Electrical conductor device and motor vehicle

Abstract

The invention relates to an electrical conductor arrangement (10) for conducting an electrical current from a charging socket (160) of a motor vehicle (100) to an energy storage device (150) of the motor vehicle (100), comprising: a direct current conductor (20) having two single direct current conductors (21, 22) for conducting a direct current (DC) from a direct current interface (120) of the charging socket (160) to the energy storage device (150); the invention relates to a charging socket (160) comprising an energy storage device (150) and an alternating current conductor (30) having a plurality of alternating current individual conductors (31) for conducting an alternating current (AC) from an alternating current connection (130) of the charging socket (160) to the energy storage device (150), each direct current individual conductor (21, 22) having an aluminum profile (25) as an electrical conductor for conducting a direct current (DC).

Description

Technical Field

[0001] The present disclosure relates to an electrical conductor arrangement for conducting electric current from a charging socket of a motor vehicle to an energy storage device of the motor vehicle. The present disclosure also relates to a motor vehicle. Background Art

[0002] Within the framework of the growing need for environmental sustainability, the ongoing transformation of mobility is a key aspect. For this and other reasons, the production and use of electric vehicles is a central component for achieving more sustainable mobility. A central component of an electric vehicle is a charging chain or charging unit, which leads from an energy storage device via an electrical conductor arrangement to a charging socket. A charging station external to the vehicle can be connected to the charging socket in order to charge the energy storage device.

[0003] The charging unit comprises an electrical conductor and a charging connector or interface for connecting the electrical conductor to a charging socket and to an interface with an energy storage device. The electrical conductor or cable extends between the energy storage device and the charging socket. The charging unit is typically a continuous component.

[0004] Motor vehicles can typically be charged with alternating current (AC) or with direct current (DC) via alternating current (AC) and direct current (DC) cable harnesses, respectively.

[0005] According to the prior art, a DC cable harness typically consists of two round copper conductors. When transmitting current, one of the round conductors is positively and one is negatively charged. Copper is suitable for round conductors because, in addition to the basic prerequisite of current transmission capacity, it is also mechanically flexible and can therefore compensate for tolerances in the arrangement of the charging unit or charging socket and the energy storage device.

[0006] However, the heat input of copper is relatively high in direct current. Copper is relatively cost-intensive and has a relatively large mass.

[0007] WO2016 / 020512A1 discloses a vehicle having a storage device for electrical energy that can be repeatedly charged by means of a charging cable and an external power source and having a body, the body having at least one body opening that can be closed by a body cover, wherein a charging cable is provided, the charging cable is or can be electrically conductively connected to the storage device and the charging cable extends at least partially in the interior of the body, the vehicle being characterized in that: the body opening is a trunk opening or a door opening of the vehicle, and the body cover is a trunk cover or a vehicle door; the charging cable is configured as a flexible flat ribbon cable or at least has a flexible flat ribbon cable section; the flexible flat ribbon cable or the at least one flexible flat ribbon cable section can pass through a body gap existing between an edge of the body opening and the body cover; and the flat ribbon cable or the at least one flexible flat ribbon cable section has current-conducting conductors arranged side by side with each other, the conductors being configured as flat ribbon conductors and the conductors being surrounded by a common electrically insulating sheath. Summary of the invention

[0008] In the context of this prior art, the object of the present disclosure is to provide an improved electric conductor device, which is suitable for enriching the prior art. A specific embodiment of the present disclosure can solve the following objectives: provide a cost-effective, light and maintenance-friendly electric conductor device, which effectively avoids problems caused by heat.

[0009] The object is achieved by the features of the independent claim. The subject matter of the dependent claims is preferred further developments of the disclosure.

[0010] Accordingly, the object is achieved by an electric conductor arrangement for conducting electric current from a charging socket of a motor vehicle to an energy storage device of the motor vehicle. The electric conductor arrangement comprises a direct current conductor and an alternating current conductor, wherein the direct current conductor has two direct current individual conductors for conducting direct current from a direct current connection of the charging socket to the energy storage device, and the alternating current conductor has a plurality of alternating current individual conductors for conducting alternating current from an alternating current connection of the charging socket to the energy storage device. In this case, each of the direct current individual conductors has an aluminum profile as an electric conductor for conducting direct current.

