High-voltage components of the high-voltage on-board electrical network in at least partially electrically driven motor vehicles

Abstract

The present invention relates to a high-voltage component (1) for a high-voltage on-board electrical network (10) of a motor vehicle (20) that is at least partially electrically driven, the high-voltage component comprising a housing (2) for power electronics (3) of the high-voltage on-board electrical network (10), such as an inverter (13). Here, the housing (2) provides a shielding device (4) for reducing electromagnetic interference. The shielding device (4) comprises a non-conductive housing body (12) of the housing (2) and an electrical discharge path (5) at least partially disposed on and / or therein of the housing body (12) and capable of being connected to a vehicle reference potential (30). The invention also relates to a method of manufacturing the high-voltage component (1) for a high-voltage on-board electrical network (10) of a motor vehicle (20) that is at least partially electrically driven.

Description

Technical Field

[0001] This invention relates to a high-voltage component for a high-voltage on-board electrical network in a motor vehicle that is at least partially electrically driven. The high-voltage component includes at least one housing device for at least one power electronic device used in the high-voltage on-board electrical network. The invention also relates to a method for manufacturing the high-voltage component. Background Technology

[0002] In pure electric vehicles and hybrid vehicles, high-voltage on-board power grids, with their correspondingly high electrical power, constitute a significant source of electromagnetic interference. Therefore, electromagnetic compatibility (EMV) is a crucial topic in the development of high-voltage on-board power grids and their electrical components. Generally, power electronic devices, and especially inverters, have a particularly decisive impact on EMV.

[0003] Therefore, power electronic devices are typically equipped with what are known as EMV filters. These filters are sometimes housed together with intermediate circuit capacitors and power semiconductors in a shared housing to protect the sensitive electronic components. In the prior art, such housings are typically made of aluminum. Here, the housing serves primarily to mechanically stabilize the various components of the inverter and simultaneously to decouple the remaining components of the electric drive system. To prevent common-mode interference caused by leakage current, the housing is generally electrically connected to the vehicle chassis. Electrical components located within the housing are typically electrically connected to the housing itself. Summary of the Invention

[0004] In contrast, the object of the present invention is to improve the EMV characteristics of high-voltage vehicle-mounted power grids in a manner that is both structurally inexpensive and saves structural space.

[0005] This objective is achieved by the high-voltage component of the present invention. Preferred improvements to the invention are obtained from preferred embodiments. Other advantages and features of the invention are derived from the overview and description of embodiments.

[0006] The high-voltage component according to the invention is provided and designed for a high-voltage on-board electrical network of at least partially electrically driven motor vehicles. The high-voltage component includes at least one housing device for at least one power electronic device (particularly composed of a plurality of interconnected electronic components and / or modules) for the high-voltage on-board electrical network. Preferably, the housing device is adapted and designed to house at least one inverter, and particularly preferably for housing a pulse inverter (PWR). Here, the housing device at least partially provides at least one shielding device for reducing electromagnetic interference (particularly that may be emitted by the power electronic device). Here, the shielding device includes at least one non-conductive housing body of the housing device. The shielding device includes at least one electrical discharge path (particularly for leakage current) arranged at least partially on and / or in the housing body. The discharge path can be electrically connected to a vehicle reference potential.

[0007] The high-voltage components according to the invention have many advantages. A significant advantage lies in providing shielding through the housing assembly with its non-conductive housing body and the electrical discharge path connected thereto. This significantly improves the EMV characteristics of high-voltage vehicle-mounted power grids. For example, it significantly reduces electromagnetic interference caused by inverters. The non-conductive housing body also provides a particular advantage, as leakage current flows only specifically along the discharge path designed for this purpose. Currently common metal housing bodies are simply unsuitable for shielding because arbitrary paths for leakage current are generated everywhere. Here, the invention provides a way to improve EMV in a constructionally low-cost and particularly economical manner. It is also particularly advantageous to have functional integration into the housing assembly, thus allowing the shielding to be placed in a particularly space-saving manner or even without requiring additional structural space.

