CN108461174B

CN108461174B - Electrical conductor arrangement system and motor vehicle

Info

Publication number: CN108461174B
Application number: CN201810147685.0A
Authority: CN
Inventors: V·格里尼特茨; F·拉贝; R·德拉邦; M·伯格哈戴恩
Original assignee: Benteler Automobiltechnik GmbH
Current assignee: Benteler Automobiltechnik GmbH
Priority date: 2017-02-17
Filing date: 2018-02-13
Publication date: 2020-07-07
Anticipated expiration: 2038-02-13
Also published as: DE102017103268B4; DE102017103268A1; CN108461174A

Abstract

The invention relates to an electrical conductor arrangement comprising at least one conductor profile (1). According to the invention, the conductor profile (1) is extruded and made of a lightweight metal alloy, wherein the conductor profile (1) has at least one channel (2) which is closed on the circumferential side. Preferably, the conductor profile (1) is made of an aluminum-plastic alloy. The channel (2) is designed in particular for conveying a heat transfer medium. A plurality of conductor profiles (1) are coupled to one another to form a conductor cable (14) which is used in a motor vehicle. The electrical conductor arrangement can form an electrical circuit between the charging socket (37) and the electrical energy store.

Description

Electrical conductor arrangement system and motor vehicle

Technical Field

The invention relates to an electrical conductor arrangement comprising at least one conductor profile and to a motor vehicle having such an electrical conductor arrangement.

Background

Electric traffic, also referred to as E-traffic (E-Mobility), provides for the use of electric vehicles which are equipped with an energy store in the form of an electric accumulator or battery cell and which comprise an electric drive which can be varied in the degree of electrification. In particular, electric motor traffic is now under dynamic development with regard to durability, taking into account traffic demands, as a result of the aim of environmental policies, so that the electrification of the drive train is increased further in motor vehicles in the future.

The charging time of the battery cells used at present or of the installed battery capacitors with reference to the amount of energy supplied to the vehicle is longer than the usual refuelling time at a petrol station using the refuelling process of an internal combustion engine. A shorter charging time is therefore desirable, in particular when a person wishes to drive with the motor vehicle over a shorter distance determined by the battery capacity. The charging time decreases with increasing charging power. The implementation of the fast charging concept requires a large electrical and thermal load capacity of the components in the charging circuit. There is a need for an electrical conductor arrangement system that is capable of transmitting the necessary power. The charging station provides a corresponding charging voltage and charging amperage for the battery cells in the vehicle. The permissible magnitudes of the voltage and of the charging intensity are determined by the components of the electrical circuit installed in the vehicle and its load capacity. The main part of the charging circuit is the arrangement of electrical conductors from a charging socket in the motor vehicle to the battery cells. Starting from the battery cell, at least one electrical conductor or a conductor cable comprising an electrical conductor likewise leads to the electric drive of the motor vehicle.

The charging time depends not only on the available power of the charging point but also on the technical design of the vehicle or the components of the charging circuit in the vehicle.

It is known from electrical conductors and plug interfaces for charging stations for electric vehicles that the power that can be transmitted in the permitted voltage is limited by the thermal loading capacity of the electrical lines and plug contacts that, in the charging circuit, have a very high power loss density in small-area contact points on the basis of the electrical contact resistance. Contact heating now defines the effective power of the fast charging station. In order to increase the power that can be transmitted, liquid-cooled, flexible electrical lines and liquid-cooled plugs or plug contacts are used. This, however, leads to an increase in size and weight and to a reduction in the flexibility of the conductor and its manual operability.

Document DE 112012003099T 5 describes a charging station for the rapid charging of an electric vehicle battery, and furthermore, in the context of this document describes a coolable galvanic connection between a charging connector and an electric battery.

Disclosure of Invention

The object of the present invention is to provide an electrical conductor arrangement for a motor vehicle, having a conductor profile made of a solid and chemically stable material, which can be produced flexibly in terms of its shape and length, is advantageous in terms of weight and is inexpensive, wherein the conductor arrangement enables heat removal at the contact points and low-loss transmission of electrical power with the use of the current strengths and high voltages necessary for the operation of power electrical devices or electric drives.

