Slotted terminal plate

Abstract

A battery for a vehicle includes an energy storage portion. A first terminal plate physically contacts and is electrically connected to the energy storage portion via a first inward-facing surface. A second terminal plate physically contacts and is electrically connected to the energy storage portion via a second inward-facing surface. The first terminal plate includes at least one recess extending into the first terminal plate from a first outward-facing surface. The first outward-facing surface is opposite the first inward-facing surface. When alternating current passes through the first terminal plate, a skin effect at the outer surface of the first terminal plate extends from a perimeter of the first terminal plate and from each edge of the at least one recess.

Description

Technical Field

[0001] This disclosure relates to battery cells, and more specifically to slotted terminal block designs for battery cells. Background Technology

[0002] Electric vehicles and hybrid electric vehicles use batteries to store electricity generated during operation and / or electricity received from external sources through charging. The stored electricity is used to operate the onboard electronic systems. In hybrid electric vehicles, the power can also be used to supplement the power from the internal combustion engine. In pure electric vehicles, electricity is supplied to an electric drive motor, which drives the rotation of the wheels.

[0003] Some exemplary vehicle batteries consist of multiple individual battery cells connected together, with each cell connected to a positive voltage connection via one terminal and to a negative voltage connection via another terminal. Using existing terminal designs, the skin effect at the terminals can cause current to concentrate at the outer edge of the terminals.

[0004] Therefore, it is desirable to provide a battery terminal structure that allows full power to be delivered through the terminals while preventing the terminal block from deteriorating due to the skin effect. Summary of the Invention

[0005] In one exemplary embodiment, a battery for a vehicle includes an energy storage portion. A first terminal plate physically contacts and is electrically connected to the energy storage portion via a first inner surface. A second terminal plate physically contacts and is electrically connected to the energy storage portion via a second inner surface. The first terminal plate includes at least one recess extending from a first outer surface into the first terminal plate. The first outer surface is opposite to the first inner surface. When alternating current passes through the first terminal plate, a skin effect of the first terminal plate at the first outer surface extends from the periphery of the first terminal plate and from each edge of the at least one recess.

[0006] Except for one or more features described herein, the second terminal board is identical to the first terminal board.

[0007] In addition to one or more of the features described herein, at least one groove includes a straight groove extending from a first edge of the first terminal plate to a second edge of the first terminal plate.

[0008] In addition to one or more of the features described herein, the at least one groove includes a set of grooves that divide the first outward-facing surface into a set of outward-facing regions, wherein each outward-facing region has the same two-dimensional shape.

[0009] In addition to one or more of the features described herein, the at least one groove includes at least one curved groove.

[0010] In addition to one or more of the features described herein, the at least one groove includes a set of grooves that divide the first outward-facing surface into a set of outward-facing regions, wherein the set of outward-facing regions includes regions with different two-dimensional shapes.

[0011] In addition to one or more of the features described herein, at least one groove extends to at least 50% of the depth of the first terminal plate.

[0012] In addition to one or more of the features described herein, the first terminal block also includes fastener holes extending from the first surface facing outwards to the first surface facing inwards.

[0013] In addition to one or more features described herein, the battery also includes an insulator disposed in the at least one recess, wherein the insulator is electrically insulating.

[0014] In addition to one or more features described herein, the insulator is a rigid insulator and is held in the at least one groove by an interference fit.

[0015] In addition to one or more of the features described herein, a rigid insulator is a single-piece insulator.

[0016] In addition to one or more features described herein, the rigid insulator includes a plurality of different components located in the at least one recess.

[0017] In addition to one or more features described herein, the insulator is an electrically insulating coating applied to the at least one groove.

[0018] In addition to one or more of the features described herein, the insulator is a flexible insulator.

[0019] In addition to one or more features described herein, the insulator includes a wedge profile having a tapered end closest to the inner surface of the first face and a wide end closest to the outer surface of the first face.

[0020] In another exemplary embodiment, the vehicle includes an electric motor electrically connected to a battery and configured to convert electrical energy into rotational power. A controller is configured to control the electric motor and control the supply of power from the battery to the electric motor. The battery includes an energy storage portion, a first terminal plate physically contacting and electrically connected to the energy storage portion via a first inward-facing surface, and a second terminal plate physically contacting and electrically connected to the energy storage portion via a second inward-facing surface. The first terminal plate includes at least one recess extending from a first outward-facing surface into the first terminal plate, the first outward-facing surface opposite the first inward-facing surface. When alternating current passes through the first terminal plate, a skin effect of the first terminal plate at the first outward-facing surface extends from the periphery of the first terminal plate and from each edge of the at least one recess.

[0021] In addition to one or more of the features described, at least one groove includes a straight groove extending from a first edge of the first terminal plate to a second edge of the first terminal plate, and at least one groove includes a set of grooves dividing the first outward-facing surface into a set of outward-facing regions, wherein each outward-facing region has the same two-dimensional shape.

