Battery Coolant Grounding Connector for Reliable Thermal Management
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Solution Overview
Problem
Existing thermal management systems for electric vehicles face challenges in reliable grounding, particularly when batteries lack a negative contactor, leading to unintended electrical discharges, and non-conductive coatings on coolant ports hinder reliable ground connections.
Innovation Solution
A thermal management system is grounded through a liquid coolant using a connector with a conductor that extends out of the channel to make electrical contact with the vehicle's chassis, featuring components like spikes or roughened surfaces to clear non-conductive coatings, allowing a single point grounding of the thermal system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple grounding points are implemented for the thermal system to ensure reliable grounding, then grounding reliability is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The connector performs multiple functions simultaneously: it provides thermal management fluid passage, establishes electrical grounding, and ensures corrosion protection. By integrating these functions into a single component, the system achieves reliable grounding without requiring separate grounding elements.
Solution Approach 2:
The electrical grounding function is merged with the thermal management connector. The conductive element within the connector housing combines the fluid connection and electrical ground connection into a single integrated component, eliminating the need for separate grounding points.
2Reliability
If additional grounding components and steps are added to ground the thermal system, then grounding reliability is improved, but manufacturing complexity and assembly time increase
Solution Approach 1:
The electrical grounding function is merged with the thermal management connector. The conductive element within the connector housing combines the fluid connection and electrical ground connection into a single integrated component, eliminating the need for separate grounding points.
Solution Approach 2:
The connector automatically establishes the ground connection through its inherent conductive element when installed. The design self-grounds the thermal system without requiring additional grounding steps or components, simplifying both manufacturing and assembly.
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 reduces manufacturing complexity and costs by enabling reliable grounding of the thermal system, minimizing the risk of electrical discharges and corrosion, while simplifying assembly processes.
Implementation Method 1
A conductor can be disposed within a channel of an apparatus of the thermal management system to make electrical contact with the liquid. The conductor can extend out of the channel to ground the liquid.
Implementation Method 2
The connector can include at least one component, feature, spike, nail, or roughened surface that clears a non-conductive coating (such as an electro-coat) from a surface of a second apparatus, receiver, or component that the apparatus connects to.
Data Source
AI summary
Grounding a component, such as a thermal management system, of a battery pack via a coolant is provided. An apparatus can include a body forming a channel to convey coolant within a battery pack. The apparatus can include a conductor electrically coupled to a ground. The conductor can include a lead into the channel to ground the coolant.