Connector Assembly With Integrated Fluid Channels for Terminal Cooling
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Solution Overview
Problem
Existing electric drive systems lack direct cooling for electric connectors and lubrication for gear meshing regions, resulting in inefficient cooling and lubrication due to the inability of most coolants to directly contact these areas.
Innovation Solution
A connector assembly integrating a fluid channel that guides cooling fluid to both electric connection terminals and gear meshing regions, enhancing cooling and lubrication efficiency by direct contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate cooling system is used for electric connectors, then cooling efficiency can be improved, but device complexity increases
Solution Approach 1:
The patent integrates the cooling function directly into the connector assembly by incorporating cooling channels within the insulating component. This merging of cooling functionality with the existing connector structure improves cooling efficiency for connection terminals without requiring a separate, complex cooling system.
Solution Approach 2:
The insulating component of the connector assembly serves multiple functions: electrical insulation, structural support, and heat dissipation through integrated cooling channels. This multi-functionality allows the same component to address both electrical connection and thermal management needs, improving cooling efficiency while avoiding additional system complexity.
2Temperature
If lubricating oil is used to cool electric connectors, then cooling function is added, but lubricating efficiency for gear meshing region decreases
Solution Approach 1:
The patent segments the fluid channel system into separate pathways: one for cooling the connector (through channels in the insulating component) and another for lubricating the gear meshing region (through the speed reducer cavity). This segmentation allows cooling fluid and lubricating oil to be independently managed, enabling the connector to receive cooling without compromising the lubrication efficiency for gears.
Solution Approach 2:
The patent introduces a dedicated cooling channel system as an intermediary structure within the insulating component, which provides a separate pathway for cooling fluid to reach connection terminals. This intermediary cooling system prevents direct competition between cooling and lubrication functions, allowing both to operate effectively in their respective zones.
3Temperature
If cooling fluid is guided directly to connection terminals, then cooling efficiency improves, but device complexity increases
Solution Approach 1:
The cooling channels are merged with the insulating component of the connector assembly, utilizing the existing structural element to house the cooling pathways. This integration achieves direct cooling of connection terminals while avoiding the need for separate, complex cooling apparatus, thus improving cooling efficiency without significantly increasing overall device complexity.
Solution Approach 2:
The insulating component serves as a flexible structural element that can incorporate cooling channels within its geometry. This approach allows the cooling system to be embedded in a non-metallic, electrically insulating material, achieving direct cooling of terminals while maintaining electrical isolation and structural integrity without adding complex metallic cooling structures.
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 integrated fluid channel improves cooling and lubrication efficiency, reducing the amount of cooling fluid required and making the system more compact and flexible.
Implementation Method 1
capable of guiding a cooling fluid from a cooling system of the electric drive system to positions where the electric connection terminals are connected to stator terminals of the electric drive system
Implementation Method 2
guiding a cooling fluid from a cooling system of the electric drive system to positions where the electric connection terminals are connected
Implementation Method 3
arranged on the first insulating component and capable of guiding a cooling fluid from a cooling system of the electric drive system
Data Source
AI summary
A connector assembly for an electric drive system, an electric drive system and a vehicle. The connector assembly includes multiple busbars, each of the multiple busbars having a first part extending in a first direction and an electric connection terminal. Also included is a first insulating component, the first parts of the multiple busbars being at least partially arranged in the first insulating component in a mutually insulated manner. A fluid channel is arranged on the first insulating component and capable of guiding a cooling fluid from a cooling system of the electric drive system.