Electrical conductor with integrated heat sink

Abstract

The present invention relates to an electrical conductor comprising at least one first terminal and at least one second terminal separated by an intermediate section configured to support current conduction between the at least one first terminal and the at least one second terminal wherein the intermediate section comprises at least one integrated heat sink.

Description

Technical Field

[0001] The present invention relates to an electrical conductor including an integrated heat sink, an electrical system including such an electrical conductor, and a method for cooling power electronic components through such an electrical conductor. Background Technology

[0002] In the art, for example, as known from US20230105637, it is understood that equipping a power module with a heat sink is a method of transferring heat from the power module to its surrounding environment. US20230105637 represents a full range of variations of mounting a heat sink to a power module. Typically, known heat sinks are made of a block of aluminum with fins thermally connected to the power module. A fan then ensures airflow through the heat sink, thereby removing heat.

[0003] A known problem with heat sinks is that they are typically large compared to the components from which they remove heat. Therefore, a problem with the prior art is to remove heat from components with smaller heat sinks without sacrificing the operating range and lifespan of the components. As described below, the present invention solves these problems. Summary of the Invention

[0004] The inventors have recognized the aforementioned problems and challenges related to heat removal in electrical systems and have solved these problems through the present invention described below.

[0005] In one aspect, the present invention relates to an electrical conductor comprising at least one first terminal and at least one second terminal separated by an intermediate segment, the intermediate segment being configured to support current conduction between the at least one first terminal and the at least one second terminal, characterized in that the intermediate segment includes at least one integrated heat sink.

[0006] Including an intermediate section with an integrated heat sink is advantageous because not only does such an electrical conductor improve the cooling of the conductor itself—for example, when used as a high-power busbar to conduct current to or from components connected to it—but such an intermediate section also has the advantage of cooling components such as power electronic parts (e.g., power modules) by mounting a power module with a thermal connection onto an electrical conductor with an integrated heat sink. This eliminates or reduces the need for a separate heat sink for the power module.

[0007] Compared to other parts of the electrical conductor where there is no heat sink, a heat sink can provide a larger surface area in the part of the electrical conductor where the heat sink is located.

[0008] Alternatively, a heat sink can provide a more open surface for the electrical conductor (especially the middle section) compared to the portion of the electrical conductor without a heat sink.

[0009] It should be mentioned that the radiator can be made of two or more materials, and therefore the conductor and radiator can be referred to as polylithic. Thus, although there are two materials, a polylithic conductor with a radiator is still composed of two materials without joints or seams.

[0010] In an exemplary embodiment of the invention, the at least one heat sink is removably attached to the middle section of the electrical conductor.

[0011] Its advantage lies in its ability to adjust the position of the heat sink on the electrical conductor. Therefore, the heat sink's capacity can be directly adjusted to hot spots, such as electrical components or areas requiring airflow cooling.

[0012] In fact, during the operation of an electrical system, a thermal image of the electrical system can be created, and one or more radiators can be adjusted or positioned based on the evaluation of the resulting image to increase cooling in the relevant area.

[0013] In an exemplary embodiment of the present invention, the at least one heat sink is an integrated portion of the intermediate segment of the electrical conductor.

[0014] The advantage of an integrated heat sink is that it does not require additional components to dissipate heat from heat-generating parts.

[0015] In an exemplary embodiment of the present invention, the electrical conductor includes an integrated fan fastening point.

[0016] Its advantage lies in its ability to allow the fan to be mounted directly onto the electrical conductor. Preferably, it is positioned directly above an integrated heat sink, for example, in the middle section of the electrical conductor. Therefore, cooling airflow can be generated by the fan directly towards the heat sink of the electrical conductor, towards additional heat sinks, towards electrical components, etc.

[0017] In an exemplary embodiment of the present invention, the integrated heat sink is formed of a conductive material in the intermediate section.

[0018] Its advantage lies in the fact that the electrical conductor itself becomes a heat transfer device, i.e., a heat sink. That is, at least the middle part of the electrical conductor has the dual purpose of transferring heat from the component and conducting current to / from the component.

[0019] In an exemplary embodiment of the present invention, the integrated heat sink is the intermediate segment of the electrical conductor, wherein the intermediate segment is at least partially fabricated with an air-permeable geometry.

[0020] The advantage of air-permeable geometry is that it allows cooling fluids, such as air, to flow between the conductor branches of the electrical conductor. This results in better heat transfer from each conductor branch and the heat-generating components connected to it.

[0021] In an exemplary embodiment of the present invention, the air-penetrating geometry is selected from the following list: spiral-like design, branch-like design, biomimetic design, mesh-like design, honeycomb design, and sponge-like design.

[0022] The advantage of the above design is that the cooling airflow can surround the electrical conductor. Furthermore, these designs may include or be designed with air guiding devices to direct the cooling airflow to the desired hot spots of the air around the heat-generating component. In this way, heat can be effectively removed from a large area surrounding the electrical conductor.

[0023] In an exemplary embodiment of the present invention, the first terminal includes a first end, and the second end includes a second end, wherein the heat sink is integrated in the first end or the second end.

[0024] The advantage of having a heat sink at the end surface of an electrical conductor is that it can eliminate heat generated at the connection between the conductor's terminals and the electrical components it is connected to. In this and similar cases, integrated heat sinks are more advantageous than known heat dissipation methods (such as simply extending the end of the conductor to create more conductor area). With the heat sink of the present invention, the same area or even a larger area can be provided with less material, without sacrificing the free space required to mount the electrical conductor to the electrical components.

[0025] In an exemplary embodiment of the present invention, the middle section having the integrated heat sink is a monolithic geometry.

[0026] The advantage of a monolithic geometry is that the middle section, including the integrated heatsink, is manufactured as a single piece. This can be achieved through molding, printing, extrusion, and other methods. Therefore, no additional parts or additional mounting and assembly are required, reducing potential sources of error.

[0027] In an exemplary embodiment of the present invention, the integral geometry includes one or more protrusions or one or more grooves.

[0028] In an exemplary embodiment of the present invention, the one or more protrusions are integrally integrated with the intermediate section as one or more outwardly extending cooling fins.

[0029] The advantage of protrusions / extensions is that they increase the area of ​​the electrical conductor, allowing the flow of cooling fluid to carry away heat. More specifically, they increase the area using minimal material.

[0030] In an exemplary embodiment of the present invention, the intermediate segment is thermally connected to the heating element, wherein the thermal connection is at a physical location on the heating element that is different from the physical location on the heating element that is electrically connected to the electrical conductor.

[0031] Its advantage lies in its ability to transfer heat from the component to the conductor and thus to the environment via the heat sink. More specifically, heat can be removed from the component at a location different from where the conductor is connected to the component. This also applies if the conductor, including the heat sink, is also an electrically connected conductor to the component.

[0032] In an exemplary embodiment of the present invention, the integrated heat sink is directly connected to the heat-generating component.

[0033] This is possible if the phase of the conductor, including the heat sink, is the same as that supplied to the component. The advantage is that no additional components are required. This allows the use of thermal paste to ensure that there is no cavitation in the thermal path between the conductor, heat sink, and component. The conductor can be secured to the component using screws, adhesives, cold spraying, etc.

[0034] In an exemplary embodiment of the invention, the electrical conductor is configured to supply power to the component, and the intermediate section including the integrated heat sink is configured to remove heat from the component via the integrated heat sink.

[0035] Its advantage lies in enabling the electrical conductor to have a dual function: supplying power to electrical components and removing heat from them. The latter achieves a significant heat removal effect through integrated heat sinks, a significant improvement over known electrical conductors which, apart from their planar surfaces not optimized for heat removal, offer no other means of heat removal.

[0036] In an exemplary embodiment of the present invention, the intermediate segment is thermally connected to the heat-generating component via an additional heat sink.

[0037] Inserting an additional heat sink between the component and the electrical conductor is advantageous because it establishes a minimum distance between them. This minimum distance can be a requirement of the electrical component manufacturer to protect the electronics, switches, etc., within the component.

[0038] Preferably, it is part of an intermediate section, including an integrated heat sink connected to an additional heat sink. The additional heat sink can be secured to the conductor and components with screws, or it can be fastened with a pivotable clamp fixed to the additional heat sink or conductor.