[0022] In addition to one or more of the described features, the at least one groove includes at least one curved groove, and the at least one groove includes a set of grooves that divide the first outward-facing surface into a set of outward-facing regions, wherein the set of outward-facing regions includes regions with different two-dimensional shapes.

[0023] In addition to one or more of the features described, the terminal block also includes an insulator disposed in at least one recess, wherein the insulator is electrically insulating.

[0024] In addition to one or more of the features described, the insulator is one of a rigid insulator, a flexible insulator, and an insulating coating.

[0025] The above-described features and advantages, as well as other features and advantages, of this disclosure will become apparent when taken in conjunction with the accompanying drawings and the following detailed description. Attached Figure Description

[0026] Other features, advantages, and details appear by way of example only in the following detailed description, which is described in detail with reference to the accompanying drawings, wherein:

[0027] Figure 1 It is based on a top view of an example vehicle;

[0028] Figure 2 It is an isometric view of the battery cell including the terminal block;

[0029] Figure 3A This is an example terminal block in a top view;

[0030] Figure 3B yes Figure 3A A side view of an example terminal block;

[0031] Figure 4A This is another example of a terminal block in the top view;

[0032] Figure 4B It is in the side view Figure 4A Example terminal board;

[0033] Figure 5A This is another example of a terminal block in the top view;

[0034] Figure 5B It is in the side view Figure 5A Example terminal board;

[0035] Figure 6 It is an example of an insulator;

[0036] Figure 7 This is another example of an insulator;

[0037] Figure 8 This is another example of an insulator; and

[0038] Figure 9 yes Figure 6 , Figure 7 and Figure 8 An example insulator outline diagram. Detailed Implementation

[0039] The following description is exemplary in nature only and is not intended to limit this disclosure, its application, or use. As used herein, the term module refers to processing circuitry that may include application-specific integrated circuits (ASICs), electronic circuitry, processor (shared, dedicated, or group) and memory executing one or more software or firmware programs, combinational logic circuitry, and / or other suitable components that provide the described functionality.

[0040] As used herein, the term controller refers to a system that includes at least a processor and memory, wherein the system is configured to perform or cause to perform at least one operation. The system may be a dedicated controller including a single-purpose processor and memory, a general-purpose controller including one or more modules for performing operations, a distributed system including multiple controllers communicating with each other and configured to control operations, or any similar system.

[0041] According to an exemplary embodiment, Figure 1A vehicle 10 is shown, including a battery 20 for storing electrical energy. The battery 20 includes multiple individual battery cells 22. The individual battery cells 22 are connected within the battery 20 and provide output energy to a connected drive motor 30. In some examples, the battery 20 may also provide electrical energy to one or more additional systems 32 within the vehicle 10. The drive motor 30 converts the electrical energy into rotational power, and the rotational power is used to rotate the wheels 40.

[0042] In some vehicle systems, the terminals connecting each unit to the voltage rail connected to unit 22 are AC voltage rails. As the current increases, the skin effect causes the current to concentrate at the outer edge of the terminals. The skin effect is the tendency of alternating current (AC) to distribute within a conductor such that the current density is greatest near the conductor surface and decreases exponentially with increasing conductor depth. It is caused by opposing eddy currents induced by the changing magnetic field generated by the alternating current. The current flows primarily at the skin of the conductor, between the outer surface and a level called the skin depth.

[0043] Continue to refer to Figure 1 , Figure 2 An example battery cell 200 isolated from the background of the vehicle 10 and battery 20 is shown. The battery 200 includes an energy storage section 210, a first terminal plate 220 (e.g., a positive terminal) and a second terminal plate 230 (e.g., a negative terminal). The energy storage section 210 can be any conventional energy storage configuration.

[0044] Each of the terminal plates 220 and 230 is made of a conductive material and includes fastener holes 222 and 232 through which fasteners protrude and maintain a physical connection between the terminal plates 220 and 230 and the energy storage section 210. Furthermore, the terminal plates 220 and 230 include recesses 224 and 234 that partially extend through the terminal plates and divide the terminal plates 220 and 230 into portions 226 and 236.

[0045] When the grooves 224 and 234 are linear (e.g., straight lines), the portions 226 and 236 can be designed to have the same overall shape rather than exactly the same dimensions. In such an example, the approximate ratio of the number of sides of each portion 226 and 236 to the side length of each portion 226 and 236 is the same.

[0046] In some alternative examples, grooves 224, 234 may include one or more non-linear (e.g., curved) grooves. A non-linear groove is a groove that traverses the surface of terminal blocks 220, 230 in a non-linear manner (e.g., via a curved or serpentine path). The curvature of the non-linear groove can be determined using empirical studies, simulations, and / or machine learning-based analysis. In a particular example, the curvature can be used to ensure that the surface area of ​​each portion 226, 236 is identical within tolerances.

