Open-Frame Power Connector for Battery Management Systems
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Solution Overview
Problem
Conventional battery-to-battery management system power connectors are prone to electrical shorts due to debris and inefficient heat management, leading to reduced reliability and increased costs.
Innovation Solution
A simplified power connector design with a housing having separate opposing side walls forming an open passageway for improved air cooling, reducing heat flow and eliminating the need for a thermal pad, while using L-shaped bus bars and additional bus bars for enhanced electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional power connector with a metal box and thermal pad is used, then electrical connection is established, but heat is drawn from the battery pack and rejected into the BMS causing heat management issues
Solution Approach 1:
The patent removes the metal box and thermal pad from the connector design. Instead of using a enclosed metal housing with thermal management components, the invention uses an open-frame structure where bus bars are exposed to ambient air, eliminating the heat sink function that was causing heat to be drawn from the battery and rejected into the BMS.
Solution Approach 2:
The open-frame bus bar structure allows natural convection and radiation cooling to occur without requiring active thermal management components. The bus bars themselves serve as the electrical connection while simultaneously providing passive thermal dissipation to the surrounding environment.
2Temperature
If a thermal pad is used in the power connector, then thermal contact is established, but the thin configuration makes it susceptible to failures from debris causing electrical shorts
Solution Approach 1:
The patent completely eliminates the thermal pad component from the design. The open-frame bus bar structure provides both electrical connection and thermal management without requiring a separate thermal interface material that would be vulnerable to contamination and failure.
3Reliability
If multiple components (metal box, thermal pad, bus bars, retainer) are used in the power connector, then electrical connection is achieved, but the device complexity increases
Solution Approach 1:
The patent merges the functions of electrical connection and structural support into the bus bar assembly itself. The open-frame bus bars provide both the electrical pathway and the mechanical framework, eliminating the need for separate metal box housings and plastic retainers that were previously required to hold the components together.
Solution Approach 2:
The bus bars serve multiple functions simultaneously: they provide electrical connection between battery terminals and BMS, provide structural support for the connector assembly, and provide passive thermal management through their exposed surface area. This multi-functionality reduces the total number of components required.
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 enhances air cooling, reduces heat flow, increases reliability, and decreases component costs by minimizing the number of parts and eliminating thermal pad failures, thereby extending the life of the battery management system and energy storage device.
Implementation Method 1
the open passageway provides fluid communication between the battery management system and the energy storage device so as to improve air cooling across the power connection
Data Source
AI summary
The present disclosure is directed to an improved energy storage system. The energy storage system includes an energy storage device having positive and negative terminals, a battery management system configured to monitor and control the energy storage device, and a power connector configured to electrically couple the battery management system with the energy storage device. The power connector includes a housing and positive and negative bus bars, each containing a positive and negative interface pin, respectively. The interface pins are operatively coupled to the positive and negative terminals of the energy storage device to form a power connection. The housing contains separate, opposing side walls defining an open passageway therebetween. Thus, the open passageway provides air cooling across the power connection.