Cooling Plate Insulation Testing With Leak-Resistant Liquid Metal
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Solution Overview
Problem
Existing insulation detection methods for battery pack cooling plates face risks of conductive material leakage and poor contact, leading to safety hazards and detection inaccuracies due to high voltages applied during insulation tests.
Innovation Solution
Utilizing liquid metal with controlled viscosity as a conductive material for insulation detection, ensuring complete contact with the cooling plate's surface and minimizing leakage risks through a fixing apparatus and sealing mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If liquid conductive material is used for insulation detection, then detection accuracy is improved, but leakage risk increases causing safety hazards
Solution Approach 1:
The patent changes the physical parameter of the conductive material from low-viscosity liquid to high-viscosity paste, fundamentally altering its flow characteristics. This parameter change enables the material to maintain good electrical conductivity for detection while significantly reducing leakage risk, thus resolving the contradiction between detection accuracy and safety
Solution Approach 2:
The patent uses a composite paste material that combines conductive properties with high viscosity characteristics. This composite material achieves both the electrical conductivity needed for accurate insulation detection and the physical stability required to prevent leakage, simultaneously satisfying both requirements
2Reliability
If conventional liquid conductive material is used, then electrical conductivity is improved, but contact completeness with cooling plate surface deteriorates
Solution Approach 1:
By changing the viscosity parameter from low to high, the paste material gains improved adhesion and staying power on the cooling plate surface. This allows the conductive material to maintain complete contact with the surface being tested, ensuring reliable electrical connection and accurate detection
3Measurement precision
If high voltage is applied during insulation test, then detection capability is improved, but safety risk increases
Solution Approach 1:
The patent applies beforehand cushioning by using high-viscosity paste material that prevents leakage before the testing process begins. This pre-preventive measure ensures that even when high voltage is applied for detection, the conductive material remains contained and cannot leak, thus maintaining both detection capability and safety
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
Enhances safety and accuracy of insulation detection by preventing leakage and ensuring thorough contact, thereby reducing detection errors and maintaining the integrity of the insulation coating assessment.
Implementation Method 1
The insulation detector is configured to measure a resistance between an inner wall of the cooling plate of the battery pack and the liquid metal
Implementation Method 2
liquid metal with viscosity may be used as conductive material
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 liquid tank, a fixing apparatus, and an insulation detector. The liquid tank is configured to hold a liquid metal. The liquid tank includes a liquid injection port and a liquid outlet. The fixing apparatus is configured to fix the cooling plate of the battery pack in the liquid tank, where the cooling plate of the battery pack is hollow, an outer surface of the cooling plate of the battery pack is coated with an insulation coating, and the outer surface of the cooling plate of the battery pack is immersed in liquid metal. The insulation detector is configured to measure a resistance between an inner wall of the cooling plate of the battery pack and the liquid metal.