EP2401747B1 - Electric component and method for producing an electric component - Google Patents

Description

The invention relates to an electrical component with an electrical conductor, wherein within the electrical conductor, a current path is predetermined with a current flow direction due to the connection of the ends of the electrical conductor to two electrical connection points within the electrical component. Furthermore, the invention relates to a method for producing an electrical component with a conductor.

The production of an electrical component, in particular a transformer with a winding as an electrical conductor, requires a high material and manufacturing costs. Conventionally, the electrical conductors of the electrical component are made of an electrically conductive copper wire or of an aluminum foil. The processing and manufacturing costs for the production of the electrical conductor and for introducing the electrical conductor into the electrical component is very high.

Furthermore, in the manufacture and manufacture of the electrical component, the thermal properties of the electrical

Component, such as heat generation and delivery during operation. The resulting during operation of the electrical component heat is ensured by means of known cooling configurations for electrical components, in particular transformers. In particular, the use of heat-conducting materials around the heat-generating windings and the introduction of vertical cooling channels within the electrical component allow the circulation of an ambient medium inside and outside the electrical component and thus a heat transfer from the electrical component to the surrounding medium.

As part of the design and manufacture of electrical components, the electrical properties of the electrical conductor of the electrical component are also crucial. In the prior art, some replacement materials for the electrical conductor, such as copper or aluminum, are known, which have a similar or better electrical conductivity, such as copper or aluminum windings.

For example, describes the EP 1 275 118 B1 an energy cable that has electrically conductive nanostructures and thereby ensures electrical conductivity of the power cable.

Furthermore, the describes EP 1 246 205 A1 an electrically conductive nanocomposite material. Due to an intrinsic nanostructure matrix within a polymer, an electrically conductive composite body is produced according to the aforementioned patent application.

US 2003/096104 A1 discloses carbon nanotubes in various orientations in a matrix to obtain different anisotropic thermal and electrical properties.

A problem with the solutions of the prior art is that the electrical components produced with nanostructures, although having an electrical conductivity, but not provide a solution for dissipating the heat generated during operation of the electrical component. In particular, with a reduced design of the electrical component results in an associated increased heat generation with deteriorated Wärmeleitfähigkeitseigenschaf-th due to the possible more compact design of the electrical component.

The object of the present invention is therefore to provide an electrical component and a method for producing an electrical component, which ensures a reduced construction compared to conventional electrical components with simultaneously improved heat dissipation.

The object is achieved by an electrical component having the features of patent claim 1.

The object is likewise achieved by a method for producing an electrical component according to the features of patent claim 13.

According to the invention, the electrical conductor has a mixture of carbon nanostructures with a preferred orientation with regard to the electrical conductivity along the direction of current flow and the heat arising during operation in the electrical conductor can be dissipated with an inner part to at least one outer surface of the electrical component, wherein the inner part a mixture of nanostructures with a preferred orientation with respect to the thermal conductivity on at least one of the outer surfaces of the electrical component comprises.

For the purposes of the present invention, the direction of current flow is understood to be the path of an electron within the electrical conductor from a first connection point to a second connection point within the electrical conductor. Nanostructures for the purposes of the present invention may be, in addition to carbon nanostructures, also other nanostructures, such as boron nitride nanostructures.

By combining carbon nanostructures with a preferred orientation with respect to the electrical conductivity along the current flow direction in combination with a nanostructure with a preferred orientation of the thermal conductivity on at least one of the outer surfaces of the electrical component, the electrical component can be designed smaller and at the same time the associated increased or worse Heat dissipation be ensured by an overall improved thermal conductivity of the inner part and thus of the electrical component.

Advantageously, the inner part of the electrical component at least partially surrounds the electrical conductor. As a result, the heat transfer from the electrical conductor to the inner part and thus to one of the outer surfaces of the electrical component is improved. In an advantageous embodiment of the electrical component, it is provided that the inner part at least partially electrically isolates the electrical conductor. In this case, the inner part of the electrical component forms not only as a connection for heat dissipation to at least one of the outer surfaces of the electrical component, but also serves for electrical insulation of the electrical conductor on the basis of a nanostructure. An additional expense for the insulation of the electrical conductor is eliminated when using the inner part as an insulator.

