Contact system with reliable insulation

Abstract

The invention relates to a cooling body (1) for electrically insulating and / or thermally conducting contact with a support body (2), wherein the cooling body (1) has a first surface (10). In order to improve the contact, it is proposed that the first surface (10) has at least one recess (11), wherein the recess (11) is arranged in a region of the first surface (10) which is provided for edge contact with a contact surface (21) of the support body (2), wherein the recess (11) forms a closed path on the first surface (10), wherein the first surface (10) is essentially configured as a planar surface. The invention also relates to a contact system (3) having such a cooling body (1) and a support body (2), wherein the contact surface (21) of the support body (2) is arranged at the cooling body (1) such that the recess (11) of the cooling body (1) extends completely along the edge of the contact surface (21). The invention also relates to a method for producing such a contact system (3), wherein the support body (2) is placed on the cooling body (1) such that the entire edge of the contact surface (21) of the support body (2) extends along the recess (11) of the cooling body (1).

Description

Technical Field

[0001] This invention relates to a cooling body having a first surface for contacting a support, particularly for electrically insulating and / or thermally conductive contact. Furthermore, this invention relates to a contact system having such a cooling body and a support. The invention also relates to a method for manufacturing such a contact system. Background Technology

[0002] In constructing electrical equipment or components, there is often a task to mechanically and partially thermally connect two main bodies, such as a cooling body and a support body, to each other. In order to form such a connection (also known as a contact) electrically, it is possible to separate the components that conduct two different potentials through an insulating layer that has an electrical insulating effect.

[0003] It has been shown that insulation layers are damaged upon contact or during the operation of equipment or components, and thereby suddenly or gradually lose their electrical insulation function over time. Summary of the Invention

[0004] The purpose of this invention is to improve contact systems for contact, particularly electrical insulating contact.

[0005] The objective is achieved by a cooling body having a first surface for contacting a support, particularly for electrically insulating and / or thermally conductive contact, wherein the first surface has at least one recess, wherein the recess is at least partially disposed in a region of the first surface configured for contact with the edge of the contact surface of the support. Here, the recess forms a closed path on the first surface. Furthermore, the objective is achieved by a contact system having such a cooling body and a support, wherein the contact surface of the support is disposed at the cooling body such that the recess of the cooling body extends completely along the edge of the contact surface. The objective is also achieved by a method for manufacturing such a contact system, wherein the support is disposed on the cooling body such that the entire edge of the contact surface of the support extends along the recess of the cooling body.

[0006] Other advantageous designs of the invention are described in the various embodiments.

[0007] This invention is also based on the understanding that the presence of a recess in the cooling body at the point of contact with the support significantly improves electrical insulation, particularly in terms of reliability and service life. It has been shown that there is a risk of damage to the insulation layer, for example, due to component defects, i.e., burrs formed during the cutting process. The danger increases with the force applied during assembly and / or persistently to press the support onto the cooling body. The insulation layer is typically thin and / or soft, making it susceptible to deformation and / or damage caused by burrs. In this case, electrical insulation may be lost abruptly or weaken over time.

[0008] An insulating layer that provides electrical insulation ensures that no current flows even if the cooling body and the support body have different potentials.

[0009] When the support is directly mounted on the coolant, i.e., without an insulating layer between them (also known as no insulation layer), the recess offers advantages. Due to mechanical defects on the surfaces, such as burrs, the two main components, the coolant and the support, do not rest flat against each other. This negatively impacts operational behavior. For example, heat transfer from electrical or electronic components to the coolant is thus degraded. Consequently, heat dissipation may no longer be guaranteed. The result is a shortened lifespan or component failure. In other words, the recess in the coolant ensures that the coolant and the support rest flat against each other at the contact surface outside the recess, achieving good heat transfer.

[0010] The recesses at the first surface of the coolant largely mitigate the negative effects of burrs. These recesses prevent excessive height caused by burrs at the contact surface edges from resulting in a small gap between the coolant and the support. By accommodating unevenness, the remaining flat portions of the support's contact surface then rest flat against the coolant. This, for example, also creates particularly good heat transfer between the coolant and the support.

