Cooling Plate Insulation Coating Defect Detection by Conductive Cotton
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Solution Overview
Problem
Existing insulation detection methods for battery pack cooling plates are inadequate in accurately assessing the insulation integrity of the outer surface coatings, leading to potential safety risks due to defects that may not be reliably detected.
Innovation Solution
An insulation detection device and method utilizing conductive cotton and conductive elements connected to an insulation detector, which determines the dielectric strength of the insulation coating by measuring resistance between the inner wall and outer surface of the cooling plate, allowing for accurate detection of defects in the insulation coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional insulation detection methods are used, then the detection process is simple, but the measurement precision of insulation integrity is insufficient
Solution Approach 1:
Conductive cotton is introduced as an intermediary substance to wrap around the cooling plate outer surface. This mediator enables the detection device to access and detect insulation defects on the outer surface by conducting electricity through the cotton to the insulation coating, thereby improving measurement precision without requiring direct contact with the cooling plate itself
Solution Approach 2:
The detection device employs a nested structure where conductive cotton is wrapped around the cooling plate, which is then placed within a detection chamber. The first conductive element penetrates the cotton to contact the cooling plate inner surface, while the second conductive element contacts the cotton outer surface. This nested arrangement enables multi-layer detection capability
2Weight of moving object
If the insulation coating is thin to reduce weight, then the weight of the cooling plate decreases, but the reliability of insulation integrity deteriorates
Solution Approach 1:
The patent replaces traditional mechanical thickness measurement methods with electrical field-based insulation detection. By applying voltage between the first and second conductive elements and measuring leakage current or resistance, the system can detect insulation defects regardless of the coating thickness, enabling reliable detection on thin coatings without compromising weight reduction
Solution Approach 2:
Conductive cotton serves as an intermediary that distributes the electrical field uniformly across the cooling plate outer surface. This mediation enables the detection system to sense even minor insulation defects in thin coatings by conducting electricity through the cotton to the coating interface, thereby maintaining reliability with reduced coating thickness
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 precise detection of insulation defects by forming an electrical path when a defect is present, ensuring the insulation coating's integrity is accurately assessed, thereby ensuring the safety and efficiency of the battery pack's cooling system.
Implementation Method 1
determining a dielectric strength of the insulation coating of the cooling plate of the battery pack based on a measured value obtained by the insulation detector
Implementation Method 2
The first conductive element is connected to an inner wall of the cooling plate of the battery pack. The second conductive element is connected to the conductive cotton
Implementation Method 3
The excess heat generated by the operation of the battery is transferred by contact with a surface of a cooling plate of the battery pack
Implementation Method 4
Due to flowing liquid having a large heat transfer coefficient, a liquid cooling system may transfer high heat based on the flow of the liquid
Data Source
AI summary
An insulation detection device and an insulation detection method for a cooling plate of a battery pack are provided. The device includes a detection position for placing the cooling plate of the battery pack, conductive cotton, a first conductive element, a second conductive element, and an insulation detector. The cooling plate of the battery pack is hollow, and an outer surface of the cooling plate of the battery pack is coated with an insulation coating. The conductive cotton is arranged in the detection position for wrapping the cooling plate of the battery pack. The first conductive element is connected to an inner wall of the cooling plate of the battery pack. The second conductive element is connected to the conductive cotton. A first end of the insulation detector is connected to the first conductive element, and a second end of the insulation detector is connected to the second conductive element.