According to the invention, the object is achieved by an electrical conductor arrangement system.

The electrical conductor arrangement comprises at least one conductor profile. According to the invention, the electrical conductor arrangement is extruded from a lightweight metal alloy and has at least one channel which is closed on the circumferential side.

Particularly preferably, the conductor profile is made of an aluminum alloy whose main component is aluminum, in which the sum of the other alloying elements, including additions and impurities resulting from melting, does not exceed 5.0 percent by mass.

Within the scope of the present invention, aluminium-plastic alloys are considered as particularly advantageous materials for conductor profiles. Preferably, an aluminium-plastic alloy having an aluminium content of at least 99%, for example a199.5(EN AW-1050), can be used.

The alloys in group 1xxx, also known as pure aluminum, have high electrical and thermal conductivities. Furthermore, the alloy group is very corrosion resistant and also weldable. Therefore, the aluminum alloys of group 1xxx are particularly suitable as conductor materials.

From group 6xxx, the aluminum alloys EN AW-6060 or EN AW-6005 are well suited as extruded conductor profiles for the applications specified according to the invention.

Also low-alloyed aluminum-plastic alloys from group 7xxx, here for example the aluminum alloy EN AW-7072, can be used.

The conductor profile according to the invention can have a plurality of internal channels which extend over the length of the conductor profile. The conductor profile is in this case an extruded profile with a plurality of channels separated from one another by internal webs. In this case, the webs can extend both vertically and horizontally relative to the cross section of the conductor profile.

The channels in the conductor profile define and are therefore designed for the passage of the heat transfer medium and/or for the passage of the line conductor and/or the tube body. The conductor body can be, for example, a high-voltage conductor or a data conductor. The pipe body can be a separate pipe line, for example a coolant conductor or a coolant pipe or a heat pipe.

One main aspect of the present invention is directed to a coolable electrical conductor arrangement. Accordingly, the or each channel is provided for conveying a cooling medium, in particular a liquid or gaseous heat transfer medium being envisaged here.

In an advantageous embodiment, the conductor profile has at least one curved section and in particular a curvature in the longitudinal direction.

The curved sections are produced by bending, in particular stretch bending, or by upsetting.

The conductor profile according to the invention can furthermore have heat-conducting elements and/or profile elements with increased hardness on its outer surface. The heat-conducting element is preferably designed as a rib or a web, as is the case with the profile element with increased hardness.

Another main aspect of the invention is an electrical conductor arrangement in which a plurality of conductor profiles are coupled to each other to form a conductor cable. In this case, a straight conductor profile and a curved conductor profile having at least one curved section are joined in series to form a conductor cable. The inner channels in the adjoining conductor profiles communicate in a purposeful manner for conveying the heat transfer medium and/or are penetrated by the line conductors or tube bodies.

The conductor profiles are coupled to one another in such a way that the conductor cables can be positively and/or frictionally and/or materially bonded. For example, a plug-in solution is possible in which the conductor profiles have end sections that are matched to one another for a plug-in connection. The conductor profile is oriented in a form-fitting manner by means of its plug section and is additionally protected against unintentional release. In particular, it is advantageous to consider a cohesive connection of the conductor profiles to one another, in which the channels engage one another in a medium-tight manner.

Such a conductor cable is provided in particular for use on board or in a motor vehicle and extends from a charging socket of the motor vehicle as far as an energy store or battery cell. Furthermore, conductor cables can be used on the electrical circuit from the battery cells to the electric drive.

In a further advantageous embodiment of the electrical conductor arrangement, it is provided that at least two conductor profiles are arranged parallel to one another.

Furthermore, at least two conductor profiles can be insulated relative to one another and joined to one another by means of an insulating element. In this case, the conductor profiles, which are arranged in particular parallel to one another, are joined to one another by insulating elements which are provided in a material-specific and geometrically corresponding manner.

Advantageously, the conductor profiles and the insulating element joining the conductor profiles to one another have complementary form-locking sections which engage in one another.

One embodiment of the electrical conductor arrangement provides that at least two conductor profiles are joined to one another by means of an insulating element, wherein the insulating element can also have at least one line channel.

