EV Battery Coupling Integrating Inlet and Outlet
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Solution Overview
Problem
Current fluid connectors for electric vehicle battery packs are complex to assemble and require significant packaging space due to tight packaging near the cold plate, making it difficult to securely connect fluid supply and cold plate components.
Innovation Solution
A coupling system with an attachment member, fluid inlet, and fluid outlet that provides separate and distinct paths for fluid communication, allowing for secure attachment to the cold plate using a fastener and reducing the need for complex assembly steps, with the inlet and outlet being brazed to a common surface and extending from walls that interface with the cold plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current fluid connectors are used to connect the cold plate, then fluid communication is achieved, but the assembly becomes complex and requires significant packaging space
Solution Approach 1:
The patent combines the fluid inlet and fluid outlet into a single integrated attachment member that directly connects to the cold plate. This merging of functions eliminates the need for separate connectors and reduces assembly steps, directly resolving the contradiction between achieving reliable fluid communication and reducing assembly complexity
Solution Approach 2:
The attachment member serves multiple functions simultaneously: it provides structural support, creates fluid communication paths through integrated inlet and outlet ports, and serves as a mounting surface for the cold plate. This multi-functionality reduces the number of components needed and simplifies the overall assembly
2Reliability
If current fluid connectors are used to connect the cold plate, then fluid communication is achieved, but packaging space requirements increase
Solution Approach 1:
By merging the fluid inlet and outlet into a single attachment member with integrated ports, the patent significantly reduces the volume required for fluid connection components. This eliminates the need for separate connector bodies, reducing packaging space while maintaining reliable fluid communication
Solution Approach 2:
The attachment member utilizes the vertical dimension by extending fluid ports through the thickness of the component rather than requiring lateral extension. This dimensional approach allows compact packaging while maintaining adequate fluid flow paths
3Volume of moving object
If tight packaging is used near the cold plate, then packaging space is reduced, but assembling fluid connectors becomes complicated and difficult
Solution Approach 1:
The patent segments the fluid connection function into a modular attachment member that can be independently manufactured and then easily attached to the cold plate. This segmentation allows for simplified assembly in tight packaging spaces while maintaining compact overall dimensions
Solution Approach 2:
The attachment member is pre-configured with integrated fluid ports and mounting features during manufacturing, eliminating the need for complex field assembly. This preliminary preparation of the component allows for simple installation even in constrained packaging environments
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 coupling system simplifies assembly, reduces packaging space requirements, and enhances durability by providing a secure and efficient fluid communication path between the cold plate and the battery pack, while maintaining ease of service and meeting coolant fill pressure demands.
Implementation Method 1
the fluid inlet and the fluid outlet are brazed to the common surface
Data Source
AI summary
An example coupling for an electric vehicle battery pack includes an attachment member configured to connect to a cold plate, a fluid inlet extending from the attachment member, and a fluid outlet extending from the attachment member.