Stacked Battery Pack Grounding Structure for Cooling Plate Leakage Control
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Solution Overview
Problem
Existing battery packs with a multi-stage structure require an effective grounding structure that differs from single-layer structures, particularly for high-performance electric vehicles using water-cooled methods, to manage electrical leakage and ensure thermal conductivity.
Innovation Solution
A novel grounding structure for battery packs with a multi-stage configuration, incorporating a PDU assembly connected to cooling plates and a base plate through a grounding unit, with separate grounding portions for the uppermost and lowermost ends, and external connection to discharge leakage currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a multi-stage structure with stacked battery modules is used, then cooling efficiency is improved, but grounding complexity increases
Solution Approach 1:
The grounding system is segmented into multiple grounding units, each serving specific battery modules. The grounding plate is divided into multiple grounding portions that can be independently connected to different battery modules, allowing modular grounding configuration that matches the stacked structure while maintaining manageable complexity
Solution Approach 2:
The grounding plate serves multiple functions simultaneously: it provides electrical grounding for all battery modules, acts as a structural support base, and functions as a thermal management component by being thermally coupled to the cooling plates. This multi-functionality reduces the need for separate dedicated grounding structures
2Temperature
If cooling plates are mounted between battery modules, then thermal management is improved, but electrical leakage risk increases
Solution Approach 1:
The grounding plate acts as an intermediary between the cooling plates and the battery modules. It provides a dedicated electrical grounding path that is separate from the thermal conduction path, allowing the cooling plates to perform both thermal management and electrical grounding functions without direct electrical contact between cooling plates and battery modules
Solution Approach 2:
The electrical grounding function is extracted from the cooling plate system and assigned to a separate grounding plate. This separation allows the cooling plates to focus on thermal management while the grounding plate handles electrical leakage protection, reducing the risk of electrical interference with the thermal management system
3Reliability
If a novel grounding structure is developed for multi-stage configuration, then grounding effectiveness is improved, but manufacturing complexity increases
Solution Approach 1:
The grounding plate is integrated with the base structure of the battery pack, merging the grounding function with the structural support function. This integration reduces the number of separate components that need to be manufactured and assembled, simplifying the manufacturing process while maintaining effective grounding across all battery modules
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 solution provides stable electrical grounding and efficient thermal management, ensuring the safety and performance of battery packs in high-performance electric vehicles by effectively managing electrical leakage and maintaining thermal conductivity.
Implementation Method 1
a grounding unit including one side connected to the PDU assembly, and the other side connected to the cooling plate or the base plate
Implementation Method 2
cooling plates mounted between the two or more battery modules
Data Source
AI summary
A battery pack includes two or more battery modules stacked in an upward and downward direction and each thereof including a plurality of battery stacks disposed in a horizontal direction, cooling plates mounted between the two or more battery modules, a base plate mounted below the two or more battery modules and the cooling plates, a power distribution unit (PDU) assembly electrically connected to the battery module, an upper cover member defining a space for accommodating the battery module and the cooling plate, and a grounding unit including one side connected to the PDU assembly, and the other side connected to the cooling plate or the base plate.