[0039] In an exemplary embodiment of the present invention, the additional heat sink is at least partially made of a non-conductive material.

[0040] Its advantage lies in the fact that by inserting such a non-conductive heat sink, current isolation can be achieved, while controlled airflow can be provided to remove heat from the component. As an example, the additional heat sink can be made of ceramic materials, plastic / polymers, etc.

[0041] Therefore, an additional heatsink can guide airflow, allowing it to pass over, for example, a backplate of an electrical conductor and through the integrated heatsink of the electrical conductor. This airflow can be generated by a fan positioned / connected to the additional heatsink or the electrical conductor.

[0042] The advantage of radiators in the form of protrusions or extensions is that, in addition to drawing heat away from the conductor, they can also be used to guide airflow in a predetermined direction.

[0043] In an exemplary embodiment of the present invention, the intermediate section having an integrated heat sink is located at a cold spot in the electrical cabinet.

[0044] A cold spot should be understood as a location within an electrical cabinet where the cooling airflow is higher than in other areas. Cold spots can be established, for example, by strategically installing air guides inside the electrical cabinet to direct airflow, which may be provided by fans, to one side, the middle section, etc. Cold spots can also be determined by the cabinet layout (i.e., the location of components that create flow paths within the cabinet, or the positions of fans, heat exchangers, pipes, etc., that form flow paths). Therefore, in such a cold spot, placing a heat sink for electrical conductors can be advantageous due to the high flow rate of the cooling fluid (such as cooling air).

[0045] In an exemplary embodiment of the present invention, the intermediate section having an integrated heat sink is located at a hot spot location in the electrical cabinet.

[0046] Hot spots can be understood as locations within an electrical cabinet that generate more heat than other areas. Hot spots are typically found in electrical components such as busbars, power modules, and reactors. It is advantageous to thermally connect a portion of the electrical conductor (such as a mid-section) that includes a heat sink to such heat-generating components.

[0047] Thermal connection can be understood as the direct connection between an integrated heat sink and a heat-generating component, or the connection via an additional heat sink and thermal paste, etc.

[0048] In an exemplary embodiment of the present invention, at least a portion of the intermediate segment and the integrated heat sink are manufactured simultaneously, at least partially, by an additive manufacturing process.

[0049] The advantage of manufacturing the electrical conductor according to the invention using additive manufacturing is that the ends and the intermediate section including the integrated heat sink can be integrally formed. This also allows the integrated heat sink to be perfectly fixed to the intermediate section, thereby greatly reducing the risk of it detaching.

[0050] In an exemplary embodiment of the present invention, the intermediate segment is integrally formed of a conductive material.

[0051] Therefore, regardless of geometry, the intermediate sections are all integral, which has the advantage of eliminating the need for manual connection of the various parts of the intermediate sections. This increases the installation speed of electrical systems with installed conductors, while simultaneously reducing or even eliminating the risk of human error during conductor assembly.

[0052] The integrated intermediate section can be manufactured using additive manufacturing, molding, extrusion or similar processes.

[0053] In an exemplary embodiment of the present invention, the intermediate segment is integrally formed at a first end with the first end of the electrical conductor, and at a second end with the second end of the electrical conductor.

[0054] In an exemplary embodiment of the present invention, the intermediate segment includes multiple conductor branches.

[0055] A conductor branch can be designed and subsequently manufactured in a harmonica-like, spiral-like, or similar shape, resulting in multiple air gaps between sections of the same or adjacent conductor branches.

[0056] It is worth mentioning that high-power electrical conductors can be composed of a mixture of conductor branches with different geometries.

[0057] In an exemplary embodiment of the present invention, the electrical conductor has a resonant frequency of at least 5 Hz, for example at least 20 Hz, for example at least 30 Hz, for example at least 70 Hz, for example at least 150 Hz, for example at least 300 Hz, for example at least 500 Hz.

[0058] The electrical conductor is advantageously designed and subsequently manufactured such that it has a resonant frequency associated with the relative motion between the first and second end segments, a resonant frequency that is not consistent with the natural frequency of the system comprising the conductor. This is to avoid vibrations caused by the natural frequency of such electrical or mechanical systems. An example of a mechanical system is a wind turbine, whose natural frequency can be 5 Hz.

[0059] The electrical conductor described in any of the paragraphs above is manufactured by the method described in the following paragraphs.

[0060] In one aspect, the present invention relates to a method for cooling power electronic components by physically connecting power electronic components to an electrical conductor, wherein the electrical conductor includes an intermediate section having an integrated heat sink, wherein the method includes the step of providing airflow through the integrated heat sink.

[0061] In an exemplary embodiment of the present invention, the airflow is generated by a fan.

[0062] The advantage of removing heat from a component via a heat sink, which is part of the electrical conductor, is that it eliminates the need for an external / additional heat sink. Thus, the area and material of the electrical conductor serve the dual purpose of removing heat from the component and supplying current to it. The same electrical conductor can simultaneously act as both a heat sink and a power source for the same component.

[0063] In one aspect, the present invention relates to a high-power electrical system, comprising:

[0064] - An electrical cabinet including air inlets and outlets,

[0065] - A plurality of electrical conductors, wherein at least one of the plurality of electrical conductors includes a first end, and

[0066] -Contains at least one heat-generating component included in the electrical cabinet.

[0067] Wherein, at least one of the plurality of electrical conductors includes at least one integrated heat sink.

[0068] The heat sink is thermally connected to the at least one heat-generating electrical component at a first location of the at least one heat-generating electrical component.

[0069] Wherein, the first end of the electrical conductor is electrically connected to the at least one heating electrical component at a second position of the at least one heating electrical component, wherein the first position and the second position are different positions.

[0070] The advantage of a system that includes an electrical conductor with an integrated heat sink is that it eliminates or reduces the need for an external heat sink, making the system more compact, cheaper, and faster to install.

[0071] In one exemplary embodiment of the invention, the fan is configured to establish an airflow between an air inlet and an air outlet, and wherein at least one of the plurality of electrical conductors includes an intermediate section in which the integrated heat sink is located, and wherein the integrated heat sink is located in the airflow.

[0072] The electrical conductor can include multiple heat sinks. In fact, it can have as many as needed or according to the number it passes through the electrical cabinet. Therefore, the need for external heat sinks can be eliminated.

[0073] In an exemplary embodiment of the present invention, the airflow is guided through the intermediate section by an external air guide.

[0074] Such external air guiding devices can be connected to electrical cabinets or electrical conductors. They can guide at least a portion of the airflow in a predetermined direction. Attached Figure Description

[0075] To gain a more complete understanding of this application, reference is now made to the following brief description taken in conjunction with the accompanying drawings and detailed description, wherein like reference numerals denote like parts. The drawings illustrate embodiments of the invention, and elements in different drawings may be combined within the scope of the invention:

[0076] Figure 1a -c illustrates various electrical conductors according to the present invention.

[0077] Figure 2 The diagram illustrates a flowchart of a method for manufacturing an electrical conductor.

[0078] Figure 3 The diagram illustrates electrical conductors, including a heat sink.

[0079] Figure 4 The diagram illustrates electrical conductors, including those connected to the heat sink of the component.

[0080] Figure 5 The diagram illustrates an electrical cabinet including an electrical conductor, which includes a heat sink.

[0081] Figure 6 The diagram illustrates a heat sink at the end of an electrical conductor, and

[0082] Figure 7 and Figure 8 Several embodiments of an electrical conductor having a heat sink are illustrated. Detailed Implementation

[0083] This invention has been described through exemplary embodiments and is only used to illustrate the principles and implementation of the invention. Those skilled in the art will be able to provide several embodiments within the scope of the claims.

[0084] Figures 1a to 1c Various embodiments of the electrical conductor 1 according to the invention are illustrated, all of which are suitable for including integrated heat sinks. Figure 1a The diagram illustrates an electrical conductor 1 with a twisted geometry / design. The electrical conductor 1 includes a first end 2 and a second end 3, wherein the second end 3 is located away from the first end 2 and is spaced apart from each other by intermediate segments 4.