[0011] If no reaction force is generated by the cooling body at the relevant parts of the contact surface, especially at the edge of the contact surface of the support, the destructive effect of burrs on the insulation layer can also be eliminated, or at least significantly reduced, by the recess. Thus, no force or only a small force acts on the insulation layer located therebetween. This is caused by the recess. Advantageously, the recess is arranged at the first surface such that it extends along the edge of the contact surface of the support. In this case, damage and / or destruction of the insulation layer by burrs present at the edge of the contact surface of the support is reliably prevented.

[0012] Advantageously, a recess can be formed only at a portion of the edge corresponding to the contact surface of the support. For example, where there is a risk of mechanical interference, such as burrs, only at a few locations on the support, the recess can be limited to an area where the edge of the contact surface of the support has an increased risk of burrs.

[0013] It has been shown that the larger the size of the support, especially the larger the size of the contact surface, the greater the risk of insulation damage. In particular, a larger side length also increases the risk of damage.

[0014] The recesses on the cooling body allow for a reduction in burr-free requirements, such as those related to component dimensions. This reduces manufacturing costs for the components. Since a burr-free state cannot always be guaranteed, waste or reprocessing, especially manual reprocessing, is reduced to ensure the required quality. Similarly, quality testing within the assembly process is simplified.

[0015] Furthermore, the following advantages are achieved: the insulating layer can be made thinner. Because the recesses, and consequently the burrs at the contact surface, have less or no force, the risk of insulation damage is low, making it possible to forgo the preventative construction of an insulating layer solely for ensuring electrical insulation. The thickness of the insulating layer can then be advantageously focused solely on electrical insulation capability. Consequently, the insulating layer can be designed to be particularly thin. Such an insulating layer is inexpensive and exceptionally easy to process. At the same time, good heat transfer is ensured.

[0016] The insulating layer can partially cover the recess. This saves on the material used in the insulating layer. Alternatively, it is also advantageous for the insulating layer to completely cover the recess. For example, this reliably prevents dust accumulation in the recess.

[0017] Here, the first surface is essentially constructed as a flat surface. Essentially, this means that a large portion, for example, more than 80%, of the first surface is constructed as a flat surface. Besides being flat, portions can also deviate from a flat surface. Examples include recesses, devices for securing the cooling body and support, threaded rods or holes with or without threads, and mounting devices, handles or grab handles for holding or transporting the cooling body. Furthermore, the cooling body can have multiple flat surfaces, where the element to be cooled can be placed. Therefore, the cooling body can, for example, be zig-shaped or have multiple sub-plates, which are, for example, brazed or fused together.

[0018] At least in the area of ​​the contact surface with the support, it is advantageous that this portion of the first surface is flat. This allows for a good, close fit connection, ensuring not only high mechanical stability but also, for example, good heat transfer. Furthermore, an insulating layer, particularly one for electrical insulation, can be arranged between the coolant and the support. The insulating layer ensures reliable prevention of unwanted currents even when the potentials of the coolant and the support differ. The planar design of the contact surface between the first surface of the coolant and the support ensures that the insulating layer, especially the insulating film, is not subjected to stress or only to small stress that would cause tearing. Due to the flat surface, there are no or very low requirements for the tear resistance of the film or insulating layer.

[0019] In an advantageous embodiment of the invention, the recess is constructed such that it extends entirely along the area provided for contact with the edge of the contact surface of the support. The entire edge of the contact surface typically presents the greatest potential risk of generating sharp edges or burrs, which could prevent the surface from lying flat or cause damage to the insulation layer. Therefore, if the entire edge of the contact surface happens to meet the recess when the support contacts the cooling body, the support lies flat on the cooling body. If an insulation layer exists between the support and the cooling body, the insulation layer is not subjected to, or only subjected to, a small mechanical load due to the recess. Therefore, it is advantageous for the recess to extend along the entire edge of the contact surface.