[0047] In one example, recesses 224, 234 extend at least 50% of the depth of terminal plates 220, 230. In some implementations, it may be desirable to extend the depth to the largest possible percentage of the depth of terminal plates 220, 230 without structurally compromising terminal plates 220, 230.

[0048] By dividing terminal blocks 220 and 230 into sections, the skin effect occurs at the outer periphery of each section 226 and 236, and the skin depth (the portion of the conductor where the skin effect concentrates the current) can be configured to cover most or all of the terminal blocks 220 and 230. The skin effect covering most or all of the terminal blocks 220 and 230 reduces the heat generated when current passes through them and improves their lifespan.

[0049] In one example, terminal blocks 220 and 230 are identical and therefore can be pulled out from a uniform pool of terminal blocks 220 and 230 during the manufacturing process.

[0050] In another example, the terminal block 220 for the negative terminal and the terminal block 230 for the positive terminal may have different configurations that require different components during the assembly process.

[0051] Continue to refer to Figure 1 and Figure 2 Figures 3-5 show exemplary terminal blocks 300, 400, and 500 in top view (3A, 4A, and 5A) and side view (3B, 4B, and 5B).

[0052] Each of terminal plates 300, 400, and 500 has a thickness of 302, 402, and 502, respectively. The thickness is the length of terminal plates 300, 400, and 500 from the first surface 304, 404, and 504 to the second surface 306, 406, and 506. When installed in battery cell 200... Figure 2 When the first surfaces 304, 404, and 504 are in contact with the internal components of the battery cell (as shown in the diagram), current is allowed to pass through the terminal plates 300, 400, and 500.

[0053] Each terminal block 300, 400, 500 includes through holes 308, 408, 508. The through holes 308, 408, 508 receive fasteners (not shown) and hold the terminal blocks 300, 400, 500 in contact with the battery 200. In alternative embodiments, the through holes 308, 408, 508 can be replaced with alternative fastening configurations capable of maintaining contact between the first surfaces 304, 404, 504 and the battery 200, and / or multiple through holes can be used according to the specifications of a particular embodiment.

[0054] Each terminal block 300, 400, 500 includes one or more recesses 310, 410, 510. A recess is an etched groove extending from a second surface 306, 406, 506 toward a first surface 304, 404, 504. Each of the recesses 310, 410, 510 extends into the terminal block 300, 400, 500 to a portion of a thickness 302, 402, 502, thereby creating a terminal block 300, 400, 500 structure, wherein the first surfaces 304, 404, 504 have a single continuous surface area, and the second surfaces 306, 406, 506 (facing outwards and facilitating external electrical connections) include multiple distinct surface areas 306A-D, 406A-C, 506A-K.

[0055] When AC current passes through terminal blocks 300, 400, and 500, the skin effect causes the current to concentrate near the edges of the terminal blocks. By adding grooves 310, 410, and 510 and dividing the outer portion of terminal blocks 300, 400, and 500 into multiple surface regions 306a-c, 406A-D, and 506A-K, the skin effect can be extended to cover all or most of the terminal blocks, thereby distributing the current across the entire terminal block and minimizing heat generation (and corresponding degradation) on terminal blocks 300, 400, and 500.

[0056] In some examples, it may be desirable to provide an insulator 320 in the recesses 310, 410, 510 to prevent electrical conduction across the recesses due to sparks, contaminants entering the recesses 310, 410, 510, or any other reason. The insulator 320 may be any insulating material capable of partially insulating the terminal blocks 300, 400, 500, including a rigid insulator 320 inserted after the formation of the recess 510, a flexible insulator inserted after the formation of the recesses 310, 410, 510, and / or an insulating coating applied after the formation of the recesses 310, 410, 510.

[0057] Continue to refer to Figure 3-5, Figure 6-8Exemplary rigid insulators 320, 420, and 520 for insertion into terminal blocks 300, 400, and 500 are shown. Each of the insulators 320, 420, and 520 shown is a single piece of insulating material (e.g., plastic, rigid rubber, etc.) shaped to match corresponding recesses 310, 410, and 510. In one example, the rigid insulators 320, 420, and 520 are held in place within the recesses 310, 410, and 510 using an interference fit (alternatively referred to as a press fit or friction fit).

[0058] Rigid insulators 320, 420, and 520 have heights aligned with the depths of recesses 310, 410, and 510, wherein the heights of the rigid insulators 320, 420, and 520 are less than the depths of the recesses 310, 410, and 510. When installed in terminal blocks 300, 400, and 500, the rigid insulators 320, 420, and 520 are positioned abutting against the bases 330, 430, and 530 of the recesses 310, 410, and 510.