In order to reduce electromagnetic emissions of the electrical component, it is provided that the inner part comprises a semiconductive shield arranged around the electrical conductor. By incorporating an electromagnetic shield around the electrical conductor, effective electromagnetic shielding of the electrical conductor can be provided.

In an advantageous embodiment of the electrical component, it is provided that the inner part forms at least one of the outer surfaces of the electrical component and has a structured surface for improved heat dissipation to the surrounding medium. In particular, the formation of ribs and wavy surfaces serves to increase the heat-emitting surface and thus improves the heat transfer from the electrical component to the surrounding medium.

Advantageously, at least one of the outer surfaces of the electrical component is coated with a nanostructure having moisture and / or dirt repellent properties. Due to a moisture and / or dirt-repellent coating, the electrical component, in particular the transformer, can also be operated in moist and dirt-prone environments. Advantageously, the inner part comprises a polymer, wherein in the polymer, the mixture of carbon nanostructures and / or nanostructures can be introduced. Thus, into the polymer can be introduced the carbon nanostructures with a preferred orientation with respect to the electrical conductivity, a mixture of nanostructures with a preferred orientation with respect to the thermal conductivity. Also, an outer surface of the electrical component in direct contact with the inner part may have a moisture and / or dirt-repellent nanostructure. In particular, the use of a film as a polymer can be applied to the inner part, so that the electrically conductive and / or thermally conductive and / or moisture / dirt-repellent properties of the carbon nanostructures and / or nanostructures can be applied to the inner part, in particular adhesively bonded.

In an advantageous embodiment of the electrical component is provided that the electrical conductor exclusively of a mixture of carbon nanostructures having a preferred orientation with respect to electrical conductivity along the direction of current flow. The exclusive use of carbon nanostructures makes it possible to dispense with previously conventionally used conductor materials, such as copper and aluminum.

Advantageously, the concentration of the mixture of carbon nanostructures and / or nanostructures within the conductor of the electrical component varies. This results in the possibility of adjusting the concentration and orientation of the mixture of carbon nanostructures and / or nanostructures to the required current density and / or heat flux density.

It is considered an advantage that the concentration of the mixture of carbon nanostructures and / or nanostructures in mechanically stressed regions within the conductor is increased. This offers the advantage that due to the good mechanical strength properties of the carbon nanostructures and / or nanostructures mechanical forces occurring within the conductor can be well received or forwarded. In particular, the inclusion of short-term high short-circuit forces within the conductor can be absorbed by appropriate concentration of the mixture of carbon nanostructures and / or nanostructures and thus damage to the conductor or even the electrical component can be avoided. Furthermore, by means of a selected concentration of the mixture of carbon nanostructures and / or nanostructures, mechanical tension elements can be formed within the conductor and thus static forces, such as, for example, the weight force, can be forwarded to fastening elements located outside the conductor.

According to the invention, it is further provided that during operation in the electrical conductor consisting of carbon nanostructures with a preferred orientation with respect to the electrical conductivity along the current flow direction, the resulting heat with an inner part to at least one outer surface of the electrical component can be dissipated, the inner part of a mixture of Nanostructures with a preferred orientation with respect to the thermal conductivity is formed on at least one of the outer surfaces of the electrical component.

In an advantageous embodiment of the method it is provided that the electrical conductor is embedded in a support structure, in particular a polyamide structure, wherein in the support structure, the mixture of nanostructures with a preferred orientation of the thermal conductivity is embedded at least in contact with one of the outer surfaces of the electrical component ,

The mixture of carbon nanostructures and / or nanostructures is advantageously embedded in the support structure, in particular in a polyamide, by means of electrophoresis. By means of the electrophoresis method, the concentration and the local distribution of the carbon nanostructures and / or nanostructures within the support structure can be specified in a targeted and very precise manner. Advantageously, a semiconducting shield is also integrated into the support structure as part of the inner part.

