Liquid Cooled Terminal Block Bus Bar Thermal Management

Solution Overview

Problem

Conventional power systems in electrified vehicles face thermal performance limitations due to inadequate cooling of bus bars in terminal block assemblies, which restricts the current carrying capability and affects the thermal management of nearby components.

Innovation Solution

A liquid-cooled terminal block assembly with a built-in cooling channel and a closed thermal loop, utilizing a coolant that circulates through the assembly to directly contact and cool the bus bars, enhancing thermal performance and current carrying capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional terminal block assemblies are used without liquid cooling, then the structure is simpler and easier to manufacture, but the thermal performance is insufficient and current carrying capability is limited

Engineering Contradiction:

Improvethermal performanceVSAvoidstructure complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling channels are integrated directly into the terminal block housing structure, merging the cooling system with the electrical component housing. This eliminates the need for separate cooling apparatus while providing effective thermal management of the bus bars and surrounding components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

A coolant fluid is introduced as an intermediary substance to transfer heat away from the bus bars and electrical components. The coolant circulates through the integrated channels, absorbing thermal energy and carrying it to external heat exchangers or cooling systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If bus bars are cooled more effectively, then current carrying capability increases, but the device complexity increases due to added cooling systems

Engineering Contradiction:

Improvecurrent carrying capabilityVSAvoidcooling system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The cooling channels are integrated directly into the terminal block housing structure, merging the cooling system with the electrical component housing. This eliminates the need for separate cooling apparatus while providing effective thermal management of the bus bars and surrounding components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The terminal block assembly serves multiple functions: electrical connection, structural support, and thermal management. The housing structure simultaneously provides mechanical protection and houses the cooling channels, making the system multi-functional without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If cooling channels are integrated into the terminal block housing, then thermal management of nearby components improves, but manufacturing complexity increases

Engineering Contradiction:

Improvethermal managementVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The cooling channels are integrated directly into the terminal block housing structure, merging the cooling system with the electrical component housing. This eliminates the need for separate cooling apparatus while providing effective thermal management of the bus bars and surrounding components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The terminal block housing structure serves itself by incorporating cooling channels directly into its design. The housing provides both mechanical protection and thermal management functionality, eliminating the need for separate dedicated cooling components and reducing overall system complexity.

Inventive Principle:

Principle #25Self-service

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 liquid-cooled terminal block assembly effectively manages heat generated by bus bars, improving their current carrying capabilities and thermal performance, thereby enhancing the overall efficiency and reliability of power systems in electrified vehicles.

Implementation Method 1

The cooling channel is configured for circulating a coolant for cooling the bus bar

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

The cooling channel is configured for circulating a coolant for cooling the bus bar

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS11622479B2Liquid cooled terminal block assemblies

Publication Date: 2023.04.04 FORD GLOBAL TECH LLC

AI summary

This disclosure is directed to power systems for transferring power between electrical components. An exemplary power system includes a first electrical component (e.g., an electric motor), a second electrical component (e.g., an inverter system), and a terminal block assembly adapted to electrically couple the first and second electrical components. The terminal block assembly includes an internal cooling channel configured to receive coolant for providing direct liquid cooling of the bus bar.