Soluble Plug Drain Plug for Battery Pack Coolant Leak Detection
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Solution Overview
Problem
In high voltage battery packs, especially in electric vehicles, coolant leakage can lead to short circuits due to unintended electrical paths, and there is a need for early detection and automated corrective action to prevent damage to the battery system.
Innovation Solution
A drain plug system with a soluble plug and strain gauge that dissolves upon coolant contact, allowing coolant drainage and triggering a circuit to notify on-board computer systems of a leak, thereby preventing damage to the battery pack and associated electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a soluble plug is used in the drain plug system, then automated detection and drainage of coolant leaks is enabled, but the device complexity increases due to the addition of strain gauge and detection circuitry
Solution Approach 1:
The soluble plug automatically dissolves upon contact with coolant, triggering the strain gauge to detect the change and activate the drainage system without requiring external monitoring or control systems. The system serves itself by using the coolant's own presence as the activation mechanism.
Solution Approach 2:
The patent replaces complex mechanical leak detection systems with a chemical dissolution mechanism. The soluble plug uses chemical interaction with coolant to trigger mechanical deformation of the carrier, which is detected by the strain gauge, converting a chemical process into a detectable mechanical signal.
2Speed
If the soluble plug dissolves quickly upon coolant contact, then rapid drainage and protection is achieved, but the detection time window is reduced making early detection more difficult
Solution Approach 1:
The strain gauge is pre-installed and calibrated on the carrier structure, ready to detect even minor deformations as the soluble plug begins to dissolve. This preliminary preparation ensures that the detection process captures the entire dissolution timeline, providing both early warning and rapid response capability.
Solution Approach 2:
The strain gauge provides continuous feedback on the dissolution progress of the soluble plug, allowing the system to monitor the rate of dissolution and adjust or maintain drainage flow accordingly. This feedback mechanism ensures optimal drainage speed while maintaining detection accuracy throughout the process.
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
Enables early detection and automatic drainage of coolant leaks, preventing short circuits and protecting the battery pack and electronics from damage in the event of a crash or containment malfunction.
Implementation Method 1
a soluble plug disposed within the cavity of the carrier, the soluble plug configured to at least partially dissolve when fluidly coupled with a coolant
Implementation Method 2
a strain gauge disposed within the cavity of the carrier such that a resistance change in the strain gauge corresponds to the dissolving soluble plug
Data Source
AI summary
A battery pack with a drain plug and a circuit to detect when a liquid coolant has entered the battery pack. A soluble plug may be disposed within the cavity of the carrier; the soluble plug is configured to at least partially dissolve when fluidly coupled with a coolant allowing a portion of the coolant to flow between the inlet and the outlet and out of the battery pack. A strain gauge cooperative with the carrier such that a measured resistance change in the strain gauge corresponds to the soluble plug in contact with the liquid coolant. An associated circuit with the drain plug provides notification of the activation of the drain plug to the on-board computer systems.