[0011] Therefore, the electrical conductor arrangement is arranged in the motor vehicle between the charging socket and the energy storage device. The electrical conductor arrangement comprises a direct current conductor and an alternating current conductor in order to enable combined charging. Therefore, both a direct current charging method and an alternating current charging method can be implemented for charging the energy storage device.

[0012] The DC line has the two DC individual conductors, one of which is assigned to a positive pole and the other of which is assigned to a negative pole.

[0013] The AC power conductor has a plurality of single AC power conductors, so that charging can be performed using multi-phase AC power and / or three-phase power.

[0014] The direct current lines and the alternating current lines are each provided via a corresponding interface for connection to the energy storage device. In order to charge the battery cells of the energy storage device, the energy storage device can have power electronics for converting direct current and / or alternating current.

[0015] Each DC single conductor has an aluminum profile as an electrical conductor for conducting direct current. The aluminum profile is therefore provided for conducting direct current. Aluminum is lighter than copper and can be obtained cost-effectively due to effective recyclability. In addition, aluminum has a relatively high thermal conductivity. The shape of the DC single conductor as a profile can improve the heat radiation and / or heat conduction of the heated DC conductor and thus lead to effective cooling of the DC conductor. As a result, the charging time for charging the energy storage device can be shortened. The profile is a component formed, for example, from a flat piece.

[0016] The aluminum profiles of the DC single conductors can be arranged parallel to each other. As a result, the magnetic fields of the two DC single conductors can partially cancel each other out. When current flows through the conductors, an electromagnetic field is generated. Since the two aluminum profiles are oppositely charged, the two electromagnetic fields generated partially cancel each other out and no or fewer additional measures for neutralizing the electromagnetic fields are required. The proposed positioning of the aluminum profiles facilitates the achievement of electromagnetic compatibility limit values. Electromagnetic compatibility (EMC) refers here to the ability of technical equipment not to interfere with other equipment or not to be interfered with by other equipment due to unwanted electrical and / or electromagnetic effects.

[0017] The aluminum profile can be a flat profile. This means that the aluminum profile has two main extension directions, in which the aluminum profile has a larger extension than in the other extension direction. It has been recognized that, for example, round aluminum profiles are relatively rigid and cannot compensate for tolerances that may occur when arranging charging units and energy storage devices. The necessary flexibility of the aluminum profile is created by the shape as a flat profile. Flat profiles are relatively flexible and can appropriately compensate for such tolerances in motor vehicles.

[0018] A thermal paste can be arranged between the individual DC conductors. A thermal paste made of, for example, so-called LH2C is inserted between the two aluminum profiles. This paste has a high heat capacity and can absorb the heat of the conductors. This increases the current carrying capacity, shortens the charging time, and the absorption of heat via the thermal paste applied between the aluminum profiles is more cost-effective than active cooling.

[0019] In other words and with reference to a specific embodiment which is not described as a limitation of the present disclosure, the above can be summarized as follows: It is proposed to replace the two copper round profile conductors of the DC charging harness with two aluminum flat profile conductors. The flat profiles are placed on top of each other so that the magnetic fields of the two flat profile conductors partially cancel each other out. When current flows through the conductor, an electromagnetic field is generated. Since the two flat profiles are oppositely charged, the two electromagnetic fields generated partially cancel each other out and no additional measures for neutralizing the electromagnetic field are required. Electromagnetic compatibility (EMC) refers to the ability of technical equipment not to interfere with other equipment or not to be interfered with by other equipment through unwanted electrical or electromagnetic effects. The proposed positioning of the flat profile facilitates the achievement of electromagnetic compatibility limits. Compared with copper, lower costs, better heat dissipation and the resulting shorter charging times can be achieved when using aluminum. However, round aluminum profiles are very hard and cannot compensate for tolerances that may occur in the charging device and the high-voltage reservoir. In addition, the charging unit consists of multiple components, so tolerances between the individual components of the charging unit are necessary. The required flexibility of the aluminum profile is achieved by changing the shape. Flat profiles are easier to bend and can compensate for tolerances better. In order to achieve short charging times and high efficiency during the charging process, it is important to keep the temperature in the charging path low. Due to the resistance in the wires, heat is released, which on the one hand affects the surroundings (e.g. the sheath) and on the other hand reduces the charging performance from a certain temperature. Air cooling and water cooling are not suitable because they have disadvantages in the following areas: complexity, cost, packaging (installation space), weight. It is therefore recommended to arrange thermal cooling via a thermal mass (LH2C) between the two aluminum flat profiles. A thermally conductive paste made of LH2C is inserted between the two aluminum profiles. The paste has a high thermal capacity and can absorb the heat of the wires.