[0085] In this particular embodiment, the intermediate segment 4 includes multiple conductor branches 5. In this particular embodiment, each conductor branch is separated by an air gap 6 in both the longitudinal direction 6a and the transverse direction 6b of the electrical conductor 1. This twisted design of the conductor branches increases the flexibility of the conductor 1 and thus increases its ability to absorb vibrations. Furthermore, this design is lightweight and easy to install.

[0086] In this particular embodiment, the first end 2 includes a first terminal 7, and the second end 3 includes a second terminal 8. The first and second terminals 7 and 8 may include one or more terminal holes 10 for connecting the electrical conductor 1 to other electrical components. The electrical conductor 1 is configured to support current conduction between the first and second terminals 7 and 8.

[0087] Each of these two terminals 7 and 8 can be electrically coupled to terminals, busbars, components (such as circuit breakers, contactors, power modules, reactors, etc.) of an electrical device via, for example, terminal hole 10, clamps, plugs, or other electrical connection devices, and other electrical conductors according to the invention. Typically, the electrical conductor 1 and the terminals, busbars, components, etc., to which it may be connected will be included in an electrical enclosure, i.e., located within a housing such as a panel or cabinet.

[0088] In various embodiments, the electrical conductor 1 may have a plurality of first ends 2, a plurality of second ends 3, a plurality of first terminals 7 and / or a plurality of second terminals 8.

[0089] Figure 1b illustrates an electrical conductor 1 with a mesh-like or lattice-like geometry / design. For example... Figure 1a The electrical conductor 1 shown, Figure 1b The electrical conductor shown includes a first end 2 and a second end 3 separated by a middle section 4. The first end 2 may include a first terminal 7, and the second end 3 may include a second terminal 8. The first and second terminals 7 and 8 may include one or more terminal holes 10 for connecting the electrical conductor 1 to other electrical components.

[0090] Between the two terminals 7 and 8, a mesh-like conductor branch 5 (only one is highlighted) extends. These conductor branches intersect and branch at multiple intersections 9. Note that the first end 2 and the second end 3 are also partially fabricated with the same mesh-like design as the intermediate section 4. Also note that the first and second terminals 7 and 8 include multiple terminal holes 10. The terminal holes 10 of the terminals 7 and 8 are formed in a portion of the ends 2 and 3, which has a non-perforated surface, i.e., in this particular embodiment, this surface is different from, for example, the mesh-like surface of the intermediate section 4 of the electrical conductor. The planar contact surfaces of the terminals 7 and 8 surrounding the terminal holes 10 preferably provide a connection surface with another flat surface having the lowest possible resistance and a sufficiently strong contact surface between the bolt / nut and the electrical conductor 1.

[0091] Figure 1c The illustration depicts an electrical conductor with biomimetic geometry / design. (Example) Figure 1a and 1b The electrical conductor 1 shown, Figure 1cThe electrical conductor shown includes a first end 2 and a second end 3 separated by a middle section 4. The first end 2 may include a first terminal 7, and the second end 3 may include a second terminal 8. The first and second terminals 7 and 8 may include one or more terminal holes 10 for connecting the electrical conductor 1 to other electrical components.

[0092] In this embodiment, the intermediate segment 4 is a so-called biomimetic design, preferably implemented as a computer-generated design. This computer-generated design is based on inputs to a computer program that controls the additive manufacturing machine / process, or is capable of exporting data to a controller of the additive manufacturing machine / process (e.g., from a user or another computer). Inputs may include dimensions, the maximum current to be conducted, the required strength, the maximum deflection (elastic or plastic), etc. As... Figure 1b The electrical conductor shown in this specific embodiment includes a longitudinal conductor branch 5a and a transverse conductor branch 5b. It is noteworthy that conductor branches 5a and 5b together form an extension of the transverse conductor branch; that is, if viewed from the side view, Figure 1c The conductor 1 is thicker at the middle section 4 than at the ends 2 and 3. The conductor branches 5 are spatially separated in the X (6a), Y (6b), and Z (6c) directions by air gaps 6. It should also be noted that the terminals 7 and 8 are designed with planar surfaces to achieve the best possible contact with components having planar surfaces, to which the conductor 1 will be clamped, for example, via bolts and nuts. It should also be noted that, independent of the geometry of the ends 2 and 3, the terminals 7 and 8 are aligned / raised such that the contact surfaces for, for example, all three terminals 7 are in the same plane.

[0093] All of the above embodiments of the electrical conductor 1 have a ventilated geometry with air gaps 5 between the conductor branches 6. In other embodiments, the electrical conductor 1 of the present invention may have other ventilated geometries, such as mesh-like, spiral-like, lattice-like, etc., as described in more detail herein, which in various embodiments can provide improved cooling, reduced material consumption, improved flexibility, and / or other advantages described in more detail herein. The term "like" is used in conjunction with spiral-like, lattice-like, etc., to emphasize that it is a ventilated geometry similar to the referred structure, rather than a specific system structure associated with the preferred embodiments of the invention.

[0094] It is important to note that Figures 1a-1cThe three different designs of the electrical conductors shown are not limitations on the designs, geometries, or structures that can be manufactured according to the invention. Other designs that can be digitally represented and transferred to additive manufacturing equipment and thus manufactured by additive manufacturing are considered to fall within the scope of the invention. This includes planar surface designs with internal channels, designs made of different materials, fabrications with protrusions or grooves, designs manufactured to have auxiliary functions in addition to conducting current, etc. In particular, it is advantageous to manufacture high-power conductors according to the invention.

[0095] It is worth noting that embodiments of the present invention (such as the electrical conductors described above) may include additional terminals 7 and 8 (not shown) between ends 2 and 3. It should also be noted that multiple electrical conductors 1 shown may be connected together to form a complete electrical conductor. In this case, the first end 2 and the second end 3 are referred to as the ends of the complete electrical conductor, which may include terminals 7 and 8 and, for example, terminal holes 10 for connecting the complete electrical conductor to other components. Between these first ends 2 and second ends 3 of the complete electrical conductor, terminals 7 and 8 of multiple electrical conductors as shown may be connected.

[0096] In the electrical conductor of this invention, the conductivity of the conductor / conductor branch cross-sectional area can be fully utilized. The conductor is designed and manufactured so that its cross-sectional area meets the requirements for conducting current without using excessive material. When supplying a nominal current, for example, to a 1400A power module, the conductor design may not have excess material that is not used for conducting current. If additional material is used, it is for cooling the conductor or for safety margin. The software used to design the conductor can determine the amount of such additional material with relatively high precision. As a rule of thumb, the larger the surface area used for cooling, the greater the current that can be conducted. The design software can take into account factors such as ampere number, cooling characteristics (cooling medium, surface, etc.), and current frequency when designing the conductor geometry. Therefore, the conductive cross-sectional area of ​​the conductor shown in Figure 1b can be 80 mm², which in some embodiments is sufficient to conduct 1300A of current due to the very favorable cooling provided by the ventilation design. In fact, tests have shown that a conventional large busbar with a cross-sectional area of ​​516 mm² will heat up to a level that poses a risk of melting to adjacent plastic components when conducting 1300A of current.

[0097] Therefore, it should be noted that conductors can be designed and subsequently manufactured such that a percentage of the cross-sectional area of ​​the electrical conductor (e.g., more than 80%, such as between 90% and 100%) is used to conduct current during normal operation. This is in contrast to known large busbars, which do not utilize the material at their center to conduct current. This is at least true for most current frequencies conducted in high-power systems, including renewable systems and vehicles.

[0098] Compared to known large conductors, the conductor of the present invention, and therefore the individual conductor branches, can achieve a higher current-conducting cross-sectional area utilization rate because they are designed to have a total cross-sectional area capable of conducting current at a given frequency. Furthermore, material reduction is possible due to the possibility of cooling also within the conductor. In fact, the conductor branches can be cooled from all angles along most of their length (and in some embodiments, along their entire length); that is, 360° cooling of the conductor branches is possible.

