Multifunction Carrier Integrating HV Busbars and Thermal Management
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Solution Overview
Problem
The assembly of circuit components in electric vehicle battery systems is labor-intensive and prone to errors due to complex cable routing, manual inspection requirements, and inadequate thermal connections, leading to long assembly times and potential safety issues with high-voltage components.
Innovation Solution
A multifunctional carrier that integrates HV busbars, PCB connectors, and wiring harnesses, allowing for fully automated assembly and welding, with a plug-in system for HV contactors that eliminates the need for screwing and additional cable lugs, and incorporates thermally conductive materials for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate component carriers and manual assembly methods are used to accommodate circuit components, then assembly flexibility and component protection are improved, but assembly time and production complexity increase significantly
Solution Approach 1:
The patent combines multiple separate components (component carrier, cable spider, insulating parts, thermal connection elements) into a single integrated high-voltage contactor assembly. This integration eliminates the need for separate component carriers and multiple assembly steps, enabling fully automated assembly while maintaining component protection and electrical isolation.
Solution Approach 2:
The high-voltage contactor is designed as a multi-functional component that simultaneously provides electrical connection, mechanical support, thermal management, and insulation functions. This universal design replaces multiple specialized components, reducing assembly complexity and enabling automated production while preserving all necessary protective functions.
2Reliability
If complex cable routing and additional carriers are used to integrate wiring harnesses, then cable management and electrical connections are improved, but device complexity and assembly steps increase
Solution Approach 1:
The wiring harness is integrated directly into the high-voltage contactor assembly, eliminating the need for separate cable spiders and additional carriers. The cables are routed through the contactor housing itself, simplifying the overall device structure while ensuring reliable electrical connections between all components.
3Manufacturing precision
If manual inspection and counter-tension testing are performed to ensure assembly quality, then assembly accuracy and safety are improved, but production time and labor requirements increase
Solution Approach 1:
The high-voltage contactor design incorporates self-checking features where the integrated structure and standardized interfaces automatically ensure proper assembly. The design inherently prevents incorrect assembly through geometric constraints and standardized connection points, eliminating the need for manual inspection and testing while maintaining high assembly accuracy.
4Temperature
If GapPads and Gapfillers with protective foils are used for thermal connection, then thermal conductivity is improved, but assembly complexity and additional work steps increase
Solution Approach 1:
The thermal management components (GapPads, Gapfillers, cooling channels) are integrated directly into the high-voltage contactor housing as a unified thermal management system. This eliminates the need for separate thermal connection steps and protective foils, as the thermal paths are built-in and pre-configured during manufacturing.
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
This solution enables fully automated assembly of battery system components, reducing production costs and ensuring reliable electrical connections while improving safety and efficiency by eliminating manual assembly steps and enhancing thermal management.
Implementation Method 1
With a thermally conductive plastic or the use of gap pads or gap fillers, hot spots in the system can also be connected, e.g., to a cooling system.
Data Source
AI summary
The present disclosure relates to a multifunction carrier for accommodating circuit components of a battery system for an electric vehicle, the multifunction carrier including: a bus bar assembly having at least a charging terminal bar and a drive terminal bar; and an insulating housing in which the power rail assembly is embedded, wherein the insulating housing has openings exposing contact surfaces of the terminal rails, and wherein the insulating housing has connectors configured to make pluggable mechanical and electrical contact between the circuit components of the battery system and the opened contact surfaces of the terminal rails. The present disclosure further relates to a high voltage contactor for a battery system of an electric vehicle.