Plane-Plane Cooling Circuit Sealing for Vehicle Assemblies
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Solution Overview
Problem
Existing fluid cooling circuit connections for electrical systems in vehicles, such as those between an inverter and an electric motor, face issues with high leakage risk, increased bulk, and misalignment, which are exacerbated by the complexity and space constraints in electric motorization systems.
Innovation Solution
A fluidic connection method utilizing plane-plane contact between flat faces of two housings with recesses and a compressed seal, eliminating the need for nozzles, sleeves, or pipes, allowing for sealed fluid transfer even when inlet and outlet are misaligned, and promoting efficient fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nozzles or sleeves are inserted deeply into housings to ensure sealing, then sealing reliability improves, but the bulk of the system increases
Solution Approach 1:
The patent merges the sealing function with the plane-plane contact interface between housings. Instead of using separate nozzles or sleeves that protrude into the housing, the sealing is achieved through the direct contact of flat faces with integrated sealing elements, eliminating the need for deep insertions and reducing overall system bulk.
Solution Approach 2:
The patent extracts the sealing function from separate nozzle/sleeve components and integrates it directly into the housing structure itself. The sealing elements are built into the flat contact surfaces, removing the need for additional protruding components and thereby reducing system bulk.
2Device complexity
If inlet and outlet of cooling circuit portions are perfectly aligned, then fluid connection simplicity improves, but adaptability to misaligned configurations deteriorates
Solution Approach 1:
The patent changes the geometric parameters of the flat contact surfaces by incorporating recesses and protrusions with specific dimensions and tolerances. These parameter variations allow the interface to accommodate misalignment while maintaining simple fluid connection, enabling both perfect alignment and misaligned configurations to work effectively.
Solution Approach 2:
The patent employs asymmetric features on the flat contact surfaces, such as recesses positioned at specific locations and protrusions with directional orientations. This asymmetry allows the interface to naturally accommodate misalignment in specific directions while maintaining sealing and fluid connection, enhancing adaptability without increasing complexity.
3Reliability
If plane-plane contact with recesses and compressed seal is used, then sealing performance improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent incorporates compliant sealing elements and recesses that provide cushioning before the final contact between flat faces. These features compensate for minor manufacturing variations and ensure consistent sealing performance even when flatness precision is not extremely tight, reducing the stringency of manufacturing precision requirements.
Solution Approach 2:
The patent uses flexible seal elements (such as O-rings or elastomeric seals) that can deform to accommodate minor variations in flat face contact. This flexibility compensates for manufacturing tolerances and ensures reliable sealing without requiring extremely precise flatness, thereby reducing manufacturing precision requirements.
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
This solution provides a sealed, low-bulk fluidic connection between cooling circuit portions, reducing the risk of leakage and bulk while ensuring efficient fluid transfer, even in misaligned configurations, thus enhancing the cooling efficiency and reliability of electrical systems in vehicles.
Implementation Method 1
a seal surrounding said area in which the fluidic connection is made, said seal being compressed between said two housings
Implementation Method 2
By means of heat exchanges between the hot components and the cooler water, the purpose is to cool said hot components
Data Source
AI summary
The invention relates to an assembly of two housings, a first housing comprising a first cooling circuit portion and a second housing comprising a second cooling circuit portion, said of this cooling circuit portions being configured to form a cooling circuit with a fluid, each housing comprising a flat face comprising an opening of a respective cooling circuit portion and defining an interface of said cooling circuit, said cooling circuit portions being configured to be fluidically connected by plane-plane contact between said flat faces, said openings being arranged substantially opposite each other.