[0008] The housing body is particularly preferably made of plastic material. Specifically, it is made of at least one type of plastic. Using plastic allows for the creation of a non-conductive and stable housing body. Furthermore, such a housing body allows for a particularly high degree of freedom in terms of geometry and design. This generally increases the versatility of variations, thereby saving structural space and weight. To date, inverter housings in the prior art have been manufactured using aluminum die-casting or cold-casting processes, thus limiting the degree of freedom in geometric design due to the required die-cast profiles. Therefore, this restricts the increase in versatility when mass-producing inverters for electric vehicles.

[0009] Particularly preferably, the housing body is manufactured using at least one additive manufacturing process. Such a housing body is particularly well-suited for shielding devices and can be specifically adapted to the requirements for shielding and protecting the components it houses. Alternatively, the housing body can be manufactured using at least one additional prototyping process suitable for plastic materials.

[0010] In a preferred and particularly advantageous design, the exit path is at least partially integrated into the housing body. The exit path is particularly at least partially completely surrounded by the material of the housing body. The exit path is particularly at least partially connected to the housing body. The exit path is particularly at least partially fixed and preferably cannot be loosened without damage from the housing body. The exit path and the housing body can be interconnected in a material-fitting manner. The exit path is particularly at least partially integrated at at least two adjacent walls of the housing body that extend laterally to each other.

[0011] Preferably, the integral connection between the export path and the housing body is established at least partially within the scope of the prototyping process used to produce the housing body. Particularly preferably, the integral connection between the export path and the housing body is established through an additive manufacturing process of the housing body. In other words, the export path is integrated into the housing body in such a way that it is embedded into the housing body during the molding of the housing body, and preferably during its additive manufacturing. It can also be achieved that the export path is connected to the housing body at least partially after molding, and preferably integrated into the housing body. For example, this can be done by attaching and, for example, bonding or inserting the export path into a recess in the housing body.

[0012] Particularly preferred and advantageous is that the outlet path is provided at least sectionally by fibers embedded in the housing body. The outlet path particularly includes such fibers. The outlet path is particularly constructed of such fibers. Conductive fibers are provided for this purpose. The fibers are interconnected, particularly in a manner that constitutes a continuous electrical conductor. Thus, the outlet path can be manufactured with particularly low cost and at the same time with particular focus (e.g., in terms of the orientation geometry described below).

[0013] Within the scope of this invention, the term "fiber" can also be understood, in particular, as other types of smaller conductive portions that can be embedded in the housing body to provide a continuous conductor. Such fibers can be provided, for example, through conductive portions or corresponding shorter wire segments. Outgoing paths can be provided, at least segmentally, through wires embedded in the housing body.

[0014] It is feasible and advantageous for the shielding device to have at least one connection unit (particularly arranged within the housing). The power electronics housed within the housing are electrically contacted with the discharge path, particularly by means of the connection unit. Therefore, leakage current from the power electronics can be transferred to the discharge path via the connection unit. The connection unit is particularly electrically contacted with the discharge path. The connection unit is particularly arranged within the receiving space of the housing for housing the power electronics. The connection unit is particularly arranged on the housing body, and preferably on the inner side of the housing body. Components of the power electronics can individually and / or at least partially in groups contact the at least one connection unit.

[0015] It is also preferred and advantageous that the shielding device has at least one connection point (particularly arranged outside the housing). The lead-out path makes electrical contact with the vehicle reference potential, and particularly with the vehicle chassis, particularly by means of the connection point. The connection point makes electrical contact with the lead-out path, particularly. The lead-out path extends, particularly between the connection unit and the connection point. The connection point is particularly arranged outside the receiving space of the housing for accommodating power electronic devices.

[0016] The lead-out path preferably has at least one directional geometry. In a particularly advantageous design, the lead-out path has a directional geometry and is adapted and designed to at least partially reduce electromagnetic radiation (especially that which may be emitted by power electronics during operation) by means of the directional geometry. The directional geometry is also used, in particular, to reduce electromagnetic radiation caused by leakage current, and especially by current in the lead-out path. The directional geometry is particularly designed such that the magnetic and / or electric fields caused by leakage current do not reinforce each other and are preferably at least partially compensated for or even eliminated. Electromagnetic radiation can be further reduced by such a directional geometry.