Fig. 1

eine halbseitige Schnittzeichnung eines Transformators als elektrisches Bauteil mit zwei separaten Nanostrukturen;

Fig. 2

eine halbseitige Schnittzeichnung eines elektrischen Bauteils mit zwei Innenteilen und kombinierten Nanostrukturen;

Fig. 3

eine halbseitige Schnittzeichnung mit zwei Innenteilen und kombinierten elektrischen Wicklungen und wärmeleitfähigen Nanostrukturen;

Fig. 4

eine halbseitige Schnittzeichnung mit drei Innenteilen und definierten elektrisch und wärmeleitfähigen Nanostrukturen;

Fig. 5

eine Darstellung der elektrisch und wärmeleitfähigen mikroskopischen Nanostrukturen innerhalb des Innenteils;

Fig. 6

eine Schnittzeichnung der Oberflächenstruktur an einer der Außenfläche des elektrischen Bauteils;

Fig. 7

eine Schnittzeichnung der Oberflächenstruktur mit einer schmutzabweisenden Nanostrukturbeschichtung an einer der Außenfläche des elektrischen Bauteils;

Fig. 8

eine Aufsicht auf drei elektrische Bauteile kombiniert zu einem Dreiphasen-Transformator.

Further advantageous embodiments will be apparent from the dependent claims. The figures show:

Fig. 1

a half-sectional view of a transformer as an electrical component with two separate nanostructures;

Fig. 2

a half-sectional view of an electrical component with two inner parts and combined nanostructures;

Fig. 3

a half-side sectional drawing with two internal parts and combined electrical windings and thermally conductive nanostructures;

Fig. 4

a half-side sectional drawing with three inner parts and defined electrically and thermally conductive nanostructures;

Fig. 5

a representation of the electrically and thermally conductive microscopic nanostructures within the inner part;

Fig. 6

a sectional view of the surface structure on one of the outer surface of the electrical component;

Fig. 7

a sectional view of the surface structure with a dirt-repellent nanostructure coating on one of the outer surface of the electrical component;

Fig. 8

a plan view of three electrical components combined to form a three-phase transformer.

The FIG. 1 shows a half-side sectional view of a transformer as an electrical component la with a carbon nanostructure 3 and a nanostructure 6. Through a core 4 of the transformer la, the cut line, which is indicated by a dashed line. An inner part 2a has a layer by layer electrically conductive structure. An electrically conductive layer as an electrical conductor 5a in the FIG. 1 located. The individual electrically conductive layers are separated from one another by insulating layers, the layered structure of the inner part 2a being realized within a matrix with a mixture of carbon nanostructures 3 with a preferred orientation with respect to the electrical conductivity along the direction of current flow.

The conductors 5a, windings or winding parts formed from the carbon nanostructures 3 are preferably embedded in a polyamide. The inner part 2a comprises a semiconducting shield 10. This is followed by a layer of a mixture of nanostructures 6 with a preferred orientation with respect to the thermal conductivity on at least one of the outer surfaces 9 of the electrical component 1a, 1b, 1c of the inner part 2a. Preferably, a mixture of nanostructures 6 with low electrical but high thermal conductivity is used, for example boron nitride carbon nanostructures.

A half-side sectional drawing of an electrical component 1a with two inner parts 2a, 2b and combined carbon nanostructure 3 and nanostructure 6 is shown in FIG FIG. 2 shown. The inner parts 2a, 2b have a layered structure of the electrical conductors 5a, 5b, 5c, 5d, 5e, 5f of a mixture of carbon nanostructures 3 with a preferred orientation with respect to the electrical conductivity along the direction of current flow. Between the electrical conductors 5a, 5b, 5c, 5d, 5e, 5f is a mixture of nanostructures 6 with a preferred orientation with respect to the thermal conductivity on at least one of the outer surfaces 9 of the electrical component 1a, 1b, 1c comprises. Between the inner parts 2a, 2b, a cooling channel 7a for additional cooling of the electrical components 2a, 2b is arranged.