[0099] As described above, the conductor of the present invention can form a ventilated geometry, which, depending on the type of ventilation, may be detrimental to forming a secure or robust platform or structure for securing the conductor to, for example, an electrical cabinet. Therefore, the conductor geometry may be non-ventilated near through-holes used to secure the conductor or for connecting the conductor to components or other conductors (e.g., terminal holes). Preferably, the conductor density is higher or more concentrated around the through-hole to form, for example, a planar surface, thereby providing the best possible prerequisites for conducting current between the two parts of the joint and distributing the forces required to secure the conductor to the joint or support structure. Thus, the through-hole can be designed as a cylinder through which bolts can pass, and has a planar upper and lower portion extending from the periphery of the cylinder to facilitate force and / or current distribution in the joint. In some embodiments, other mounting and / or termination points, such as flanges, protrusions, plugs, or sockets with or without through-holes, may be preferred, but the same consideration is taken to ensure that the electrical conductor used for the intended mounting or connection method has sufficient robustness and stability. The through-hole diameter may be 6 mm, 8 mm, 10 mm, or 12 mm.

[0100] It is worth noting that terminals for electrical connections can be located at the ends or between the ends of the conductor. Therefore, in principle, the conductor can be manufactured using additive manufacturing processes, and while manufacturing the first ends and the first portion of the intermediate segment, they can be wound onto a conductor holder while manufacturing the intermediate segment continues. Alternatively, the conductor can be guided out of the printing area via a conveyor belt during manufacturing. This may result in a long conductor with two ends. Terminals can be manufactured within the conductor either during or after manufacturing, and after manufacturing, the conductor can be cut to the desired length. In this way, terminals can be manufactured or supplied at the ends or between the ends of the conductor.

[0101] In this specification, the term "monolithic" is used to describe the geometry or structure of the electrical conductor according to the invention. Such a conductor is preferably manufactured by an additive manufacturing process, and thereby it is manufactured as a single piece, unit, or block from one end to the other, or at least one end, and the intermediate segment is manufactured as a single piece. Thus, such a conductor can be formed from a single material as a single piece, unit, or block, wherein one or more of its ends are integrally formed with the intermediate segment connecting the one or more ends; that is, integral formation should be understood as being made in a continuous process without adding one component to another. Specifically, one or more ends are manufactured together with the intermediate segment as a single unit without the need for connections such as welding, brazing, or any clamping or fastening devices, except for the micro-bonding types inherent to the specific additive manufacturing technology used, such as layer-by-layer melting, sintering, liquid bonding, spraying, etc. That said, it is worth mentioning that additional elements, such as terminals, cooling fins, etc., can be added in later manufacturing processes, for example, by a cold spraying process.

[0102] In other words, the conductor of the present invention is the result of a process in which a conductor is formed in a structure consisting of conductive material without joints or seams, and thus constitutes a rigid, integral conductor exhibiting rigid, uniformity. Additional conductors can be connected to such a conductor via terminals, thereby branching a current path into two or more current paths, and vice versa.

[0103] It is worth noting that the conductor can be made of various types of materials. In this case, the conductor can be multi-body. The term "multi-body" should be understood herein as the geometry or structure of an electrical conductor manufactured as a single, integral structure, as described above, wherein the conductor is made of two or more materials. Therefore, the multi-body conductor of the present invention is a conductor obtained by a process of forming the conductor in a single structure, wherein the process uses two or more different materials. These two or more materials can be a combination of conductive or non-conductive materials.

[0104] In most embodiments, the conductor 1 is designed to withstand high voltages, i.e., voltages above 24V, such as 110V, 230V, 400V, 690V, 1000V, 1500V, and systems up to kV. Only a few voltage levels of electrical installations to which the conductor 1 of the present invention is applicable are mentioned. In terms of current, the conductor 1 according to the invention can be designed to conduct hundreds of amperes (16, 32, 64, etc., up to 100, 200, etc., up to, for example, 900A) up to several thousand amperes (1000A-3000A). The conductor can be designed to conduct currents above 3000A, for example, by improving conductor cooling and increasing the cross-sectional area of ​​the conductive portion of the conductor.

[0105] Regarding these voltages, it should be noted that, in principle, there are no lower limits to voltage and current. That is, versions of the electrical conductor can be designed for systems such as 3.3V, 5V, 9V, 12V, 15V, 20V, 24V, or 48V (such as USB power delivery PD systems) to conduct currents below, for example, 10A, such as 5A, 3A, 2.4A, or 2A, to name just a few.

[0106] Therefore, the electrical conductor 1 of the present invention is applicable to almost any type of electrical installation. This includes all systems that require the transmission / conduction of current or communication signals, from low-voltage to high-voltage AC and / or DC systems.

[0107] This invention is particularly advantageous for electrical busbars designed for high-power electrical systems, such as those from 10 kW and above (e.g., 22 kW, 50 kW, 110 kW, 150 kW, 225 kW, 300 kW, 350 kW, 500 kW, 800 kW, 1 MW, 2 MW, 3 MW), or even higher (e.g., 5 MW or 10 MW systems), with voltages such as 110 V, 230 V, 400 V, 690 V, 800 V, 1000 V, 1500 V, 6 kV, or, for example, 10 kV, and currents such as from 16 A, 32 A, or 64 A to several hundred A (e.g., 100 A, 200 A, or 500 A), or even several thousand A (e.g., 1000 A to 4000 A). Local connection busbars refer to busbars used for local connections within high-power electrical systems. Examples include busbars included within electrical cabinets housing power converters, inverters, transformers, generators, motors, circuit breakers, high-power battery systems, battery chargers, or similar electrical systems, which may include capacitors, reactors or inductors, power resistors, bleed loads, etc. Systems, components, or conductors operating in the current range of 800-1000A or higher are classified as high-power systems, components, or conductors.

[0108] Non-limiting examples of such electrical installations / systems include energy facilities such as grid components (such as substations, transformers, power transmission plants, etc. with grid support), energy generation systems (such as wind turbines, wind farms, solar power plants, etc.), electrical installations in private residences and industries, industrial machinery, household appliances, etc., and devices for transportation (such as aircraft, heavy vehicles, light vehicles (such as automobiles, trains, ships, etc.).

[0109] Therefore, electrical conductors can be high-power conductors in high-power electrical systems. In high-power electrical systems, the spacing and / or isolation distance between conductors can be larger than the distance in motors, etc. This distance is called a safety clearance, and its size depends on the voltage difference in the system. Therefore, when relying on air as a barrier between a non-isolated busbar / conductor and another conductor or conductive material structure (such as a metal cabinet), the distance must be considered to comply with safety regulations. It is worth mentioning that air quality / pollution levels, such as humidity and particulate content, may also be related to the distance of the safety clearance. If conductors are used in high-voltage systems, their surfaces are manufactured to reduce field strength concentration.

[0110] Furthermore, according to the invention, the cross-sectional area of ​​the current path through the conductor is larger than, for example, the cross-sectional area of ​​a motor winding. This may be true for the cross-sectional area of ​​a given point on the conductor, as well as the distance (e.g., 20 cm or 30 cm) and physical dimensions along the conductor's longitudinal direction.

[0111] High-power devices or systems typically have their current-carrying busbars fixed to the structural components of the system every 25-35 cm. If the current is conducted through cables, the distance between cable fasteners may be even smaller. Cables / busbars can be secured by screwing bolts into the supporting structure (such as an electrical cabinet) or by screwing clamps into the supporting structure and then closing it. The conductive cables / busbars are, of course, insulated from the supporting structure.

[0112] In such high-power devices, the primary purpose of the conductor is to distribute electrical energy to the various components, and the magnetic field around the conductor of this invention is not as important as, for example, the magnetic field around the windings of an electric motor. Therefore, since a magnetic field is not the primary purpose of manufacturing electrical conductors for high-power devices, the conductor is typically not designed to have a specific magnetic field when conducting current.

[0113] Furthermore, compared again to, for example, the windings of an electric motor, the conductors of the present invention are typically designed with the largest possible surface area to optimize the potential advantages of the invention as described herein. Depending on the intended use of the conductor, the surface may be designed for conductivity, conductivity and heat dissipation, or heat dissipation. Therefore, although all portions of the conductors of the present invention may comprise conductive material, not all portions must be used to conduct current through the conductor. Generally, the surface area of ​​the conductor is expanded by utilizing the available area around the conductor for purposes such as heat dissipation or conductivity, or other purposes such as improving flexibility, reducing material consumption, air guidance, etc. The available area is limited by safety clearances with other conductors of different phases with different voltage levels, and grounding structures (such as electrical cabinet components).

