and connection points, thereby reducing device complexity while simultaneously improving mechanical stability through the unified structure.
Solution Approach 2:
The interconnector is nested within the heat exchange member structure, creating a protected internal arrangement. This nesting provides mechanical protection to the interconnector while maintaining a relatively simple overall device structure, thereby reducing device complexity while improving mechanical stability and reducing leakage risk.
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 provides improved mechanical reinforcement and liquid-tight containment of coolant, reducing the risk of leakage and enhancing heat dissipation efficiency across stacked battery module levels, thus maintaining performance and safety.
Implementation Method 1
a cooling tube (70) arranged inside the heat exchange member (110)
Implementation Method 2
supplying coolant to the cooling tube (70)
Data Source
Figure 1
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AI summary
The present invention refers to a battery pack (100) with a plurality of stacked battery module levels (20, 21), wherein coolant circuits (60, 61, 70, 71) of the stacked battery module levels (20, 21) are vertically connected via coolant interconnectors (80). The coolant interconnectors (80) are enclosed by encapsulation elements (81), wherein each encapsulation element (81) confines a volume with an outer surface of a coolant interconnector (80) and between the connected battery module levels (20, 21). Another aspect of the invention refers to an encapsulated interconnection for a battery pack (100) comprising such a coolant interconnector (80) and such an encapsulation element (81).