The FIG. 3 shows a half-side sectional view with two inner parts 2a, 2b and combined electrical windings 5a, 5b and thermally conductive nanostructures 6 of an electrical component 1a. Within a matrix of thermally conductive nanostructures 6, winding conductors 5a, 5b are embedded with electrically conductive carbon nanostructures 3.

A half-side sectional drawing with three inner parts 2a, 2b, 2c and defined electrically and thermally conductive carbon nanostructure 3 with nanostructure 6 is shown in FIG FIG. 4 shown. The inner parts 2a, 2b, 2c are designed as cylinders and consist of a mixture with thermally conductive nanostructures 6. The cylinders have bays to one of the outer surfaces 9 of the electrical component 1a into which the mixture of electrically conductive carbon nanostructures 3 is introduced and thus an electric Ladder 5a, 5b, 5c, 5d, 5e, 5f forms. The thus formed electrical windings 5a, 5b, 5c, 5d, 5e, 5f of the individual internal parts 2a, 2b, 2c can be electrically connected by means of electrical connectors 8. The individual inner parts 2a, 2b, 2c are spaced apart relative to one another, so that the intermediate spaces thus created serve as cooling channels 7a, 7b.

The FIG. 5 shows a representation of the electrical and thermally conductive microscopic carbon nanostructure 3 with nanostructure 6 within the inner part 2a. Conductors or winding parts formed from electrically conductive carbon nanostructures 3 preferably oriented in the direction of current flow 5a form a first region within the microscopic structure of the inner part 2a. Thermally conductive nanostructures 6 with high thermal conductivity, preferably in the direction of the desired heat flow, form secondary regions that are clearly separated within the microscopic structure.

The substantial size reduction allows the concept of compact encapsulated and I or shielded systems or complete plant structures. By means of this electrical component results in the possibility to design a complete substations as a composite. It is possible to design complete encapsulated complete systems, which may include, for example, several transformers, chokes, converters, current limiters, safety and monitoring devices and switching devices.

In FIG. 6 is a sectional drawing of the surface structure and in the FIG. 7 a sectional view of the surface structure with a dirt-repellent nanostructure coating on one of the outer surface 9 of the electrical component 2a shown.

To improve the heat transfer to the surrounding medium, it is necessary that the surface is enlarged by a rib structure 8. These ribs 8 are inventively designed so that thermally conductive nanostructures 6 with very good thermal conductivity and high electrical resistance not only in the potting compound of the winding 5a (not shown) are introduced, but are arranged so that they transport the heat into the cooling fins. 8 take.

The density of the thermally conductive nanostructures 6 is expediently in the transition zone to the rib 8 particularly high in order to achieve a favorable ratio of increasing the rib efficiency to the cost of the thermally conductive nanostructures 6.

To achieve a moisture and / or dirt repellent surface, the introduction of dirt and / or moisture-repellent nanostructures 11 on the outer surface 9 of the potting compound is possible; similar to so-called easy-toclean coatings). In special cases, this can also take place by means of a film containing dirt and moisture-repellent nanostructures 11 or a lacquer containing dirt and moisture-repellent nanostructures 11. If the electrical components 1a used under water, it comes to a very favorable cooling, so that additional cooling devices can be omitted.

Due to the risk of a heat-insulating layer due to fouling, fouling processes or crust formation, the coating with a dirt and moisture-repellent nanostructures 11 prevents the above-mentioned surface processes.

Internal leakage effects limit the short-circuit current within a single electrical conductor 5a made of electrically conductive carbon nanostructures 3 (not shown). By reducing the number of so-called parallel connected nanowires of the electrically conductive carbon nanostructures 3 in a transition region, current-limiting elements can be incorporated into the electrical components 1a (not shown) in the routing, implementation or in certain areas of the electrical conductors 5a.