[0114] An example of a conductor portion primarily used for non-conductive purposes (such as heat dissipation or air guiding) is an extension from the conductor surface that is not connected at its distal end where it grows from the conductor surface. For heat dissipation purposes, such an extension or protrusion preferably includes some kind of biomimetic design, with air gaps between the branches, and may have a continuous surface facing the airflow direction for air guiding purposes. If these portions are part of the conduction current of the intermediate section from one end to the other, these portions will be referred to as conductor branches. In principle, such extensions can take any form or geometry that utilizes the free space around the area, provided a safe clearance distance is maintained. In such examples, the proportion of current conducted by the surface area of ​​the extended conductor portion is very small, even if not zero.

[0115] An example of a conductor portion solely used for conducting current is theoretically impossible, as heat dissipation occurs even from solid blocks and planes. The portion of a conductor primarily used for current conduction should be understood as the varying structure or geometry of the middle section of the conductor between the first and second terminals. When the space between components in an electrical system narrows, the surface area of ​​a specific portion of the conductor's middle section may decrease to fit the available space if other conductors must pass through, such as current sensors or bushings, thus typically increasing conductor density to achieve a narrower outer dimension. In this example, in this particular section of the conductor, the current-conducting portion of the conductor's surface area becomes high; it may become so high that hot spots are generated, requiring additional cooling to maintain a certain level of current conduction. Therefore, this is an example that can benefit from a combination of the conductive portion and, for example, extensions on each side of the narrow section of the conductor, as described above. In this way, heat generated in the narrow space can be dissipated via the nearby extensions, for example, by further incorporating internal cooling channels.

[0116] An example of a conductor used for heat dissipation and current conduction is the intermediate section between terminals, featuring a ventilated design or geometry. In such examples, the surface areas serving the primary purposes of heat dissipation and current conduction can be identical or nearly identical. This is due to the geometry comprising conductor branches spaced apart from each other, allowing cooling airflow to pass freely through each conductor branch, i.e., through the air gap defined by the conductor branches. In this example, the current conduction surface area is large compared to conventional conductors / buses and windings (e.g., in motors). Another difference between motor windings and the conductor described herein lies in the conductor's perimeter. The limited internal space of a motor obviously restricts the winding's perimeter. This is not the case, for example, in an electrical cabinet incorporating the conductor of the present invention. There is more available space, allowing for a larger perimeter, thus creating a ventilated design with air gaps to enhance cooling. Furthermore, the cross-sectional area of ​​the individual conductor branches of the conductor according to the invention is generally smaller than the cross-sectional area of ​​the motor winding.

[0117] As described above, the electrical conductor 1 may include a first end 2 and a second end 3 spaced apart by an intermediate segment 4. A complete or final electrical conductor may include multiple interconnected electrical conductors 1 of the type described above. In such an embodiment, the electrical conductor shown may be used as part of a final or completed electrical conductor. Therefore, the final or completed electrical conductor may include a first end 2 and a second end 3, having multiple first terminals 7 and second terminals 8 at or between the ends, for example having terminal holes 10, for connecting multiple electrical conductors shown / described to form a final or completed electrical conductor.

[0118] Terminals 7 and 8 may include one or more terminal holes 10 or other structures for connecting the electrical conductor 1 to electrical components such as busbars, cables or other electrical conductors such as circuit breakers, power modules, batteries, etc.

[0119] Alternatively, in one embodiment, one or both of the terminals 7, 8 of the electrical conductor 1 form part of an electrical component as an alternative to providing a free connectable location at the conductor 1.

[0120] In a simplified embodiment, terminals 7 and 8 may include terminal holes 10 passing through them. Through these holes, bolts can pass through and continue through the component to which the electrical conductor 1 is to be connected. The conductor and component are then clamped together by nuts and bolts.

[0121] Alternatively, terminals 7 and 8 may be snap-fit ​​terminals designed to receive snap-fit ​​portions from components to which electrical conductors will be connected, or may be designed to have click portions to which they will be inserted into other such components.

[0122] Alternatively, the terminals 7 and 8 at the ends 2 and 3 of the conductor can be manufactured to have threads, which, when engaged with a bolt, can help clamp the component onto the conductor 1.

[0123] Furthermore, it should be noted that the electrical conductor shown in the figure, or a completed electrical conductor comprising multiple electrical conductors (such as the aforementioned conductor), may have multiple first ends 2 or multiple second ends 3. Therefore, one end of the electrical conductor 1 may branch into, for example, three terminals, each with a terminal hole. This can be advantageous because the geometry of the electrical conductor is specifically designed according to the components it is to connect to. Branching the end into several terminals also improves heat dissipation at potentially denser terminal sections, improves the electrical connection between the conductor and the components, and avoids the use of additional connectors or shunts to connect adjacent components to a common conductor.

[0124] The intermediate segment 4 may include one, but preferably multiple, conductor branches 5. Similar to the end segments 2 and 3, the conductor branches 5 are at least partially made of a conductive material (such as copper or aluminum or their alloys) to enable the electrical conductor 1 to conduct current between its terminals 7 and 8. The design of the conductor branches 5 can be optimized for specific purposes (such as cooling, material consumption, flexibility (control in a particular direction), area occupied, etc.). Therefore, depending on which parameters the electrical conductor 1 is designed according to, the conductor branches can be designed as longitudinal cylinders (or other geometries, such as ellipses, squares, etc.), mesh-like, biomimetic, spiral-like, lattice-like, branch-like, sponge-like, coil or solenoid designs, helices, etc.

[0125] Therefore, electrical conductors can have perforated surfaces, non-perforated surfaces, large-scale structures, or structures with internal channels to optimize the electrical conductor based on factors such as the skin effect and cooling.

[0126] Two or more conductor branches 5 may meet at intersection 9, and two or more conductor branches 5 may branch off from intersection 9. The effect of this is to create an electrical conductor that maintains the desired strength (defined yield point) with minimal material. Furthermore, this reduces the cost of conductive materials and lightens the weight of the conductor. It is worth noting that the two conductor branches meeting at intersection 9 can be the same two conductor branches that have left intersection 9. Alternatively, two other conductor branches may leave the intersection; however, this can be a matter of defining the conductor branches. Moreover, a conductor branch may branch into multiple conductor branches, and multiple conductor branches may merge to form a smaller number of conductor branches.

[0127] Furthermore, it is worth mentioning that the electrical conductor 1 can be designed as multiple electrical conductors, for example, as a combination of three-phase conductors, or as a wire harness or printed circuit board trace for mounting in an electrical panel.

[0128] At least the first end 2 and the intermediate segment 4, but preferably also the second end 3, of the electrical conductor 1 of the present invention are integrally formed because they are made from a single piece of material, which is machined to provide the electrical conductor 1. Here, the material body should be understood as a material such as the conductive material constituting the electrical conductor 1, for example, a solid, powder, liquid, wire, etc. The machining here should be understood as manufacturing by additive manufacturing, i.e., the electrical conductor 1 is made as a single piece without any mechanical connection between the first end 2, the second end 3, and the intermediate segment 4.

[0129] It is worth noting that multiple types of materials (e.g., two blocks of materials) can be used to create an electrical conductor. One of these two or more blocks of materials can be non-conductive.

[0130] It is worth noting that in some embodiments, it may be necessary to manufacture more than one electrical conductor. In this case, the electrical conductor may be referred to as a finished or final electrical conductor, which includes multiple electrical conductors 1 as described above. This may occur, for example, if it is necessary to install the electrical conductor in a location where it cannot be inserted, unless the electrical conductor is divided into two or more parts, or the finished electrical conductor must be larger than the size that can be manufactured by additive manufacturing. In this case, the terminals of the two electrical conductors are connected, extending the length of the intermediate section, thereby extending the current path between the first end 2 and the second end 3, and thus extending the overall length of the electrical conductor. This connection can be fabricated by designing terminal holes in the conductor, for example, a fishplate or other connector can be fixed in the terminal holes to connect the two intermediate sections.

[0131] It should be noted that the electrical conductor 1 can have a non-uniform geometry / design. The design / geometry can take any machinable / printable shape. This shape can be optimized based on factors such as conduction current (skin effect), cooling, guidance of cooling fluid flow, other components in the panel, resistance, power loss, or current displacement.