The channel can be closed at the end of the conductor profile by a closing element, for example a plug. In this way one or more channels can be closed appropriately. In an electrical conductor arrangement having a plurality of conductor profiles which are combined to form one conductor cable, this takes place on the end side on the last conductor profile of the conductor cable. Thereby affecting the continuity of the channel in the conductor cable. This allows the flow rate of the heat transfer medium to be adjusted.

It is also possible to integrate switching elements or switching elements in one conductor profile. This allows for a shunting or supply of the heat transfer medium, which crosses in the conductor cable or is inside the conductor cable or inside the electrical arrangement formed by the conductor cables.

In a further main aspect of the invention, the conductor profile has at least one connection piece, which communicates with the channel. Such a connection may preferably be a coolant connection.

Furthermore, the application possibilities are increased if at least one conductor profile is provided with a contact surface for connecting a functional element. In this way, the functional element can be joined to the conductor profile in the conductor cable according to the application. The functional element is, for example, an electrical connection or a contact or contact socket (kontkattschuh), but, like the heat pipe, is also a coolant collector or a coolant conductor.

The heat transfer medium in the form of a gas or a liquid can flow around the outside as well as through the conductor arrangement or the conductor profiles of the conductor arrangement inside. The conductor profile can be coated at least in regions, preferably at contact points, end points or joining points, with a material having a small electronic work function W_e< (less than) 7.9 × 10^-19Joule, equivalent to 4.93 electron volts. Starting from a light metal or its alloys (from which the conductor profiles are produced), the coating of the contact material applied up to the surface has at least one part of the following layer sequence: zinc, chromium, nickel, copper and/or silver. The conductor arrangement or the conductor profile thereof can be coated at least in regions, preferably at locations that will not be electrically contacted, with an electrically insulating or heat-radiating material, for example a varnish. Furthermore, the conductor arrangement system can be used as a heat conductor which conducts heat caused by the current intensity from lines, cables, plugs or plug contacts to a cooling surface or a cooling device in the motor vehicle.

The inner space of the conductor arrangement, which is formed by the at least one channel, can additionally protect the electrical conductors, in particular the data lines or the control lines, from environmental influences and guide them and fix them, in isolation from the electrical potential of the conductor arrangement.

The conductor arrangement according to the invention is distinguished by low transmission losses and by a large effective coefficient of action and a large electrically effective power or transmission capacity. The possibility of conducting the heat caused by the current intensity out of the peripheral lines and plugs onto the cooling surface or the cooling device allows the mass of the electrical conductor arrangement to be reduced. Furthermore, it is possible to anticipate a reduction in the charging time of the battery in a motor vehicle by means of the conductor arrangement system. In particular, in cooled conductor arrangement systems, cooling of the conductors on the motor vehicle side makes it possible to increase the electrical power that can be transmitted.

Drawings

The invention is described in more detail below with the aid of embodiments shown in the drawings. In the drawings:

fig. 1 shows a detail of an electrical conductor arrangement according to the invention with a conductor profile;

fig. 2 likewise shows a detail of a conductor arrangement system with an alternative embodiment of the conductor profile;

fig. 3 shows a conductor profile in another embodiment;

fig. 4 shows a further embodiment of the electrical conductor arrangement;

fig. 5 shows an alternative configuration of the conductor profile;

fig. 6 shows a vertical cross-sectional view of a conductor arrangement with two conductor profiles arranged parallel to each other;

fig. 7 shows a variant of the conductor arrangement system according to fig. 6;

fig. 8 shows a vertical cross-sectional view of a conductor arrangement with two conductor profiles arranged parallel to one another;

fig. 9 shows a variant of the conductor arrangement system according to fig. 8;

fig. 10 shows a vertical cross-sectional view of another conductor arrangement with three conductor profiles arranged parallel to one another;

fig. 11 shows a variant of the conductor arrangement system according to fig. 10;

fig. 12 shows a further variant of the conductor arrangement system;

fig. 13 shows a further variant of the conductor arrangement system;

FIG. 14 shows yet another embodiment of a conductor arrangement system;