[0017] In particular, the orientation geometry of at least the exit path is integrated into the housing body. The exit path has this orientation geometry, particularly in sections between connecting units and connecting portions. The orientation geometry extends, particularly along at least two adjacent walls of the housing body, and preferably laterally extending from each other. The exit path extends, particularly along at least one cover surface of the housing body and at least one side surface extending laterally from the cover surface. The orientation geometry includes at least one change of direction, and preferably includes multiple targeted changes of direction along the exit path within the housing body. The orientation geometry, for example, has exit sections extending laterally from each other (particularly in a common plane).

[0018] Preferably, the routing geometry is designed so that the magnetic fields generated during the operation of the power electronics as current flows through the lead-out path can be specifically mutually compensated. Preferably, this can also reduce the electric fields generated due to time variations in the magnetic field. The magnetic field is understood herein, in particular, as magnetic flux density (also known in technical terms as the so-called B field). The electric field is understood herein, in particular, as electric field strength (also known in technical terms as the so-called E field).

[0019] The high-voltage component may include at least one power electronic device and preferably at least one inverter, and particularly preferably at least one pulse inverter (PWR). The high-voltage component particularly includes such a power electronic device housed in a housing body and at least partially shielded by a shielding device. The power electronic device is electrically connected to the output path, particularly via a connection unit. The power electronic device is electrically contacted with the vehicle reference potential, particularly via a connection point. Here, the power electronic device may include at least one component selected from the group consisting of: an inverter, and preferably a pulse inverter, an EMV filter, an intermediate circuit capacitor, a power module, a power semiconductor, a DC rail, and an AC rail.

[0020] Power electronics are particularly suitable for and designed for controlling at least one electric motor, and preferably for controlling an electric drive, such as a permanent magnet synchronous motor. In particular, power electronics are suitable for and designed for generating alternating current or voltage of a defined frequency from direct current or direct current from a high-voltage battery. The power electronics can adjust the frequency, in particular, according to driving operation and, for example, power requirements.

[0021] The method according to the invention is used to manufacture high-voltage components for a high-voltage on-board electrical system of a motor vehicle that is at least partially electrically driven. The high-voltage component includes at least one housing device for at least one power electronic device for the high-voltage on-board electrical system. The housing device at least partially provides at least one shielding device for reducing electromagnetic interference. To provide the shielding device, at least one non-conductive housing body is formed, and preferably formed by an additive manufacturing process. At least one electrical discharge path is designed on and / or therein of the housing body. The discharge path is in particular in electrical contact with the power electronic device and in electrical contact with a vehicle reference potential.

[0022] The method according to the invention also advantageously achieves the above-mentioned objectives. The method is particularly designed to enable the manufacture of high-voltage components or designs thereof according to the invention. High-voltage components according to the invention can be manufactured, in particular, according to this method.

[0023] In particular, the outlet path is integrated into the housing body. Conductive portions, and especially fibers, are added to and embedded in a non-conductive material, and preferably in the plastic material of the housing body. Particularly preferably, the outlet path is created by embedding conductive fibers, and preferably formed simultaneously with the molding of the housing body. The conductive fibers are embedded particularly during the additive manufacturing of the housing body.

[0024] The applicant reserves the right to claim protection for at least partially electrically driven motor vehicles having at least one high-voltage component, the motor vehicle including, according to the invention, at least one high-voltage component according to the invention.

[0025] Within the scope of this invention, the vehicle reference potential is particularly understood to be zero potential or other potential provided by operation. The vehicle reference potential corresponds particularly to the potential of the vehicle mass and, for example, the vehicle chassis. Connection to the vehicle reference potential corresponds particularly to connection to the vehicle mass and, for example, the vehicle chassis. Within the scope of this invention, conductivity is particularly related to the voltage or current expected during the intended operation.

[0026] Shielding devices are particularly used to shield against EMV-related interference. Shielding devices are especially suitable for and designed to (by means of a lead-out path) cancel common-mode and / or differential-mode interference. A shielding device can be part of a shielding system that includes other components for reducing electromagnetic interference. The shielding system may, for example, include at least one EMV filter. Other components of the shielding system are operatively connected to the shielding device. However, the shielding device can also be formed separately.