[0132] In a particular embodiment, the electrical conductor 1 may have a non-uniform diameter along its length (measured in the transverse direction). Nevertheless, a well-defined diameter can still be determined, for example, at the transverse plane where the electrical conductor 1 has its minimum diameter.

[0133] Furthermore, in embodiments of the invention, the perimeter of the electrical conductor 1 or its conductor branch 5 can vary in a transverse plane at different locations along the length of the electrical conductor 1. The perimeter of a given portion of the intermediate section can be simply measured as the sum of the perimeters of all branches on a given cross-section. Therefore, the perimeter at a given portion can be the length of the perimeter of the conductor branch measured across / perpendicular to the longitudinal direction of the electrical conductor at that portion. A portion of the conductor can also be referred to as a part of the conductor and should be understood as a reference to a specific section of the conductor (such as an end or intermediate section).

[0134] The perimeter of conductor branch 5 can be the sum of the perimeters of all individual conductor branches 5. Since a conductor branch can split from a trunk into two or more twigs (i.e., multiple branches of a branch), the perimeter of a portion of a conductor branch may vary from one portion (e.g., a twig portion) to another (e.g., a trunk portion). Therefore, the sum of the perimeters of the conductor branches can be the sum of the perimeters of all individual twigs, or the sum of the perimeters of all individual trunks. If there are multiple different possible perimeters for a portion of the conductor along its length, the smallest perimeter is preferably used to calculate the current-conducting capacity of the conductor 1.

[0135] Similarly, the cross-sectional area of ​​an electrical conductor at a given section is measured as the sum of the cross-sectional areas of all conductor branches at that section along the length of the conductor. The cross-sectional area at this section should be measured perpendicular to the longitudinal direction of the electrical conductor.

[0136] In one embodiment, the electrical conductor 1 may include one or more cooling channels, wherein the cooling channels may be placed laterally and / or longitudinally within one or more conductor branches.

[0137] The electrical conductor 1 can be manufactured using additive manufacturing processes. These processes can be based on, but are not limited to, one of the following additive manufacturing techniques: 3D printing, layer-by-layer printing, line-arc additive manufacturing, fused deposition modeling (FDM), direct energy deposition, direct metal deposition, sintering-based processes, laser-based processes such as powder bed fusion (PBF), selective laser melting (SLM) or selective laser sintering (SLS), cold spray additive manufacturing (CSAM), binder jetting, or binder jetting 3D printing. It is worth noting that the actual additive manufacturing process used to print or construct the electrical conductor 1 may not be important as long as the material constituting the conductor is conductive.

[0138] Figure 2 The illustration depicts method steps for machining an electrical conductor 1 according to an embodiment of the present invention. This particular method relates to forming an electrical conductor having two ends or two terminals (i.e., a first end / terminal and a second end / terminal via a middle section), but can be used to produce any type of electrical conductor according to the present invention.

[0139] It is worth noting that this can include manufacturing both ends and the middle segment in a single process. Therefore, by additive manufacturing along the conductor's longitudinal direction, the method can begin by manufacturing (e.g., printing) one end, then proceeding to the transition of the middle segment, possibly with one or more conductor branches, then the middle segment, then to the transition of the second end, and finally the second end. In another embodiment, additive manufacturing is performed along the conductor's longitudinal direction, for example, simultaneously manufacturing portions of both ends and the middle segment, increasing the cross-sectional area of ​​the layer for each application. In yet another embodiment, additive manufacturing is radial or arbitrary relative to the conductor's longitudinal direction, for example using cold spray CSAM or fused deposition modeling (FDM), while rotating or freely moving the conductor unit or nozzle being constructed, or both. Preferably, these segments are manufactured in a single process, for example, while one segment is being manufactured, the next segment is being manufactured. A transition portion can be created between the two segments, which may initiate or include the first segment. Similarly, the second segment may include or connect to such a transition portion.

[0140] It should also be mentioned that, in some embodiments, the method may include manufacturing intermediate segments and subsequently attaching end segments. The end segments may be attached during additive manufacturing or after manufacturing using additive manufacturing thermal paste or adhesive. The end segments may also be welded, bonded, or attached to the intermediate segments in any other way, such as by cold spraying CSAM.

[0141] Another embodiment of the invention may be a manufacturing method comprising two or more intermediate segments being additively manufactured. The two or more intermediate segments may be formed into an electrical conductor in the same process as two end segments through additive manufacturing. Alternatively, the two or more intermediate segments may be additively manufactured separately and then joined together to form an electrical conductor.

[0142] Two or more intermediate segments can be identical or two intermediate segments of different shapes or properties, depending on where the electrical conductor should be placed, such as in an electrical cabinet.

[0143] A transition section can be directly defined as a change in layer size compared to the previous layer. In this way, a transition section can be formed as a vertical transition between conductor branches at the ends and in the middle. Alternatively, subsequent layers can change their cross-sectional area and thus form a circular transition section, which is advantageous for reducing the resistance of the current conducted between the ends of the conductors.

[0144] The integral conductor according to the invention is made of a single material. One or more additional materials can be used, for example, as insulation, heat dissipation, etc., in which case the conductor can be referred to as a multi-body conductor. Regardless of the amount of material, the conductor produced by additive manufacturing is produced point by point from a first spatial coordinate (x, y, z) to an end of a second spatial coordinate. At least when the conductor is completed, the first and second spatial coordinates are electrically / mechanically connected. As described above, there are several methods for manufacturing conductors, including the deposition, bonding, or welding of a certain material, to manufacture a conductor in integral form.

[0145] In this paper, regardless of the additive manufacturing method used, the conductor can be referred to as being manufactured layer by layer. Therefore, if a conductor is sliced ​​(in any direction) and its cross-section is observed, it is easy to imagine that the conductor is manufactured starting with the material at a first point, then with the material at a second point, and so on. Since the conductor has volume, i.e., a three-dimensional geometry, the first point differs from the second and subsequent points at least in one of the spatial X, Y, and Z directions / planes. Therefore, referring to the spatial X, Y, and Z planes, it can be said that the conductor is constructed from multiple subsequent layers, even though during manufacturing, all the material in a plane (such as X=1, Y=0, and Z=0) is not provided as a single layer, nor is it provided in a single layer before the material of the next layer (e.g., layer X=2) is provided.

[0146] Therefore, regardless of which process is used to manufacture a three-dimensional object (such as the conductor used), it can be said that the conductor is manufactured layer by layer, even if some of these manufacturing processes are based on deposition, bonding, or curing, with material added together in areas, lines, points, etc. This is because, regardless of the additive manufacturing process used, the conductor is manufactured point by point. Multiple points in the same plane (e.g., X=3) are also considered a layer if they are not physically connected in that plane. When all the points in this layer have been added, the points in the next layer (e.g., X=4) are added to the points in the X=3 layer. As mentioned above, layers can be defined in any plane of the spatial Cartesian coordinate system.

[0147] Alternatively, the end segment can be a separate segment connected via an intermediate segment. The intermediate segment can be printed, and during the manufacture of the intermediate segment, it can be attached to the end segment by means such as printing, heating, or bonding. The intermediate segment can be joined to the end segment by means of welding, printing, brazing, etc.

[0148] It should be noted that the end may include terminals for connecting the electrical conductor to other electrical components / conductors / windings in the electrical system. Such terminals may be manufactured, similar to the rest of the electrical conductor, by additive manufacturing (i.e., integrally formed with the end).

[0149] In step S1 of this particular method, a conductor is additively manufactured along its longitudinal direction from a first end toward a second end, and a first end segment and an intermediate segment in the form of conductor branches of a plurality of conductor branches are integrally formed via individual transition portions. These transition portions may or may not include circular connections to form concave inner angles between the first end segments and the conductor branches of the plurality of conductor branches, and to spatially separate the conductor branches of the plurality of conductor branches.

[0150] Various methods can be used to achieve the step of integrally forming the first end segment and the conductor branch, such as additive manufacturing methods, 3D printing, casting, and simply removing material from a large metal sheet via machining to form the conductor branch bonded to the first end segment.

