Pressurized Battery Pack Sealing Against Coolant and Moisture Ingress
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Solution Overview
Problem
Battery packs in vehicles face issues with coolant leakage and contamination due to compromised seals, leading to reduced performance and safety risks such as smoke or fires, which existing solutions like fire retardant foam or moisture drainage introduce inefficiencies and costs.
Innovation Solution
A battery system that controls the internal pressure of a liquid-cooled battery pack to be above ambient pressure using a compressed air supply from the vehicle's air-controlled brake system, incorporating pressure-reducing and relief valves, and a controllable outlet valve to manage air flow and prevent contaminants from entering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the battery pack is sealed to prevent coolant leakage, then coolant containment is improved, but any seal compromise allows contaminants to enter and reduce battery performance
Solution Approach 1:
The system applies preliminary anti-action by maintaining positive pressure inside the battery pack before seal failure occurs. The compressed air supply continuously pressurizes the interior, creating a pressure barrier that prevents contaminants from entering even when seals are compromised, thereby counteracting the harmful effect in advance
Solution Approach 2:
The system creates an inert environment by filling the battery pack interior with compressed air at positive pressure. This inert atmosphere acts as a protective medium that prevents external contaminants (coolant, water, dust) from penetrating into the battery pack through seal defects or damage
2Reliability
If fire retardant foam is used to prevent smoke and fires, then safety is improved, but system complexity and cost increase
Solution Approach 1:
The system converts the potentially harmful compressed air (which could cause overpressure) into a beneficial safety feature. The same compressed air that maintains positive pressure for contaminant prevention also acts as a fire suppressant by displacing oxygen and preventing combustion, thereby converting a potential hazard into a safety advantage without adding fire retardant foam
Solution Approach 2:
The compressed air supply system performs multiple functions simultaneously: it maintains positive pressure to prevent contaminant ingress, suppresses fires by oxygen displacement, and provides a clean inert atmosphere. This multi-functionality eliminates the need for separate fire suppression systems, reducing overall system complexity
3Object-affected harmful factors
If the internal pressure is increased above ambient pressure to prevent contaminant entry, then contamination protection is improved, but pressure control complexity increases
Solution Approach 1:
The system applies self-service by utilizing the vehicle's existing compressed air brake system to provide the pressurization function. The brake system's compressed air supply automatically serves dual purposes: vehicle braking and battery pack pressurization, eliminating the need for a dedicated pressurization system with its own complex control mechanisms
Solution Approach 2:
The system merges two previously separate functions into one integrated system: the vehicle's air brake system is combined with the battery pack pressurization system. By connecting the brake system's compressed air supply to the battery pack interior, the patent consolidates infrastructure, reducing overall system complexity while achieving contaminant prevention
4Reliability
If a pressure relief valve is added to control overpressure, then safety is improved, but device complexity increases
Solution Approach 1:
The system employs a simple, passive pressure relief valve that operates on a fail-safe principle. The valve is designed to be simple and inexpensive, opening automatically when pressure exceeds a predetermined threshold to release air, and closing automatically when pressure normalizes. This simple mechanical solution provides reliable overpressure protection without complex electronic controls or expensive components
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 approach enhances the battery pack's lifetime and safety by preventing coolant and moisture ingress, reducing the risk of fires and maintaining efficient operation even with compromised seals, while being cost-effective and efficient.
Implementation Method 1
the battery system is configured to control an internal pressure of the battery pack to be greater than an ambient air pressure
Implementation Method 2
the battery pack comprises a pressure relief valve configured to open responsive to the internal pressure of the battery pack being above a pressure relief threshold
Implementation Method 3
battery packs are generally provided with a thermal management system to cool the battery pack. It is common in battery system for commercial vehicles is to use a liquid coolant as a heat exchange medium
Implementation Method 4
some form of thermal management system is generally provided to cool the battery pack
Data Source
AI summary
A battery system includes a liquid-cooled battery pack and a compressed air supply connected to a high pressure inlet valve of the battery pack and connectable to an air-controlled brake system of a vehicle, wherein the battery system is configured to control an internal pressure of the battery pack to be greater than an ambient air pressure.