[0027] The lead-out path is particularly designed to facilitate leakage current flow toward the vehicle reference potential and especially toward the vehicle chassis. The lead-out path particularly includes at least one, and preferably at least two or more lead-out sections. These lead-out sections are particularly electrically connected to each other. For example, the individual lead-out sections constitute a branched lead-out path design. The lead-out path is particularly suitable for and designed to facilitate leakage current flow toward the vehicle reference potential. The lead-out path is particularly suitable for and designed to compensate for common-mode interference and / or differential-mode interference.

[0028] The housing body particularly provides mechanical protection for power electronic devices and, more preferably, for inverters. The housing body particularly provides at least a housing space for the inverter. The housing body is particularly used to house (all) components belonging to the inverter. The housing body is especially an inverter housing. In particular, the housing body is used to house not only individual components of the inverter, such as diodes. The housing assembly may include additional housing portions, such as mounting devices for fastening the housing body, etc. It is possible that at least one additional housing element supports the mechanical function of the housing body. Attached Figure Description

[0029] Other advantages and features of the present invention are derived from the embodiments, which will be described below with reference to the accompanying drawings.

[0030] In the attached diagram:

[0031] Figure 1 A schematic diagram showing the height of a high-voltage vehicle-mounted power grid having high-voltage components according to the present invention; and

[0032] Figure 2 Show Figure 1 Detailed illustration of the high-voltage components. Detailed Implementation

[0033] Figure 1 The diagram illustrates a high-voltage component 1 according to the invention for a high-voltage on-board electrical grid 10 of an electrically driven motor vehicle 20, not shown in further detail herein. The high-voltage component 1 comprises a housing assembly 2 having a non-conductive housing body 12 and is manufactured according to the method of the invention. The housing body 12 is used to house power electronics 3, which are designed herein as an inverter 13 and, for example, as a pulse inverter.

[0034] The high-voltage on-board electrical network 10 includes a high-voltage battery 50 and an electric machine 60 designed as a permanent magnet synchronous motor for driving. The power electronics 3 provides the alternating current required by the machine 60 based on the direct current from the high-voltage battery 50. The machine 60 can be controlled by the frequency of the alternating current. For this purpose, the power electronics 3 is exemplarily equipped only with an EMV filter 23, an intermediate circuit capacitor 33, a power module 43 having multiple power semiconductors 53, a DC rail 63, and an AC rail 73. Components housed within the housing body 12 are also indicated herein.

[0035] To reduce electromagnetic interference emitted by the inverter 13 during operation, a shielding device 4 is provided. The housing body 12 constitutes the main part of the shielding device 4. Furthermore, the shielding device 4 includes an electrical discharge path 5 connected to the vehicle reference potential 30 via one or more connection points 35. The vehicle reference potential 30 is, for example, provided by the vehicle chassis 40.

[0036] Within the housing body 12, the outlet path 5 is electrically connected to the power electronics 3 and, for example, to the power module 43 via one or more connection units 25. Leakage current can flow out to the vehicle chassis 40 via the outlet path 5 to eliminate, for example, common-mode interference and / or differential-mode interference.

[0037] exist Figure 2 The shielding device 4, comprising the housing body 12 and the outlet path 5, is shown in detail. The inverter 13, not visible here, is located inside the housing body 12. For better visualization, the housing body 12 is shown transparently in this section, revealing the internal connection unit 25 and the embedded outlet path 5. The outlet path 5 contacts the vehicle chassis 40 externally via a connection portion 35.

[0038] The exit path is integrally integrated into the housing body 12. Conductive fibers 15 are embedded therein during the molding of the housing body 12. In the example shown here, the housing body 12 is made of plastic material using an additive manufacturing process. During additive manufacturing, the fibers 15 are specifically embedded into specific areas of the housing body 12. This targeted distribution of the fibers 15 results in a specific orientation geometry 6 of the exit path 5 within the housing body 12. The geometry of the housing body 12 and the orientation geometry 6 of the exit path 5 are only shown here as an example and are simplified.

[0039] The routing geometry 6 is designed such that the magnetic fields generated when current flows through the outlet path 5 can at least partially compensate for each other. It also reduces the electric field that would otherwise be generated due to the time-varying nature of the magnetic field. This intelligent shaping of the routing geometry 6 of the outlet path 5 can significantly reduce electromagnetic radiation.