[0059] In some alternative examples, a single piece of insulating material can be replaced by multiple components (e.g., strips) that are individually inserted into the grooves 310, 410, 510.

[0060] In another alternative example, rigid insulators 320, 420, and 520 can be replaced by an electrically insulating coating applied to the interior of recesses 310, 410, and 510. Similar to the rigid insulators, the coating is applied to the bases 330, 430, and 530 and extends upwards along the walls of the recesses 310, 410, and 510, with a portion of the top of each recess left uncoated. The specific amount of uncoated material left depends on the specific application and can be as small as 5% of the height of the recesses 310, 410, and 510.

[0061] Continue to refer to Figure 1-8 , Figure 9 The side profile of an insulator (such as rigid insulator 320, flexible insulator, and / or coated insulator) is shown. In a basic example, the side profile may be rectangular, where the base 902 and top 904 of the insulator have the same width. In another example, the side profile is wedge-shaped, where the base 902 has a smaller width than the top 904. In yet another example, the insulator profile is U-shaped, with a base 902 extending the entire width of a recess and two outwardly extending walls 906.

[0062] Wedge profiles combined with flexible insulators can be particularly advantageous because the tapered tip allows for insulator insertion, despite its flexible nature. U-shaped profiles combined with coatings can be particularly advantageous due to their ease of fabrication. However, any profile can be used with any insulating material. In other examples, a single insulator can achieve a similar effect using any or all combinations of profiles.

[0063] Although the examples in Figures 3 through 5 are shown as straight lines dividing terminal blocks 300, 400, and 500 into approximately uniform segments, it should be understood that the specific shape of the grooves 310, 410, and 510 and the surface area of ​​the segments do not need to be uniform. Analysis of the terminal blocks can be performed using empirical evidence, machine learning, physical modeling, and / or any combination thereof. The resulting grooves can be curved, complex, straight, or any combination determined by analysis to provide the optimal skin effect.

[0064] The terms “a” and “an” do not indicate a limitation of quantity, but rather that at least one of the referenced items is present. Unless the context clearly indicates otherwise, the term “or” means “and / or”. Throughout the specification, the reference to “aspect” means that a particular element described in connection with that aspect (e.g., a feature, structure, step, or characteristic) is included in at least one aspect described herein and may or may not be present in other aspects. Furthermore, it should be understood that the described elements may be combined in any suitable manner in the aspects.

[0065] When an element, such as a layer, film, region, or substrate, is referred to as being “on” another element, it can be directly on the other element, or there may be intermediate elements present. Conversely, when an element is referred to as being “directly” on another element, there are no intermediate elements present.

[0066] Unless otherwise stated herein, all test standards are the most recent standards in force up to the date of filing of this application, or, if priority is claimed, the date of filing of the earliest priority application in which a test standard appears.

[0067] Unless otherwise defined, the technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains.

[0068] While the foregoing disclosure has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and elements can be substituted with equivalents without departing from its scope. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of this disclosure without departing from the basic scope of this disclosure. Therefore, it is intended that this disclosure be limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A battery for a vehicle, the battery comprising: Energy storage section; A first terminal block, which physically contacts and is electrically connected to the energy storage portion via a first inner surface; The second terminal board is physically in contact with and electrically connected to the energy storage portion via a second inner surface; The first terminal plate includes at least one groove extending from a first outer surface into the first terminal plate, the first outer surface being opposite to the first inner surface; and When alternating current passes through the first terminal block, the skin effect of the first terminal block at the first outward-facing surface extends from the periphery of the first terminal block and from each edge of the at least one groove.

2. The battery according to claim 1, wherein the second terminal board is the same as the first terminal board.

3. The battery according to claim 1, wherein the at least one groove comprises a straight groove extending from a first edge of the first terminal plate to a second edge of the first terminal plate.

4. The battery of claim 3, wherein the at least one groove comprises a set of grooves that divide the first outward-facing surface into a set of outward-facing regions, wherein each outward-facing region has the same two-dimensional shape.

5. The battery according to claim 1, wherein the at least one groove comprises at least one curved groove.

6. The battery of claim 5, wherein the at least one groove comprises a set of grooves dividing the first outward-facing surface into a set of outward-facing regions, wherein the set of outward-facing regions comprises regions with different two-dimensional shapes.

7. The battery of claim 1, wherein the at least one groove extends to at least 50% of the depth of the first terminal plate.

8. The battery of claim 1, wherein the first terminal plate further includes a fastener hole extending from the first outward-facing surface to the first inward-facing surface.

9. The battery according to claim 1, further comprising an insulator disposed in the at least one groove, wherein the insulator is electrically insulating.

10. The battery of claim 9, wherein the insulator is one of a rigid insulator held in the at least one groove by an interference fit, an electrically insulating coating applied to the at least one groove, and a flexible insulator.

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