Multiaxial Critical Plane Strain Life Analysis for Conformal Cooled Tooling
Multiaxial critical plane strain-life analysis models out-of-phase thermal and pressure fatigue on internal conformal cooling walls to prevent die failure.
Coolant Breakthrough
Meaning
Mechanical failure event where thermal management fluid penetrates the internal volume of a battery pack or module. A coolant breakthrough occurs when seals, gaskets or heat exchanger plates lose integrity and allow glycol or water-based mixtures to contact high-voltage components. This breach creates a path for electrical shorts and potential thermal runaway.
Detection Mechanism
Detection of fluid leaks relies on pressure drop sensors or moisture indicators installed within the enclosure. When a coolant breakthrough is identified, the battery management system usually triggers an isolation fault to disconnect the pack from the vehicle powertrain.
Material Degradation
Degradation of internal insulation happens rapidly when conductive fluids bridge the gap between cell terminals. While modern plates use aluminum alloys or stainless steel, a coolant breakthrough is often the result of galvanic corrosion or vibration fatigue in the cooling manifold. Physical inspection of the damaged area reveals mineral deposits or chemical residue that indicates the precise location of the seal failure.
The ingress of fluid can also cause localized swelling in prismatic cell pouches as the chemistry reacts with the external moisture.
System Consequence
Consequence of a leak involves the total loss of the module or pack due to electrochemical contamination. Replacing a pack after a coolant breakthrough is a standard requirement because the residual moisture cannot be fully removed from porous insulation materials.