[0151] More specifically, known large conductors (such as main busbars 3-5m long) can conduct 1-2A per square millimeter. If the same busbar is designed with ventilation, such as internal cooling, then due to improved cooling, it can still conduct the same 1-2A per square millimeter with the same efficiency, even with material removal. Typical conductor materials (such as aluminum and copper) have a temperature coefficient of about 0.4% per degree Celsius. If such conductors are effectively cooled, making the temperature 25 degrees Celsius lower than, for example, conventional conductors, the resistance will decrease by about 10%. Therefore, about 10% of the material can be removed without loss. Furthermore, in AC conductors, the current distribution within the conductor volume is not uniform. Typically, the current density decreases towards the center of the conductor. Taking these factors into account, further material can be removed without affecting the conductor's efficiency.

[0152] In step S2 of the method, the first end segment is electrically coupled and mechanically coupled to the second end segment via an intermediate segment of an electrical conductor formed by multiple conductor branches. This can also be achieved integrally, for example, by continuing additive manufacturing, as described in step S1.

[0153] The coupling between the end sections and the middle sections can also be accomplished by welding, gluing, male / female locking mechanisms, or any other method that can mechanically and electrically connect the sections.

[0154] Optional additional steps in the method for manufacturing the conductor of the present invention include steps prior to the steps of additive manufacturing the first, second, or intermediate segments. The step prior to manufacturing the electrical conductor is the step of designing a digital representation of the electrical conductor in a software program (e.g., 3D CAD software). Designing the digital representation of the electrical conductor in the software program includes considering the electrical, mechanical, structural, geometric, and other aspects of the physical electrical conductor. Therefore, based on these inputs (e.g., provided by the user of the 3D CAD software), the 3D CAD software provides a digital representation of the conductor. Once the digital representation of the electrical conductor is complete, the additive manufacturing process can begin.

[0155] Further optional steps can be applied, namely heat treatment of the final conductor. Depending on the material, the heat treatment can, for example, be at 400°C or higher for 4 hours. The advantage of heat treatment is that the particles of the manufactured conductor can be aligned or fused together, resulting in higher thermal and electrical conductivity. At least for This is indeed the case for CP1 20 / 63 aluminum powder and other aluminum-iron-zirconium powder solutions. This type of powder can be used in laser powder bed fusion machinery. Using this type of powder and heat treatment can result in higher thermal stability, thermal conductivity, corrosion resistance, surface finish, and higher electrical conductivity.

[0156] The intermediate segment can, in principle, have any design / geometry, for example, to provide flexibility, thus allowing the electrical conductor to deform. It can be formed from solid conductor branches or those with internal cavities to reduce the amount of material required to manufacture the electrical conductor. It can be formed from a mesh or a mixture of conductor branches or meshes; only a few possible designs are mentioned.

[0157] The internal cavity can be used as a cooling channel and / or an additional surface for conducting high-frequency currents. Therefore, the end sections and intermediate sections can be designed for the specific panel / electrical system used, to conduct specific types of current, or to have desired or dual functions, etc.

[0158] In addition to the functions mentioned above, one such function can be as structural support. Therefore, if needed, the electrical conductor can be designed to help support the weight of the electrical components connected to it. Thus, its size can be larger than the current required to carry the desired current. Similarly, its geometry can be designed for a combination of mechanical support and electrical conduction. This is especially true if such support is flexible / deformable, as it can both help provide support and simultaneously help absorb vibrations.

[0159] It is worth noting that the electrical conductor 1 can be manufactured at two or more resolutions. The thicker the layer, the faster the manufacturing speed. The layer thickness depends on the material and printing equipment and can range from a few millimeters to 20 μm; using some combinations, the layer thickness can be between 50 μm and 150 μm. In the case of additive manufacturing, the resolution can be defined by the thickness of the layers that constitute (another way of saying machining and processing) the electrical conductor. When manufacturing the joint between the electrical conductor and the component it is connected to, a first resolution that is finer than the second resolution can be used, i.e., with a thinner layer size. This joint can be the part where the terminal contacts other parts. Alternatively, the resolution can be determined by the material deposition rate, material flow rate, etc., depending on the type of additive manufacturing used.

[0160] To avoid electrical losses when two electrical conductors are connected, the two components preferably have mating surfaces, which is most simply achieved by having flat surfaces. However, it can also be achieved through convex-concave combinations, mortises or finger joints, meshing teeth, cylinders and pins, tenons, sliding locks, etc., to further achieve additional advantages, such as a larger connection surface area and easier assembly of electrical conductors (such as busbars) in electrical systems through self-locking, provided that a good electrical connection is preferred. The more refined these joints are manufactured, the better / less post-manufacturing processing is required to ensure a perfectly mating surface, such as a flat surface.

[0161] For example, a second resolution fabricated with thicker layers will be coarser, resulting in a larger surface area. This can lead to more current conduction, at least for mid- and high-frequency currents, without increasing the demand for conductor material / size. In fact, intermediate sections can be intentionally fabricated with corrugated surfaces to increase the current-carrying outer surface of the conductor (for mid- and high-frequency current carrying), as the turbulence (e.g., cooling airflow) generated by the corrugated surface allows for more efficient cooling. It should be noted that if the conductor includes an internal space, the inner surface of the conductor forming this internal space can also be corrugated for the same purpose. In addition to providing a larger surface area, corrugated surfaces also introduce turbulence into the flow of cooling fluids such as air. The increased velocity of the cooling fluid can enhance the cooling effect.

[0162] As an example, in a particular embodiment, the depth of the conductor used to conduct current at intermediate and high frequencies can be approximately 1.5 mm. In this specific example, the conductor is made of copper with a resistivity of approximately 1.68 μΩcm and a relative permeability of approximately 1 at a frequency of 2 kHz. Therefore, the conductor used in this particular embodiment can be hollow with a conductor thickness of twice 1.5 mm. In practice, such a conductor can be manufactured with a thickness of 4-5 mm to allow space for internal cooling, or simply by reducing the conductor material to reduce weight.

[0163] The skin effect is known to occur at frequencies such as 50Hz. The skin effect refers to the mid-frequency range, specifically frequencies starting around 500Hz. Conductor design can take the skin effect into account. The mid-frequency range can be between 500Hz and 10kHz; frequencies above 10kHz are considered high-frequency, where the skin effect is a fact (the higher the frequency, the closer the current is to the surface).

[0164] In addition, it is worth mentioning that the outer surface can also be corrugated or designed with fins to increase heat dissipation from the electrical conductor.

[0165] The electrical conductor produced by this method can be used as an electrical conductor in electrical equipment. This electrical equipment can be an electrical panel, which may be part of renewable energy facilities such as wind turbines, solar systems, power grids, and substations. The electrical equipment or systems using the electrical conductor can be electric vehicles, battery systems, universal power supply facilities, ships, or other small or large electrical systems. Furthermore, the electrical conductor produced by this method can be used inside electrical panels, i.e., in cabinets / enclosures, or outside such panels, where it can be used to connect separate panels, etc.

[0166] Variations of the electrical conductor according to the invention are connected to conventional cables or busbars. In such embodiments, a conventional busbar, for example, on the back of an electrical panel or a conventional cable, for example, between two electrical panels, can be connected to the electrical conductor of the invention. In this way, conventional cables or busbars can be connected to components via the conductor according to the invention. Therefore, the flexibility of the electrical conductor of the invention facilitates easy connection.

[0167] However, it should be noted that the fabrication of the electrical conductor, and thus the realization of the electrical and mechanical coupling between the first and second end segments, is typically performed before the electrical conductor is installed into the electrical installation and before the electrical installation is installed into the renewable energy facility. Therefore, according to a typical embodiment of the invention, the electrical and mechanical coupling is performed prior to the installation / integration of the electrical conductor. However, the method according to the invention is not necessarily limited to a specific sequence of steps. Furthermore, various methods according to the invention may include additional steps such as performing digital geometry optimization, additive manufacturing of the electrical conductor, and conduction of current.

[0168] In summary, designers are creating digital representations of conductors in 3D CAD software such as Solidworks, based on electrical, mechanical, and structural requirements. The files (digital representations) from these 3D development tools are then exported to, for example, a 3D printer, where the conductors are printed according to the CAD files.

[0169] As mentioned above, Figures 1a-1c Various embodiments of the electrical conductor 1 according to the present invention are illustrated, which may include one or more heat sinks 11. Figure 3 The conductor 1 shown is a top view, having two ends 2, 3 and a middle section 4. At least the middle section 4 of the conductor 1 includes a heat sink 11 formed as an air-permeable heat sink 11b.

