Battery Pack Cooling Plate Insulation at Weld Joint Burrs
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Solution Overview
Problem
Existing battery packs face challenges in effectively insulating and protecting battery modules due to weld joint burrs that can pierce insulating films, leading to short circuits, and conventional methods fail to provide adequate insulation and heat exchange efficiency.
Innovation Solution
A battery pack design featuring a liquid cooling plate connected to a beam body via friction stir welding, with an insulating layer covering the weld joint to prevent short circuits and enhance heat exchange, using dimensions and materials that balance insulation and heat transfer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect the liquid cooling plate to the beam body, then the connection strength is improved, but weld joint burrs are generated that can pierce insulating films and cause short circuits
Solution Approach 1:
An insulating layer is introduced as an intermediary component between the liquid cooling plate and the battery cell. This insulating layer specifically covers the weld joint area, preventing burrs from piercing the insulating film while maintaining the electrical connection functionality. The insulating layer acts as a mediator that resolves the conflict between strong welding connection and prevention of short circuits.
Solution Approach 2:
The insulating layer is selectively applied only at the weld joint position rather than covering the entire liquid cooling plate. This localized insulation approach maintains heat exchange efficiency in non-weld areas while providing targeted protection against burr-induced short circuits at the welding position, thus resolving the contradiction between connection strength and short circuit prevention.
2Reliability
If an insulating layer is added to cover the weld joint, then short circuit prevention is improved, but the heat exchange efficiency may be reduced
Solution Approach 1:
The insulating layer is selectively positioned only at the weld joint area where burrs are generated, rather than covering the entire heat exchange surface. This localized insulation strategy provides necessary electrical isolation to prevent short circuits while minimizing the impact on overall heat exchange efficiency, as the majority of the liquid cooling plate surface remains exposed for thermal contact with the battery cell.
3Productivity
If friction stir welding is used instead of conventional welding, then production efficiency and sealing performance are improved, but the process complexity increases
Solution Approach 1:
Friction stir welding replaces conventional arc welding or resistance welding methods with a mechanically-driven friction-based welding process. This substitution eliminates the need for complex welding power supplies, electrode systems, or filler materials, while achieving superior sealing performance and production efficiency through a simpler, more direct mechanical welding mechanism.
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
The design provides secure insulation and high heat exchange efficiency while maintaining low costs and production efficiency, improving space utilization and energy density by preventing short circuits and optimizing heat dissipation.
Implementation Method 1
several battery cells, disposed within the accommodating sub-chamber and connected to the insulating layer and the liquid cooling plate to perform heat exchange with the liquid cooling plate
Implementation Method 2
the welding is friction stir welding
Data Source
AI summary
A battery pack includes: a box with an accommodating space inside; a beam body, disposed in the accommodating space to divide the accommodating space into several accommodating sub-chambers; a liquid cooling plate, attached to one side of the beam body facing the accommodating sub-chamber, where the liquid cooling plate is connected to the beam body through welding, and a weld joint is formed at a welding position; an insulating layer, attached to one side of the liquid cooling plate facing the accommodating sub-chamber and covering at least the weld joint; and several battery cells, disposed within the accommodating sub-chamber and connected to the insulating layer and the liquid cooling plate to perform heat exchange with the liquid cooling plate.