[0020] This device ensures uniform pressure across most of the contact surface between the cooling element and the support. This results in good heat transfer, for example, in direct contact, or in a uniform and appropriate load on the insulation layer, which reliably and persistently protects the insulation layer from damage, where there is an insulation layer in between.

[0021] In another advantageous embodiment of the invention, the cooling body has multiple closed recessed paths. These multiple closed paths enable the connection of multiple supports to the cooling body or the connection of supports of different designs to the cooling body. Thus, the cooling body can be designed with particular flexibility and is suitable for both cooling multiple components and accommodating supports of different designs, thereby enabling particularly flexible use.

[0022] In another advantageous embodiment of the invention, the recess has a rectangular or circular cross-section. The recess can be introduced into the first surface of the coolant particularly easily in a rectangular manner. This can be achieved simply using standard tools. A circular cross-section can also be easily introduced using standard tools. Since there are no sharp edges in the circular cross-section, the risk of injury during assembly is simultaneously reduced. Similarly, especially when the insulating layer is constructed as a thin film, there is only a small risk of damaging the insulating layer when the recess has a circular cross-section.

[0023] In another advantageous embodiment of the invention, the transition between the recess and the flat portion of the first surface is formed in a broken manner. This broken-off design ensures that the cooling body, particularly its first surface, is burr-free. In other words, the first surface of the cooling body is formed without burrs. This ensures that the support and the cooling body abut each other flatly, and that the insulating layer possibly located between them is not subjected to high loads or high voltages. Therefore, if the recess is formed with broken edges, the risk of damage is further reduced and the service life of the insulation is increased.

[0024] In another advantageous embodiment of the invention, an electrical insulating layer is arranged between the cooling body and the support body. The flatness and planar contact of the cooling body and the support body result in extremely low load on the insulating layer arranged between them. Consequently, there is no risk, or only a small risk, of tearing or penetration of the insulating layer. Tearing or penetration results in loss of insulation, particularly electrical insulation. The insulating layer can then be constructed to be particularly thin. Simultaneously, the insulating layer also covers part or all of the recesses, resulting in a flat surface free of dirt and / or dust accumulation.

[0025] The described design has proven effective, especially when using very soft or thin insulation and very thick support, and when the force of the support is applied to the cooling body.

[0026] Advantageously, it ensures that the substrate, support, and insulation do not move relative to each other. As a result, the load on the insulation layer is particularly small, and damage can be at least almost completely eliminated even when the insulation layer is thin.

[0027] In another advantageous embodiment of the invention, the electrically insulating layer is thermally conductive. A particular advantage of this device is that the insulating layer can be constructed to be particularly thin. Therefore, the insulating layer is also particularly suitable for connecting two bodies together, where heat exchange should occur between them. An example of this application is when electrical or electronic components serve as supports on a cooling body. For electrical insulation, a thermally conductive insulating layer with electrical insulating properties is typically arranged between the component and the cooling body.

[0028] Although every material has thermal conductivity, however low. In this respect, thermal conductivity can be understood as thermal conductivity greater than... For the insulating layer, electrically insulating and robust materials are available, which also possess appropriate thermal conductivity. Furthermore, for requirements of good thermal conductivity, materials with thermal conductivity greater than [missing value] can be used. A thermally conductive pad. This thermally conductive pad is optimized for thermal conductivity and is correspondingly sensitive to mechanical damage. Therefore, the proposed device is particularly suitable for applications with thermal conductivity greater than [insert value here]. The insulating layer.

[0029] In another advantageous embodiment of the invention, the electrically insulating layer is formed by a thin film. The film is particularly easy to use and handle in production. During production, the required quantity can be easily supplied and processed by winding it onto a roller. The disadvantage of the risk of film tearing is reliably avoided by the recesses of the cooling body. Therefore, using a thin film as the insulating layer is particularly advantageous. Furthermore, particularly high potential differences can be electrically insulated from each other with only a small film thickness. Moreover, the use of an adhesive-coated film is particularly advantageous. This film is also thin and therefore has particularly good thermal conductivity. Furthermore, movement of the film relative to the cooling body and / or support is reliably prevented. This ensures durable and good heat transfer and durable and good electrical insulation.

