Modular Bulkhead Fitting for Serviceable Battery Pack Coolant Lines
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Solution Overview
Problem
Existing vehicle systems require disassembly of the battery pack to replace or service coolant line fittings, which is invasive and time-consuming, especially when dealing with components of varying thicknesses.
Innovation Solution
A modular bulkhead fitting assembly with an internal fitting coupled to a coolant line within the battery pack and an external fitting coupled to a coolant line outside the pack, featuring retention tabs and compression gaskets for secure sealing and easy replacement without disassembling the pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the battery pack is disassembled to replace or service coolant line fittings, then the fittings can be accessed and replaced, but the maintenance process becomes invasive and time-consuming
Solution Approach 1:
The bulkhead fitting is divided into two separate fittings: a first fitting that is permanently coupled to the battery pack and a second fitting that is removably coupled. This segmentation allows the second fitting to be accessed and replaced independently without disassembling the battery pack, thereby reducing maintenance time while ensuring proper access to the coolant line connection point.
Solution Approach 2:
The serviceable portion of the fitting (second fitting) is extracted as a separate, removable component from the battery pack assembly. This extracted component can be serviced independently by simply removing it from the first fitting, eliminating the need to disassemble the entire battery pack and significantly reducing maintenance time.
2Strength
If a fixed coupling method is used for the fitting, then the fitting is securely attached, but it cannot accommodate battery packs of varying thicknesses
Solution Approach 1:
The first fitting incorporates an adjustable retention tab with a movable retention member that can be positioned at different locations along the tab. This dynamic adjustment mechanism allows the fitting to accommodate battery packs of varying thicknesses while maintaining secure attachment through the retention member's engagement with the battery pack surface at the appropriate position.
Solution Approach 2:
The retention tab is designed with adjustable parameters, specifically the position of the retention member along the tab length. By changing the position parameter of the retention member, the fitting can adapt to different battery pack thicknesses while maintaining secure attachment through consistent retention force at the optimized position for each thickness variation.
Data Source
AI summary
The present disclosure relates to a system. The system can include a first fitting that can couple with a portion of a first fluid line. The first fluid line can be at least partially internal to a battery pack. The system can include a second fitting that can couple with a portion of a second fluid line. The second fluid line can be at least partially external to the battery pack. The first fitting can include a tab that can couple the first fitting with a portion of the battery pack. The first fitting can couple with the second fitting to fluidly couple the first fluid line with the second fluid line.