Battery Pack Wiring Layout to Isolate Coolant Leak Risks
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Solution Overview
Problem
Conventional battery packs face safety issues due to potential short circuits from coolant leakage and external impacts, which can lead to explosions or ignitions, particularly in high-temperature conditions and when multiple battery cells are stacked closely.
Innovation Solution
The battery pack design includes HV and LV lines positioned above the coolant pipe, with a pack coolant pipe housing and housing cover, and a simplified arrangement of battery modules to minimize exposure to coolant leaks and external shocks, enhancing insulation and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple battery cells are stacked closely to improve capacity and output, then productivity increases, but the risk of short circuits from coolant leakage increases
Solution Approach 1:
The patent applies dimensional separation by positioning HV and LV lines in different vertical layers (above vs. below coolant pipes) to prevent harmful interactions while maintaining high battery cell density for improved capacity and output
2Volume of moving object
If battery modules are arranged in a compact configuration to improve space utilization, then volume efficiency increases, but vulnerability to external impacts increases
Solution Approach 1:
The patent segments the battery pack into modular units with standardized stacking arrangements, where each module maintains compact dimensions for space efficiency while the modular structure provides inherent protection against external impacts
Solution Approach 2:
The patent uses vertical layering to position critical components (HV/LV lines) above coolant pipes, creating dimensional separation that reduces vulnerability to external impacts while maintaining compact overall packaging
3Temperature
If coolant pipes are positioned to optimize cooling performance, then temperature control improves, but exposure to external impacts increases
Solution Approach 1:
The patent positions coolant pipes in the lower vertical layer while placing HV/LV lines above them, optimizing cooling contact with battery cells while protecting the coolant system from external impacts that typically occur at higher levels
4Reliability
If HV and LV lines are routed through the battery module to improve electrical connection, then electrical conductivity improves, but risk of coolant contact increases
Solution Approach 1:
The patent routes HV and LV lines through the upper vertical layer above coolant pipes, maintaining optimal electrical connections to battery terminals while eliminating the risk of coolant contact through spatial separation
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 configuration reduces the risk of short circuits and improves safety by stabilizing the HV and LV lines, preventing coolant contact and enhancing cooling performance.
Implementation Method 1
the battery cells inside the battery module 1 generate electrical energy and dissipate heat, and the coolant pipe 2 supplies a coolant to the periphery of the battery module 1, so that cooling can be performed
Data Source
AI summary
A battery pack includes a plurality of battery modules including a battery cell stack in which a plurality of battery cells are stacked, a terminal bus bar connected to the battery cell, and a sensing assembly for measuring the temperature and voltage of the battery cell; a pack frame for storing the battery module; an HV line connected to the terminal bus bar of the battery module; an LV line connected to the sensing assembly of the battery module; and a pack coolant pipe for supplying a coolant to the battery module, wherein the HV line and the LV line are located above the pack coolant pipe.