[0030] In another advantageous embodiment of the invention, the insulating layer covers the recess, creating a closed channel between the recess and the insulating layer. Covering the recess reduces the risk of contamination. Contact typically requires electrical insulation properties between the coolant and the support. Since contamination in the recessed area would create a creepage distance that reduces electrical insulation capability, electrical insulation can be ensured persistently by avoiding contamination. Consequently, the corresponding device has a long service life and high reliability.

[0031] In another advantageous embodiment of the invention, a gel-like material is arranged in the recess. For example, the gel-like material can be a gel-like liquid. Here, it can be, for example, a liquid, particularly a thermally conductive liquid, which has a higher viscosity than water. Through the closed channel, the liquid is held in the recess and its thermal behavior (i.e., heat transfer to the cooling body) is improved. Alternatively, a shape-variable material, such as rubber, can also be introduced into the recess. In this way, the thin film, in particular, adheres as a thermally conductive layer and significantly reduces the risk of tearing.

[0032] In another advantageous embodiment of the invention, the support is formed by a busbar. The busbar is typically formed of copper. The copper is shaped into the busbar through a cutting process, which creates burrs at the edges of the busbar. These burrs can damage the film or layer when contacted by means of an insulating layer, i.e., a thin film. Therefore, the proposed cooling body is particularly suitable for contacting the busbar with the cooling body because it can reliably and securely connect to the cooling body even without post-processing.

[0033] In another advantageous embodiment of the invention, the contact system has multiple buses, particularly three buses, wherein the cooling body has multiple closed recessed paths, the number of which corresponds to the number of buses. In this case, a three-phase system with busbars can be cooled by the cooling body, for example, for connection to a converter. By fixing the buses to the cooling body, in addition to heat dissipation, the necessary spacing for electrical insulation between the buses can be ensured. Furthermore, busbar assembly is simplified and susceptibility to damage caused by recesses in the cooling body during assembly is reduced.

[0034] In another advantageous embodiment of the invention, the support is connected to the cooling body without movement by means of a fixing device. This type of connection prevents relative movement between the cooling body and the support. Such relative movement leads to wear and consequent deterioration of the contact surfaces. If the surfaces are in direct contact with each other, surface roughening occurs. In the case of layers, such as films, located therebetween, the layers are subjected to mechanical stress. Due to the connection without movement, wear is permanently avoided, and reliable and durable heat transfer is ensured while maintaining electrical insulation. Attached Figure Description

[0035] The present invention will now be described and explained in more detail with reference to the embodiments shown in the accompanying drawings. The drawings show:

[0036] Figure 1 This illustrates a prior art contact system.

[0037] Figure 2 A detailed diagram of the aforementioned contact system is shown.

[0038] Figure 3 , Figure 4 An embodiment of the contact system having the proposed recess is shown, and

[0039] Figure 5 The closed path of the recess is shown. Detailed Implementation

[0040] Figure 1 A cross-section of the contact system 3 is shown. The contact system includes a cooling body 1 and a support body 2, the support body having a reliable insulating portion by means of an insulating layer 4. The insulating layer 4 is disposed between the cooling body 1 and the support body 2. For this purpose, the cooling body 1 has a first surface 10, which is configured to contact the support body 2. The support body 2 has a contact surface 21, which is configured to contact the first surface 10 of the cooling body 1.

[0041] For clarity, the components used to ensure a lasting contact between the cooling body 1 and the support body 2 are omitted. This can be achieved, for example, by a threaded connection, a spring connection, a tension band, etc. Typically, this can be referred to as a fixing device. The support body 2 can be formed, for example, by a semiconductor module or a busbar. For example, in the case where the contact system 3 consists of the cooling body 1 and the busbar, it must be additionally ensured that different potentials do not cause a compensation current between the cooling body 1 and the support body 2. Therefore, the cooling body 1 and the support body 2 are electrically insulated from each other by means of an insulating layer 4. This suppresses undesirable compensation currents between the bodies 1 and 2.