FIG. 15 shows yet another embodiment of a conductor arrangement system;

fig. 16 shows a partial end side of a conductor arrangement with a connected electrical ferrule and a connected tube body;

fig. 17 again shows a detail of the end face of the conductor arrangement in a different form of configuration;

fig. 18 shows another end-side connection structure of the electrical conductor arrangement system;

fig. 19 shows a technically simplified illustration of a conductor arrangement system with a connected cooling device;

fig. 20 likewise shows a conductor arrangement system with a cooling device;

FIG. 21 shows a cross-sectional view of another embodiment of an electrical conductor arrangement system;

FIG. 22 shows a cross-sectional view of another embodiment of a conductor arrangement system according to the invention;

fig. 23 shows a motor vehicle with an electrical conductor arrangement according to the invention in a technically simplified manner; and

fig. 24 shows a view of a motor vehicle with an electrical conductor arrangement according to the invention together with further system components.

Detailed Description

Corresponding components or component assemblies are denoted by the same reference numerals in all the figures.

Fig. 1 to 18 each show different embodiments of an electrical conductor arrangement system or variants of a conductor profile 1 of a conductor arrangement system.

The section of the conductor arrangement shown in fig. 1 comprises a conductor profile 1. The conductor profile 1 is extruded and made of a light metal alloy. The conductor profile 1 has an inner, circumferentially closed, rectangularly arranged channel 2. The conductor profile 1 is also of substantially rectangular configuration in cross section, with an upper longitudinal wall 3 and a lower longitudinal wall 4 and side walls 5.

The light metal alloy is an aluminum-plastic alloy, and the extruded profile of the conductor profile 1 is made of the light metal alloy. In particular, an aluminum alloy whose main component is aluminum is used, and the sum of other alloying elements including additives and impurities caused by melting in the aluminum alloy is not more than 5.0 mass%.

The conductor profile 1 has a curvature in the longitudinal direction. The differently oriented

profile sections

1a, 1b, 1c, 1d, 1e are connected to one another by means of arc-shaped sections 6 to 9. The curved sections 6 to 9 are produced by bending, in particular by stretch bending or upsetting. Here, it may be the upsetting arcs 6, 7, the stretching arcs 8 or the bending arcs 9.

The channel 2 formed inside the conductor profile 1 serves for conveying the heat transfer medium.

In all the conductor arrangement systems or the conductor profiles 1 thereof described below, these conductor profiles 1 from extruded profiles are made of a light metal alloy and have at least one channel 2 closed on the circumferential side.

As shown in the embodiments of the conductor profile 1 shown in the views in fig. 2 to 5, the conductor profile 1 has a plurality of channels 2 which are separated from one another by

internal webs

10, 11. The

webs

10, 11 can be designed vertically (vertical webs) or horizontally (horizontal webs) with reference to the central longitudinal plane of the conductor profile 1.

In the case of the conductor profiles 1 according to fig. 3, 5 to 9 and 12 and 13, heat-conducting elements and/or profile elements with increased hardness, in particular ribs 13, are arranged on the outer surface 12.

The outer

longitudinal walls

3, 4 of the conductor profile 1 may have not only flat surfaces (see fig. 1 to 3) but also curved surfaces (see fig. 4 and 5).

A plurality of conductor profiles 1 can be coupled together and to one another to form a conductor cable 14 (fig. 23 and 24). The conductor profiles 1 are bonded to one another in a material-locking manner.

In the conductor arrangement according to the illustrations in fig. 6 to 9, two conductor profiles 1 are arranged parallel to one another.

In the conductor arrangement as shown in fig. 10 to 13, three conductor profiles 1 are arranged parallel to one another.

Fig. 14 and 15 show an embodiment of a conductor arrangement in which four conductor profiles 1 are arranged parallel to one another.

In the embodiments of the conductor arrangement according to fig. 6 to 15, the conductor profiles 1 are insulated from one another and joined to one another by the insulation 15. For this purpose, the conductor profile 1 and the insulating part 15 have complementary form-locking

sections

16, 17, which engage in one another. The insulator 15 (see fig. 7, 9, 13, and 14) may have at least one wire passage 18. A cable 19 surrounded by insulation or shielding can be placed in the conductor channel 18.