[0020] The present invention also provides a motor vehicle, which comprises a charging socket, an energy storage device and the above-mentioned electric wire device.

[0021] The motor vehicle may be a passenger car, in particular a car. The motor vehicle may be an electrically driven motor vehicle. For this purpose, the motor vehicle may have an electric drive device, which can be loaded with electric energy from an energy storage device in order to convert the electric energy into kinetic energy. The optionally automated motor vehicle may be designed to at least partially and / or at least temporarily take over the longitudinal guidance and / or the transverse guidance during the automated driving of the motor vehicle. The automated driving may be carried out in such a way that the motor vehicle moves forward (essentially) autonomously. The automated driving may be controlled at least partially and / or temporarily by a data processing device. The motor vehicle may be a motor vehicle with an automated driving level of 0 to 5.

[0022] What has been described above with reference to the electrical conductor arrangement also applies analogously to the motor vehicle and vice versa. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The following will refer to Figures 1 to 4 An implementation scheme is described.

[0024] Figure 1 Schematically illustrates a motor vehicle according to one embodiment of the present disclosure;

[0025] Figure 2 A perspective view showing an electrical conductor arrangement according to one aspect of the present disclosure;

[0026] Figure 3 schematically shows a cross section of a respective DC conductor of an electrical conductor arrangement according to one aspect of the present disclosure; and

[0027] Figure 4 A threaded connection device of an electrical conductor device according to one aspect of the present disclosure is schematically shown. DETAILED DESCRIPTION

[0028] Figure 1 A motor vehicle 100 according to an embodiment of the present disclosure is schematically shown.

[0029] Motor vehicle 100 comprises a charging socket 160, an energy storage device 150 and an electrical conductor arrangement 10. Charging socket 160 is provided to establish an electrical connection between motor vehicle 100 and a charging station 200 external to the vehicle, through which motor vehicle 100 or its energy storage device 150 can be supplied with current and charged.

[0030] For this purpose, the charging socket 160 is connected to the energy storage device 150 in order to conduct the electric current via the electrical conductor arrangement 10 . The electrical conductor arrangement 10 is provided for conducting the electric current from the charging socket 160 to the energy storage device 150 .

[0031] The electrical conductor arrangement 10 comprises a direct current conductor 20 and an alternating current conductor 30 .

[0032] The DC line 20 is provided for conducting DC power DC from the DC connection 120 of the charging socket 160 to the energy storage device 150 . The AC line 30 is provided for conducting AC power AC from the AC connection 130 of the charging socket 160 to the energy storage device 150 .

[0033] The AC conductor 30 includes a plurality of single AC conductors 31 (for better illustration, only one single AC conductor 31 is shown).

[0034] Reference Figures 2 to 4 An electrical conductor arrangement 10 is also described.

[0035] Figure 2 A perspective view of an electrical wiring device 10 according to one aspect of the present disclosure is shown. The electrical wiring device 10 is an electrical wiring device 10 for a motor vehicle 10. Figure 1 Such a motor vehicle 10 is described. Figure 2 Reference Figure 1 and its description.

[0036] according to Figure 2 The AC conductor 30 includes the plurality of AC single conductors 31, which are arranged in a sheath 38 and electrically insulated from each other. The AC single conductors 31 are made of copper, for example, and each has a circular cross section. The sheath 38 is electrically insulating and is made of plastic, for example.

[0037] The electrical conductor arrangement 10 has an AC plug connection 33 that can be connected to the AC conductor 30. The AC plug connection 33 is provided for connecting the electrical conductor arrangement 10 to the AC interface 160. The AC plug connection 33 has a plug and an associated socket (not shown). At the end (not shown) of the AC conductor 30, the electrical conductor arrangement 10 has a further AC plug connection 33, which is provided for connecting the electrical conductor arrangement 10 to the energy storage device 150. Therefore, via the AC plug connection 33 and the AC conductor 30, the energy storage device 150 can be electrically connected to the charging socket 160 to transmit the alternating current AC.