[0042] Therefore, the contact system 3 has a three-layer structure, consisting of a cooling body 1 with a first potential, an insulating layer 4, and a support body 2 that guides a second potential, wherein the first potential and the second potential are typically different from each other. This embodiment's structure is used, for example, for dissipating heat from the busbar via the cooling body 1. Here, the busbar forms the support body 2.

[0043] Figure 2 yes Figure 1 A detailed view of the circular area at the left edge of the support 2 shown. To avoid repetition, refer to... Figure 1 The description and the reference numerals introduced therein are used. Here, it is assumed that the support 2 has geometric errors exceeding the conventional geometry of a component, such as burrs 5. When the support 2 is pressed or squeezed onto the coolant 1, these errors can completely penetrate the insulation layer 4, resulting in electrical contact between the coolant 1 and the support 2, and consequently causing an undesirable electrical connection of potentials to be separated. However, burrs can also only partially penetrate the insulation layer 4, thus, contacts caused, for example due to settling or partial discharge effects, can only appear with a time delay and cannot be reliably identified in tests.

[0044] If the insulating layer 4 is very thin and / or soft, such as in cases of limited build space or where thermal transition is necessary, the error will have a particularly severe effect.

[0045] Figure 3 A cross-section of one embodiment of the proposed contact system 3 is shown. To avoid repetition, refer to... Figure 1 and Figure 2 The description and the reference numerals introduced therein. In this embodiment, a recess is introduced into the cooling body 1 in the first surface 10. This recess compensates for existing geometric errors, such as burrs 5 of the support body 2.

[0046] The support 2 ideally has slotted edges according to its specifications to protect the insulation layer 4 from damage. Here, in Figure 3In the view, the left edge of the support 2 is chamfered at the transition to the contact surface 21, and the left edge of the support 2 is rounded at the transition to the contact surface 21. However, this is not reliable protection against the effects of the protruding portion of the support 2. The risk of damage is thus reduced, but not eliminated.

[0047] Therefore, to improve the contact system 3 in terms of electrical insulation contact, it is proposed that one or more recesses be provided at the first surface 10 of the cooling body 1. The recesses are able to accommodate significant geometric errors, such as burrs 5, without applying pressure to the insulating layer 4 located therebetween. This provides reliable protection for the insulating layer 4 by providing the possibility that the recesses 11 of the insulating layer 4 will retract into the cavity of the recesses 11 in the event of an erect burr 5 or other protruding geometric error. The thus greatly reduced force action on the insulating layer 4 prevents damage or even penetration of the insulating layer 4 by the support 2. The cavity is formed by material recesses (also referred to as recesses 11) in the cooling body 1. The recesses are advantageously located at the edges of the contact surfaces 21 of the support 2 in the contact system 3. The recesses are particularly capable of having a rectangular cross-section, as shown in the recess 11 on the left. Alternatively or additionally, it is also possible that the recesses 11 have a circular cross-section, particularly at the transition to the first surface 10. Furthermore, different shaped cross sections are also feasible and meaningful for recess 11.

[0048] As shown, the insulating layer 4 can completely, but alternatively only partially, cover the cavity.

[0049] also, Figure 4 A cross-section of another embodiment with an elliptical cross-section having a recess 11 is shown. To avoid repetition, for... Figure 4 For explanation, please refer to Figures 1 to 3 The description and the reference numerals introduced therein. Advantageously, the cooling body 1 has slotted edges, particularly on the side extending through the support 2. This again reduces the load on the insulation layer 4. It proves advantageous, just as the insulation layer 4 covers the entire recess 11, that the edges are also constructed as slotted edges on the opposite sides of the recess. The slotted edges prevent the cooling body 1 from immersing into the insulation layer.