The channels 2 of the conductor profiles 1, which are connected to form a conductor cable, communicate with each other. Each channel 2 is designed for conveying a heat-carrying medium for cooling the electrical conductor arrangement. It is also possible to guide a line body or tube body, for example a data line or a heat pipe 20 (see fig. 17), through the channels 2.

Fig. 16, 17 and 18 each show an end-side section of the conductor arrangement. In the case of a conductor arrangement system or in the case of a conductor cable 14, the last conductor profile 1 has a contact surface 21 for connecting a functional element 22 in the form of a contact socket or a contact plug. Furthermore, a connection 23, in particular a coolant connection, is provided, which communicates with the channel 2 in the interior of the conductor cable or conductor profile 1. The open end of the last conductor profile 1 is closed by means of a closing element 24 in the form of a plug for controlling the coolant flow.

In the embodiment according to fig. 16, which is identical to fig. 17, the coolant conductor or the heat pipe is designated by reference numeral 20.

The conductor arrangement according to the illustration in fig. 18 shows a conductor profile 1 with a contact surface 21 for connecting a functional element in the form of a coolant collector 25. Furthermore, a functional element 22 in the form of the same electrical contact as the coolant conductor or heat pipe 20 is connected there. The coolant conductor or heat pipe 20 is electrically isolated from the conductor profile 1.

Fig. 19 and 20 each show the conductor arrangement together with the conductor profile 1, to which a cooling module 26 with a blower 27 is connected upstream as a cooling device. The blower 27 comprises a rotor drive 28 with a rotor shaft 29 and rotor blades 30. The cooling module 26 has electrical conductors and contact elements 31 for establishing an electrical connection to the conductor arrangement.

In the conductor arrangement shown in fig. 21 and 22, two conductor profiles 1 are again arranged parallel to one another in the longitudinal direction and are insulated and joined with respect to one another by means of an insulating element 15. In the conductor arrangement according to fig. 21, the upper channel 2 and the lower channel 2 are joined to one another in a medium-conducting manner by means of a tube 32. The tube 32 is electrically isolated from the conductor profile 1. A coolant connection is established between the upper channel 2 and the lower channel 2 by means of the pipe 32.

In the conductor arrangement according to fig. 22, the upper conductor profile 1 and the lower conductor profile 1 each have a lateral connecting piece 33 with an integrated connecting piece 34, which are locked to one another by a bent tube 35. With this arrangement, it is likewise possible to exchange the heat transfer medium between the upper channel 2 and the lower channel 2. A liquid-tight connection between the upper channel 2 and the lower channel 2 thus also enables heat exchange between the two channels 2.

A wire passage 18 of rectangular configuration is provided in the insulating member 15. The conductor paths serve for carrying, for example, data conductors or control conductors 19.

Fig. 23 and 24 each show a motor vehicle with an electrical conductor arrangement and a conductor profile 1. These conductor profiles 1 are combined to form a conductor cable 14 and form a high-current conductor.

The views of fig. 23 and 24 are technically simplified and serve to illustrate the main components that cooperate with the electrical conductor arrangement system. The battery container is provided with reference numeral 36. A coolant collector 37 may optionally be provided. The charging receptacle 38 includes a receiver for conductive electrical transmission. The electrical energy is supplied to the on-board system of the motor vehicle via the charging socket 38. The conductor cable 14 of the conductor arrangement system extends from the charging socket 38 as far as the battery receptacle 36. A blower 27 can optionally be connected upstream of the conductor arrangement. The heat pipe 20 can be integrated at a suitable location. The conductor arrangement system leads from the charging socket 38 to the battery receptacle 36 and from there to the front wheel electric drive 39 and to the rear wheel electric drive 40. Furthermore, an external space heat exchanger 41, a heat transfer pump 42 and an internal space heat exchanger 43 as well as an electric clutch 44 are shown.