[0040] A particular advantage of this invention is that a defined path for leakage current is formed by combining the non-conductive housing body 12 with the conductive discharge path 5. This allows for compensation of the B-field and thus reduces the E-field. Simultaneously, it effectively prevents arbitrary and uncontrollable leakage current outside the electrical discharge path 5. Undesirable low-impedance capacitive paths for leakage current are also prevented in this invention. Therefore, electromagnetic radiation can be significantly reduced and overall electromagnetic compatibility can be significantly improved.

[0041] List of reference numerals in the attached diagram:

[0042]

Claims

1. A high-voltage component (1) for a high-voltage on-board electrical network (10) of a motor vehicle (20) that is at least partially electrically driven, the high-voltage component comprising at least one housing device (2) for at least one power electronic device (3) of the high-voltage on-board electrical network (10). Its features are, The housing device (2) provides at least a shielding device (4) for reducing electromagnetic interference, and the shielding device (4) includes at least one non-conductive housing body (12) of the housing device (2) and at least one electrical outgoing path (5) disposed at least partially on and / or in the housing body (12) and capable of being connected to a vehicle reference potential (30), wherein the outgoing path (5) has a directional geometry (6) and is adapted and designed to at least partially reduce electromagnetic radiation that can be emitted by the power electronics (3) during operation by means of the directional geometry (6), wherein the directional geometry (6) is designed such that the magnetic fields generated when current flows through the outgoing path (5) during operation of the power electronics (10) can be selectively compensated for each other, and wherein the electric field caused by time variation of the magnetic field can also be reduced.

2. The high-voltage component (1) according to claim 1, wherein the housing body (12) is made of plastic material.

3. The high-voltage component (1) according to claim 1 or 2, wherein the housing body (12) is manufactured by additive manufacturing.

4. The high-voltage component (1) according to claim 1 or 2, wherein the outgoing path (5) is at least partially integrated into the housing body (12).

5. The high-voltage component (1) according to claim 1 or 2, wherein the integral connection between the outgoing path (5) and the housing body (12) is established within the scope of the prototyping process used to produce the housing body (12).

6. The high-voltage component (1) according to claim 1 or 2, wherein the outlet path (5) is provided at least in sections by fibers (15) embedded in the housing body (12).

7. The high-voltage component (1) according to claim 1 or 2, wherein the shielding device (4) has at least one connection unit (25) and the power electronics (3) disposed in the housing device (2) is electrically contacted with the outgoing path (5) by means of the at least one connection unit.

8. The high-voltage component (1) according to claim 1 or 2, wherein the shielding device (4) has at least one connection portion (35) and the outgoing path (5) is electrically contacted with the vehicle reference potential (30) by means of the at least one connection portion.

9. The high-voltage component (1) according to claim 1 or 2, wherein the high-voltage component includes at least one power electronic device (3) housed in the housing body (12) and at least partially shielded by the shielding device (4).

10. The high-voltage component (1) according to claim 1 or 2, wherein the at least one power electronic device (3) is an inverter (13).

11. The high-voltage component (1) according to claim 8, wherein a vehicle chassis (40) is provided as the vehicle reference potential (30).

12. A method for manufacturing a high-voltage component (1) for a high-voltage on-board electrical network (10) of a motor vehicle (20) that is at least partially electrically driven, wherein the high-voltage component (1) comprises at least one housing device (2) for at least one power electronic device (3) of the high-voltage on-board electrical network (10), wherein the housing device (2) at least partially provides at least one shielding device (4) for reducing electromagnetic interference, and wherein at least one non-conductive housing body (12) is formed to provide the shielding device (4), and wherein at least one [missing information] is designed on and / or in the housing body (12). An electrical discharge path (5), wherein the discharge path (5) is in electrical contact with the power electronics (3) and with the vehicle reference potential (30), wherein the discharge path (5) has a directional geometry (6) and is adapted and designed to at least partially reduce electromagnetic radiation that can be emitted by the power electronics (3) during operation by means of the directional geometry (6), wherein the directional geometry (6) is designed such that the magnetic fields generated when current flows through the discharge path (5) during operation of the power electronics (10) can be selectively compensated for each other, and wherein the electric field caused by time variation of the magnetic field can also be reduced.

13. The method according to claim 12, wherein the at least one non-conductive housing body (12) is formed by additive manufacturing.

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