[0050] Figure 5Another cooling body 1 with recesses 11 is shown. The closed path of the recesses 11 can be identified by the perspective view. Two separate recesses 11 exist in the left portion of the cooling body 1, which can contact two support bodies 2. Here, the support bodies 2 have approximately rectangular contact surfaces, which overlap a portion of the recesses 11 upon contact. An 8-shaped recess is shown in the right portion of the cooling body 1. Here, different sections of the recess can have different widths. In the 8-shaped design of the recesses 11, the intermediate connecting piece can be wider. This ensures greater flexibility when using the cooling body. The 8-shaped design of the recesses 11 also constitutes a closed path. For example, two support bodies 2 can contact at the recesses 11. Thus, at the intermediate connecting piece of the recesses 11, the two support bodies 2 utilize the recesses. Alternatively, it is also possible to contact the larger support body 2 separately, with the support body only using the outer portion of the recesses 11. This type of recess 11 is particularly flexible because different designs of the support bodies 2 can be connected to the cooling body 1 while utilizing the aforementioned advantages.

[0051] In summary, the present invention relates to a cooling body for electrically insulating and / or thermally conductive contact with a support, wherein the cooling body has a first surface. To improve the contact, it is proposed that the first surface has at least one recess, wherein the recess is arranged in a region of the first surface configured for contact with the edge of a contact surface of the support, wherein the recess forms a closed path on the first surface, and wherein the first surface is substantially constructed as a flat surface. The invention also relates to a contact system having such a cooling body and a support, wherein the contact surface of the support is arranged at the cooling body such that the recess of the cooling body extends completely along the edge of the contact surface. The invention further relates to a method for manufacturing such a contact system, wherein the support is disposed on the cooling body such that the entire edge of the contact surface of the support extends along the recess of the cooling body.

Claims

1. A contact system (3) having: -A cooling body (1) for electrically insulating and / or thermally conductive contact with the support (2), and -The support body (2), wherein The cooling body (1) has a first surface (10), wherein the first surface (10) has at least one recess (11), wherein the recess (11) is arranged in a region of the first surface (10) configured to contact the edge of the contact surface (21) of the support (2), wherein the recess (11) forms a closed path on the first surface (10) of the cooling body (1), wherein the first surface (10) is substantially constructed as a flat surface, wherein the contact surface (21) of the support (2) is arranged at the cooling body (1) such that the recess (11) of the cooling body (1) extends completely along the edge of the contact surface (21), wherein an electrical insulating layer (4) is arranged between the cooling body (1) and the support (2) and the electrical insulating layer (4) is thermally conductive, wherein the insulating layer (4) covers the recess (11) such that a closed channel is formed by the recess (11) and the insulating layer (4).

2. The contact system (3) according to claim 1, wherein, The cooling body (1) has multiple closed paths of multiple recesses (11).

3. The contact system (3) according to claim 1, wherein, The recess (11) has a rectangular or circular cross-section.

4. The contact system (3) according to any one of claims 1 to 3, wherein, The transition between the recess (11) and the flat portion of the first surface (10) is constructed in a slotted manner.

5. The contact system (3) according to any one of claims 1 to 3, wherein, The electrical insulating layer (4) is thermally conductive.

6. The contact system (3) according to any one of claims 1 to 3, wherein, The electrically insulating layer (4) is formed from a thin film.

7. The contact system (3) according to any one of claims 1 to 3, wherein, A gel-like material is arranged in the recess (11).

8. The contact system (3) according to any one of claims 1 to 3, wherein, The support body (2) is formed by the busbar.

9. The contact system (3) according to claim 8, wherein, The contact system (3) has multiple busbars, wherein the cooling body (1) has multiple closed paths of multiple recesses (11), wherein the number of paths of the recesses corresponds to the number of busbars.

10. The contact system (3) according to claim 9, wherein, The contact system (3) has three busbars.

11. The contact system (3) according to any one of claims 1 to 3, wherein, With the aid of a fixing device, the support (2) is connected to the cooling body without moving.

12. A method for manufacturing a contact system (3) according to any one of claims 1 to 11, wherein, An insulating layer (4) is disposed on the cooling body such that the insulating layer (4) covers the recess (11) such that a closed channel is formed by the recess (11) and the insulating layer (4), wherein the support (2) is disposed on the cooling body (1) such that the electrical insulating layer (4) is disposed between the cooling body (1) and the support (2) and such that all edges of the contact surface (21) of the support (2) extend along the recess (11) of the cooling body (1).

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