List of reference numerals:

1-conductor profile

1 a-Profile section

1 b-Profile section

1 c-section bar section

1 d-Profile section

1 e-section bar section

2-channel

3-upper longitudinal wall

4-lower longitudinal wall

5-side wall

6-arc segment (upset arc)

7-arc segment (upset arc)

8-arc section (stretching arc part)

9-arc section (bending arc part)

10-connecting sheet

11-connecting sheet

12-outer surface

13-Rib

14-conductor cable

15-insulating part

16-form-locking section

17-form-locking section

18-conductor channel

19-cable

20-Heat pipe

21-contact surface

22-functional element

23-connecting piece

24-blocking element

25-Coolant collector

26-Cooling Module

27-air blower

28-rotor drive

29-rotor shaft

30-rotor blade

31-conductor and contact element

32-pipe fitting

33-lateral connection

34-connecting block

35-bend pipe

36-accumulator container

37-Coolant collector

38-charging socket

39-front wheel electric drive device

40-rear wheel electric drive

41-external space heat exchanger

42-Heat transfer Pump

43-interior space heat exchanger

44-electric clutch

Claims

1. Electrical conductor arrangement comprising at least two conductor profiles (1), wherein the conductor profiles (1) are extruded and made of a lightweight metal alloy and the conductor profiles (1) have at least one channel (2) which is closed on the circumferential side, characterized in that the at least two conductor profiles (1) are arranged parallel to one another and are insulated from one another by an insulating element (15) and are joined to one another, the conductor profiles (1) and the insulating element (15) having form-locking sections (16, 17) which are complementary to one another and which engage in one another.

2. Electrical conductor arrangement system according to claim 1, characterized in that the conductor profile (1) is made of an aluminium alloy whose main component is aluminium, in which the sum of the other alloying elements including additions and impurities caused by smelting does not exceed 5.0 mass percent.

3. Electrical conductor arrangement according to claim 1, characterized in that the conductor profile (1) has a plurality of channels (2) which are separated from one another by internal webs (10, 11).

4. Electrical conductor arrangement system according to claim 3, characterized in that the or each channel (2) is designed for conveying a heat carrier medium and/or for being penetrated by a conductor or tube body.

5. Electrical conductor arrangement system according to claim 1, characterized in that the conductor profile (1) has at least one arc-shaped section (6-9).

6. The electrical conductor arrangement system as claimed in claim 5, characterized in that the conductor profile (1) has a curvature in the longitudinal direction.

7. The electrical conductor arrangement system as claimed in claim 6, characterized in that the arc-shaped sections (6-9) are produced in a bending technique.

8. Electrical conductor arrangement system according to claim 7, characterized in that the arc-shaped sections (6-9) are produced in a stretch bending technique or in an upsetting technique.

9. Electrical conductor arrangement system according to claim 1, characterized in that the conductor profile (1) has at least one heat conducting element and/or at least one profile element of increased stiffness on its outer surface.

10. The electrical conductor arrangement system as claimed in claim 1, characterized in that the conductor profile (1) has at least one heat-conducting element and/or at least one rib (13) on its outer surface.

11. Electrical conductor arrangement system according to claim 1, characterized in that a plurality of conductor profiles (1) are mutually coupled to form one conductor cable (14).

12. The electrical conductor arrangement system as claimed in claim 1, characterized in that the insulation (15) has at least one conductor channel (18).

13. Electrical conductor arrangement according to claim 12, characterized in that the channel (2) can be closed at the end side of the conductor profile (1) by a closure element (24).

14. Electrical conductor arrangement system according to claim 1, characterized in that at least one conductor profile (1) has at least one connection piece (23) which communicates with the channel (2).

15. The electrical conductor arrangement system as claimed in claim 1, characterized in that at least one conductor profile (1) has at least one coolant connection which communicates with the channel (2).

16. Electrical conductor arrangement system according to claim 1, characterized in that at least one conductor profile (1) has a contact surface (21) for connecting a functional element (22).

17. Electrical conductor arrangement system according to claim 1, characterized in that at least one contact face (21) is coated with a contact material having W_e＜7.9×10^-19Joule electronic work function and, starting from the light metal or its alloy from which the conductor profile is made, has at least one part of the following layer sequence: zinc, chromium, nickel, copper and/or silver.

18. Motor vehicle having an electrical conductor arrangement according to one of the claims 1 to 17.