[0038] As in Figure 2 As shown in FIG, the DC line 20 is provided for being electrically conductively fixed to the DC connection 120 via a screw connection 24 having a plurality of screws 23. Figure 4 The threaded connection device 24 is described in detail. Figure 2 At one end not shown in the figure, the DC conductor 20 is provided for being electrically conductively fixed to the energy storage device 150 via another screw connection device 24 having a plurality of screws 23. Therefore, the energy storage device 150 can be electrically connected to the charging socket 160 via the screw connection device 24 and the DC conductor 20 to transmit direct current DC. Figure 3 The DC power conductor 20 is described in more detail.

[0039] like Figure 2 As shown, the electrical conductor arrangement 10 has a grounding device 40 for connection to the motor vehicle 100 .

[0040] Figure 3 The cross section of each direct current conductor 20 of the electrical conductor arrangement 10 according to one aspect of the present disclosure is schematically shown. Figure 3 Show reference Figure 1 and 2 An electrical conductor arrangement 10 is described. Figure 3 Reference Figure 1 and 2 and its description.

[0041] Figure 3 Four different embodiments of the DC conductor 20 are shown ( Figure 3 (A), 3(B), 3(C) and 3(D)).

[0042] according to Figure 3 The DC conductor 20 has two DC single conductors 21 and 22 for conducting DC. Each of the DC single conductors 21 and 22 has an aluminum profile 25 as an electrical conductor for conducting DC. The aluminum profile 25 is a flat profile 26. That is, each of the aluminum profiles 25 has two main extension directions, which are horizontal and in the plane of the drawing, and another extension direction, which is a vertical direction. The extension dimension of the aluminum profile 25 is greater in the main extension direction than in the other extension direction. The aluminum profile 25 can be manufactured, for example, by rolling and forming.

[0043] The aluminum profiles 25 of the DC single conductors 21 and 22 are arranged parallel to each other. The respective main extension directions of the aluminum profiles 25 define a plane in which each aluminum profile 25 has a surface of maximum extension. Here, the aluminum profiles 25 of the DC single conductors 21 and 22 are arranged so that their largest surfaces are parallel to each other.

[0044] The DC conductor 20 has an insulating element 28. The insulating element 28 is arranged around the DC individual conductors 21, 22 and between the DC individual conductors 21, 22. The insulating element 28 is electrically insulating and is made of plastic, for example.

[0045] Figure 3 (B) About Figure 3 (A) is described. Figure 3 (B), the DC conductor 20 has an insulating member 28. The insulating member 28 is arranged around the DC single conductors 21, 22 respectively. An air gap is arranged between the insulating members 28 of the DC single conductors 21, 22. The air gap can achieve improved heat transfer from the DC single conductors 21, 22 to the surrounding environment.

[0046] Figure 3 (C) About Figure 3 (A) is described. Figure 3 (C) The DC conductor 20 has a heat storage paste 27 arranged between the DC individual conductors 21 , 22 .

[0047] The heat storage paste 27 has a higher heat capacity than aluminum and is provided to absorb the heat generated during the charging process in the DC line 20. As a result, the temperature of the DC line 20 rises less significantly, which can facilitate charging.

[0048] The thermal storage paste 27 has a paste-like consistency. Therefore, the thermal storage paste 27 can effectively follow the contour that may be curved (see Figure 2 ) is arranged on the DC conductor 20.

[0049] The heat storage paste 27 contacts the DC individual conductors 21, 22 on one of their largest surfaces in order to enable efficient heat transfer from the respective DC individual conductor 21, 22 to the heat storage paste 27. The heat storage paste 27 is electrically insulating and therefore forms electrical insulation between the DC individual conductors 21, 22.

[0050] Figure 3 (D) About Figure 3 (C) is described. Figure 3 (D) The sheath 28 is arranged to enclose the heat storage paste 27. The heat storage paste 27 is not in direct electrical contact with the DC single conductors 21, 22. Therefore, a heat storage paste 27 that can conduct electricity can also be used.

[0051] Figure 4 The threaded connection device 24 of the electrical conductor arrangement 10 according to one aspect of the present disclosure is schematically shown. Figure 4 Show reference Figures 1 to 3 An electrical conductor arrangement 10 is described. Figure 4 Reference Figures 1 to 3 and its description.