The FIG. 8 shows a plan view of three electrical components 1a, 1b, 1c combined to a three-phase transformer. The Cores 4 (not visible) are connected by a yoke. The inner and the outer side of the winding body as electrical components 1a, 1b, 1c are coated with a thermally conductive nanostructures 6.

The novel combination of different carbon nanostructures 3 and nanostructures 6, 11 and as electrical components 2 a, 2 b, 2 c, 5 a, 5 b, 5 c, 5 d, 5 e, 5 f of the electrical component 1 a, 1 b, 2 b affords the possibility of forming the carbon nanostructures 3 and to arrange nanostructures 6, 11 on the basis of different dopings, orientations and spatial distributions in a matrix and thus to provide a compact electrical component.

With this structure, it is possible, for example, to use the electrical conductor with aligned electrically conductive carbon nanostructures 3 as alignment electrodes.

The placement of semiconductive shields in the inner parts 2a, 2, b, 2c, a linkage and / or field control is possible. By using electrically conductive carbon nanostructures 3, the electrical losses are reduced compared to conventional conductors and at the same time a good dissipation of the heat loss to the outside is ensured. The absence of internal cooling media and the high thermal stability of the thermally conductive nanostructures 6 allow the operation of the electrical component 1a, 1b, 1c at very high temperatures. As a result, the effectiveness of cooling over the outer surfaces is extremely increased.

The embedding of the electrical conductor 2a, 2b, 2c, 5a, 5b, 5c, 5d, 5e, 5f in a thermally conductive nanostructures 6 leads to a high mechanical strength of the entire inner part 2a, 2b, 2c.

At the same time an extreme reduction in the size and mass of the electrical component is possible, so that extremely robust and compact electrical devices - such as compact transformers in the smallest form for high-voltage applications - can be built. In addition, the substantial reduction in size allows the design of novel compact systems. Thus compact power station or compact system of transformers, chokes, transducers, current limiters and safety devices are conceivable with the present invention.

Claims (18)

