Battery Busbar Terminal With Integrated Cooling and Wedge Clamping
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Solution Overview
Problem
Existing terminal blocks for battery packs in electric vehicles face challenges in efficiently transferring current and heat while requiring multiple coolant connections, leading to complex and space-consuming cooling systems.
Innovation Solution
A busbar with integrated cooling channels and clamping elements, combined with electrically conductive and insulating coatings, facilitates efficient current and heat transfer, reducing the number of coolant connections and optimizing space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If each cell is equipped with its own cooling channel, then heat dissipation efficiency is improved, but the number of coolant connections increases significantly
Solution Approach 1:
Multiple cooling channels are merged into a single integrated cooling element that cools multiple cells simultaneously. The cooling element is designed with multiple channels that can cool several cells through a unified structure, reducing the number of separate coolant connections required while maintaining effective heat dissipation for each cell.
Solution Approach 2:
The cooling element is designed as a multi-functional component that serves multiple cells at once. A single cooling element with multiple channels can cool different cells or groups of cells, making the cooling system more versatile and reducing the overall number of connections needed in the battery pack.
2Reliability
If wedge-shaped clamping elements are used, then self-locking capability is improved, but the overall height of the terminal block increases
Solution Approach 1:
The clamping element features an asymmetric design with a wedge shape that provides self-locking capability. The asymmetric geometry allows the clamping element to maintain secure contact with the busbar and cell terminals while preventing loosening under vibration and thermal cycling, achieving reliable electrical connection without requiring excessive height.
3Temperature
If multiple coolant connections are provided, then cooling performance is improved, but space utilization deteriorates
Solution Approach 1:
Multiple cooling channels are integrated into a single cooling element that occupies less space than multiple separate cooling components. The merged design allows coolant to flow through multiple channels within one compact structure, maintaining effective cooling performance while improving space utilization in the battery pack.
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 enables high-quality current and heat transfer with reduced complexity, allowing for scalable parallel connections and efficient heat dissipation, even at high power outputs, while ensuring safety and reliability.
Implementation Method 1
at least one cooling channel is provided in the busbar, through which a cooling fluid can flow, so that the busbar is simultaneously a cooling element for the battery block
Implementation Method 2
the busbar is made of a material with high electrical conductivity... enables high-quality current and heat transfer
Implementation Method 3
clamping elements, in particular clamping screws, are further provided which press the clamping elements against the contact surfaces of the busbar
Implementation Method 4
The wedge bodies have a trapezoidal cross-section... the arrangement is self-locking; that is, even if the clamping elements, in particular clamping screws, loosen, secure contact is maintained
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a connecting terminal (1) for arresters (5) of cells (6) of a battery block, comprising a bus bar (4) with at least two recesses into which a respective trapezoidal wedge-type body (2) is inserted. The wedge-type bodies (2) are inserted into the bus bar (4) with the shorter parallel side of the trapezoid in front, and two respective arresters (5) can be securely clamped between each wedge-type body (2) and the bus bar (4) in two clamping regions. The wedge-type bodies (2) are pressed against the bus bar (4) with clamping screws (3). The bus bar (4) is formed as a single piece from a material with high electrical conductivity. According to the invention, a cooling channel (7) is provided in the bus bar (4) between two recesses, through which a coolant can flow, such that the bus bar (4) is simultaneously a cooling element (4) for the battery block. Alternatively, the bus bar (4') can be flat and elongated, wherein two respective contact surfaces are provided at both ends of the bus bar (4'), lying symmetrically relative to the longitudinal axis, and the arresters are clamped between these contact surfaces and strip-shaped clamping elements (2') with clamping screws (3). In this way, one bus bar (4, 4') can cool up to four arresters (5).