[0052] The DC line 20 is electrically conductively fastened to the DC connection 120 via a screw connection 24 having two screws 23. In this case, each of the screws 24 is arranged perpendicular to one of the aluminum profiles 25 in the assembled state. In this case, each of the screws 24 contacts exactly one of the aluminum profiles 25 in an electrically conductive manner.

[0053] Each of the aluminum profiles 25 has a first through hole 29a and a second through hole 29b, each of which is passed through by one of the screws 24. The through holes 29a and 29b of each of the aluminum profiles 25 have different diameters D. In other words, the diameter D of the through hole 29a of each of the aluminum profiles 25 is larger than the diameter D of the other through hole 29b. A tolerance range is provided for each through hole 29b with a smaller diameter D, that is, the diameter D of the corresponding smaller through hole 29b is slightly larger than the diameter of the screw 24. Here, the diameter D of the corresponding smaller through hole 29b is selected so that a reliable mechanical and electrical connection is achieved between the DC single conductors 21, 22 and the charging socket 160. The diameter D of the corresponding larger through hole 29a is selected so that the screw 24 is excluded from contacting the DC single conductor 21, 22 at the larger through hole 29a. For example, the larger through hole 29a has a diameter D that is equal to a multiple of the diameter of the screw 24.

[0054] The screw 24 vertically passes through the DC single conductors 21 and 22, so that one screw 24 is connected to only one DC single conductor 21 and 22 respectively. The two screws 24 are in contact with different DC single conductors 21 and 22. The two screws 24 pass through the two DC single conductors 21 and 22, but only contact one of the DC single conductors 21 and 22. The connection of the screw 24 and the DC single conductor 21 and 22 for electrical connection and disconnection is respectively achieved by a small and a large distance between the screw 24 and the DC single conductor 21 and 22, that is, by different diameters D of the through holes 29a and 29b.

[0055] The electrical conductor arrangement 10 has a cap 41 or contact cap. The cap 41 is electrically insulating. The screw connection 24 can be protected from mechanical influences by the cap 41.

[0056] Reference numerals list

[0057] 10 Electrical wire device

[0058] 20 DC conductors

[0059] 21 DC single conductor

[0060] 22 DC single conductor

[0061] 23 Threaded connection

[0062] 24 Screws

[0063] 25 Aluminum Profile

[0064] 26 Flat profiles

[0065] 27 Thermal storage paste

[0066] 28 Insulation

[0067] 29a first through hole

[0068] 29b Second through hole

[0069] 30 AC conductor

[0070] 31 AC single conductor

[0071] 33 AC plug connection device

[0072] 38 Sheath

[0073] 40 Grounding device

[0074] 41 Blocked

[0075] 100 Electric locomotive

[0076] 120 DC interface

[0077] 130 AC interface

[0078] 150 Energy storage device

[0079] 160 Charging socket

[0080] 200 charging stations

[0081] AC

[0082] DC Direct Current

[0083] D Diameter

Claims

1. An electrical conductor arrangement (10) for conducting electric current from a charging socket (160) of a motor vehicle (100) to an energy storage device (150) of the motor vehicle (100), comprising: A direct current conductor (20) having two direct current single conductors (21, 22) for conducting direct current (DC) from a direct current interface (120) of a charging socket (160) to an energy storage device (150), and an alternating current conductor (30) having a plurality of alternating current single conductors (31) for conducting alternating current from an alternating current interface (130) of a charging socket (160) to an energy storage device (150), It is characterized in that Each of the direct current single conductors (21, 22) has an aluminum profile (25) as an electrical conductor for conducting direct current (DC).

2. The electrical conductor arrangement (10) according to claim 1, wherein: The aluminum profiles (25) of the direct current single conductors (21, 22) are arranged parallel to each other.

3. The electrical conductor arrangement (10) according to claim 1 or 2, wherein: The aluminum profile (25) is a flat profile (26).

4. The electrical conductor arrangement (10) according to any one of the preceding claims, wherein: A heat storage paste (27) is arranged between the DC single conductors (21, 22).

5. A motor vehicle (100) comprising a charging socket (160), an energy storage device (150) and an electrical conductor arrangement (10) according to one of the preceding claims.

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