1. Electric component (1a, 1b, 1c) comprising an electric conductor (5a, 5b, 5c, 5d, 5e, 5f), wherein inside the electric conductor (5a, 5b, 5c, 5d, 5e, 5f) a current path having a current flow direction is specified because of the ends of the electric conductor (5a, 5b, 5c, 5d, 5e, 5f) being connected to two electric connection points inside the electric component (1a, 1b, 1c), characterized in that the electric conductor (5a, 5b, 5c, 5d, 5e, 5f) exhibits a mixture of carbon nanostructures (3) having a preferred orientation with respect to the electric conductivity along the current flow direction and the heat produced during the operation in the electric conductor (5a, 5b, 5c, 5d, 5e, 5f) can be removed to at least one outside surface (9) of the electric component (1a, 1b, 1c) by means of an inner part (2a, 2b, 2c), the inner part (2a, 2b, 2c) comprising a mixture of nanostructures (6) having a preferred orientation with respect to the thermal conductivity to at least one of the outside surfaces (9) of the electric component (1a, 1b, 1c).
2. Electric component (1a, 1b, 1c) according to Claim 1, characterized in that the inner part (2a, 2b, 2c) encloses the electric conductor (5a, 5b, 5c, 5d, 5e, 5f) at least partially.
3. Electric component (1a, 1b, 1c) according to Claim 2, characterized in that the inner part (2a, 2b, 2c) electrically insulates the electric conductor at least partially.
4. Electric component (1a, 1b, 1c) according to one of Claims 1 to 3, characterized in that the inner part (2a, 2b, 2c) comprises an electric shielding (10) arranged around the electric conductor (5a, 5b, 5c, 5d, 5e, 5f).
5. Electric component (1a, 1b, 1c) according to one of Claims 1 to 4, characterized in that the inner part (2a, 2b, 2c) forms at least one of the outside surfaces (9) of the electric component (1a, 1b, 1c) and has a structured surface (8) for the improved heat delivery to an environmental medium.
6. Electric component (1a, 1b, 1c) according to one of Claims 1 to 5, characterized in that at least one of the outside surfaces (9) of the electric component (1a, 1b, 1c) is coated with a nanostructure (11) having moisture- and/or dirt-repelling characteristics.
7. Electric component (1a, 1b, 1c) according to one of Claims 3 to 6, characterized in that the inner part (2a, 2b, 2c) comprises a polymer, wherein carbon nanostructures (3) and/or nanostructures (6, 11) can be inserted into the polymer.
8. Electric component (1a, 1b, 1c) according to Claim 7, characterized in that the polymer can be applied to the inner part (2a, 2b, 2c) as a foil.
9. Electric component (1a, 1b, 1c) according to one of Claims 1 to 8, characterized in that the electric conductor (5a, 5b, 5c, 5d, 5e, 5f) consists exclusively of the mixture of carbon nanostructures (3) having a preferred orientation with respect to the electric conductivity along the current flow direction.
10. Electric component (1a, 1b, 1c) according to one of Claims 1 to 9, characterized in that the concentration of the mixture of carbon nanostructures (3) and/or nanostructures (6, 11) varies within the conductor (5a, 5b, 5c, 5d, 5e, 5f).
11. Electric component (1a, 1b, 1c) according to one of Claims 1 to 10, characterized in that the concentration of the mixture of carbon nanostructures (3) and/or nanostructures (6, 11) is increased in mechanically loaded regions within the conductor (5a, 5b, 5c, 5d, 5e, 5f).
12. Electric component (1a, 1b, 1c) according to one of Claims 1 to 11, characterized in that the electric component (1a, 1b, 1c) is a transformer, a choke or a coil and the electric conductor (5a, 5b, 5c, 5d, 5e, 5f) comprises at least one part-winding.
13. Method for producing an electric component (1a, 1b, 1c) comprising an electric conductor (5a, 5b, 5c, 5d, 5e, 5f), wherein inside the electric conductor (5a, 5b, 5c, 5d, 5e, 5f) a current path having a current flow direction is formed because of the ends of the electric conductor (5a, 5b, 5c, 5d, 5e, 5f) being connected to two connection points inside the electric component (1a, 1b, 1c) and the heat produced during the operation in the electric conductor (5a, 5b, 5c, 5d, 5e, 5f) can be removed to at least one outside surface (9) of the electric component (1a, 1b, 1c) by means of an inner part (2a, 2b, 2c), the inner part (2a, 2b, 2c) being formed of a mixture of nanostructures (6) having a preferred orientation with respect to the thermal conductivity to at least one of the outside surfaces (9) of the electric component (1a, 1b, 1c).
14. Method according to Claim 13, characterized in that the electric conductor (5a, 5b, 5c, 5d, 5e, 5f) is embedded into a carrier structure, particularly a polyamide structure, the mixture of nanostructures (6) having a preferred orientation with respect to the thermal conductivity to at least one of the outside surfaces (9) of the electric component (1a, 1b, 1c) being embedded into the carrier structure.
15. Method according to one of Claims 13 to 14, characterized in that a semiconducting shielding (10) is integrated into the carrier structure as a component of the inner part (2a, 2b, 2c).
16. Method according to one of Claims 13 to 15, characterized in that at least one of the outside surfaces (9) of the electric component (1a, 1b, 1c) is coated with a nanostructure (11) having moisture- and/or dirt-repelling characteristics.
17. Method according to one of Claims 13 to 16, characterized in that the mixture of carbon nanostructures (3) and/or nanostructures (6, 11) is inserted in a defined manner into the carrier structure by means of electrophoresis.
18. Method according to one of Claims 13 to 17 for producing an electric component (1a, 1b, 1c) according to one of Claims 1 to 12.

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