[0170] The remaining portion of the conductor / conductor surface can have the same geometry as heat sink 11, so the entire conductor 1 can effectively function as a heat sink. However, in Figure 3 In the embodiment shown, only a portion of the middle segment 4 includes the heatsink definition design.

[0171] The air-permeable radiator 11b should be understood as a structure of the current-conducting intermediate section 4, which allows airflow to pass through while current flows through the structure. Therefore, the air-permeable structure includes multiple air gaps 6, which can be uniform (as shown in a mesh structure) (see...). Figure 1b ), or they can be different (as shown in biomimetic design) (see Figure 1c ).

[0172] It is important to note that, regardless of whether a heat sink is used or not, the conductive cross-sectional area of ​​conductor 1 should remain the same or at least greater than the minimum cross-sectional area. Therefore, when manufacturing conductor 1 with an integrated heat sink 11, the air gap 6 for establishing the air penetration design can be compensated for, for example, by increasing the physical dimensions of the conductor to maintain the desired minimum cross-sectional area.

[0173] Figure 4 The diagram illustrates a component 12 connected to conductor 1. Component 12 is a heat-generating component that generates heat during operation. This heat must be removed from the component to ensure continuous operation under rated load, achieve the expected lifespan, and generally meet the component manufacturer's requirements for operating conditions. To achieve a compact design for high-power electrical systems using component 12, conductor 1, with an integrated heat sink 11, is electrically connected to the component, for example, as a power / power conductor for component 12. The electrical connection is at the component's terminals. Furthermore, conductor 1 is also thermally connected to component 12 at a location different from the electrical connection between conductor 1 and component 12.

[0174] As shown in the figure, component 12 is connected to a first conductor 1a including a heat sink 11 and a second conductor excluding the heat sink. It should be noted that a conductor with a heat sink not electrically connected to the component can also be used to remove heat from the component via an integrated heat sink thermally connected to the component. In all cases, requirements for distance and isolation must be observed.

[0175] Conductor 1 is shown as a load-bearing component 12 or is at least connected to component 12 via fasteners 21 (such as screws or bolts). Such fixation of component 12 in / to conductor 1 may be possible, but typically component 12 is also fixed or supported by DIN rails or other support structures, and is therefore usually indirectly supported by an electrical cabinet that houses component 12 and conductor 1.

[0176] The heat sink 11 shown includes various components, such as an air-permeable geometry 11a serving as a base, a protrusion 11b (which may also be ventilated) forming from the base, and finally a groove 11c forming in the base. It is worth noting that the heat sink is designed by computer software based on user input (e.g., input related to available space, current level, operating time, etc., relating to the heat sink geometry).

[0177] The groove 11b can be used to establish a predetermined airflow into the base portion 11a and the protrusion 11b. It should be noted that an air guide, not shown, can also be used to guide the airflow in a specific direction. Furthermore, the protrusion 11b can have the dual function of guiding airflow and removing heat from the component.

[0178] As a result of the additive manufacturing process, the heat sink 11 can be integrally formed with one of the end and / or intermediate sections. Alternatively or additionally, the heat sink or additional heat sink can be releasably mounted to the conductor, for example, via heat sink fasteners.

[0179] The heat sink can be an integrated component formed integrally with the conductor, such as through additive manufacturing processes. It should be noted that the heat sink can be made of a different type of material than the conductor. In this case, a multi-body formed heat sink and conductor might be more accurate.

[0180] The conductor may include radiator fasteners, which can be formed by grooves or protrusions for attaching external or additional radiators. The advantage of such radiator fasteners is that they not only facilitate easy attachment of the radiator to the conductor 1, but also ensure that the removably attached radiator is accurately positioned in a predetermined location. This location is typically determined from experience or simulation of the electrical cabinet layout in which the conductor is installed.

[0181] A removable or attachable heatsink may include protruding or recessed portions configured to engage with heatsink fasteners. The heatsink may be constructed such that it forces the recesses / protrusions together, or it may include springs that ensure the heatsink is securely fastened to a conductor. To remove the heatsink, force may be applied at a predetermined location on the heatsink to release the recesses / protrusions from the heatsink fasteners.

[0182] If the heatsink fastener is a protrusion, the removable heatsink may include a corresponding recess; conversely, if the heatsink fastener is a recess, the removable or attachable heatsink may include a protrusion. Therefore, a removable or attachable heatsink can be connected by engaging the recess / protrusion of the heatsink with a corresponding heatsink fastener on one side of the conductor. The removable or attachable heatsink is then pushed into the recess / protrusion of the conductor, engaging with the heatsink fastener on the other side of the conductor.

[0183] The heat sink fasteners can be either protrusion or recess type. Other types besides those shown can also be used. Furthermore, some components (i.e., protrusions or recesses) can surround conductor 1.

[0184] As shown in the figure, an additional heat sink 13 is located between component 12 and heat sink 11. This additional heat sink can be used to establish a safety clearance between the component and the conductor / heat sink.

[0185] Depending on the required clearance distance, it is sufficient to provide a thermally conductive but non-conductive material between component 12 and conductor 1 / heat sink 11. Examples of such materials include ceramics, plastics (such as polyester film, polycarbonate, acetylene, etc.), and rubber. Such materials are only used when air is insufficient to meet the clearance requirements.

[0186] The additional heat exchanger 13 can, in principle, be located anywhere on conductor 1, regardless of the component's position. Therefore, if, for some reason, the temperature at a certain point on the conductor is higher than expected, an additional heat exchanger can be installed on the conductor at that location. This allows for temperature reduction without requiring any major adjustments to the electrical system or its operation. If no heat exchanger fasteners are available on the conductor, the additional heat exchanger can be attached to the conductor using cable ties, glue, or similar methods.

[0187] Figure 5 The illustration shows an electrical cabinet 22 comprising a high-voltage and / or high-power electrical system 17. System 17 includes multiple conductors 1, one of which includes an integrated heat sink 11 and power electronic components 14, such as power modules. During operation, the power electronic components 14 and other components generate heat, which can be at least partially removed by a liquid cooling system. However, some of the generated heat may not be removed by the liquid cooling system. Heat must be removed from the components via airflow (e.g., via a heat sink) to ensure safe and stable operation, especially since heat generated by non-liquid-cooled components requires a heat sink.

[0188] Figure 5 The system shown benefits from the conductor 1 with a heat sink 11. Therefore, regardless of whether it is electrically connected to components 14, 12, the heat sink 11 of the conductor 1 is thermally connected to the component to remove heat from it. In this way, at least some heat sinks connected to the component are no longer needed, and thus the system can become more compact when using a conductor with an integrated heat sink as suggested by the present invention.

[0189] Then, in order to remove heat from the radiator 11, an airflow 15 is preferably established from the inlet 18 to the outlet 19 via the fan 16. The fan 16 can be controlled by a signal from a temperature sensor, which can be received directly from the sensor or from a controller that communicates with both the sensor and the fan 16.

[0190] As shown in the figure, in order to ensure that air 15 flows correctly through the heat sink 11, an external (to conductor) air guide 20 can be positioned in the cabinet 22 to ensure the desired direction of airflow. This external air guide 20 can be supported by the cabinet, the conductor, or both.

[0191] As shown and described above, the integrated heat sink may not be directly connected to components 12, 14. Therefore, to establish the desired safety clearance, non-conductive thermal paste or an additional heat sink can be used between the integrated heat sink 11 and components 12, 14. Figure 5In the specific embodiment shown, the power module is separated from the heat sink 11 by an additional heat sink 13, while the component 12 is separated from the heat sink only by a thermally conductive material. This is because the power and / or voltage of the power module 14 is higher than that of the component 12, and therefore the safety clearance with the component 12 is lower than that with the power module 14. Thus, both the power module 14 and the component 12 can be at least partially cooled via the integrated heat sink 11 of the conductor 1.

[0192] Figure 6 An embodiment of the invention is illustrated, wherein an integrated heat sink 11 is integrated at end 2 of conductor 1. This is merely to illustrate that the heat sink 11 can be integrated at any location on conductor 1. The reason the heat sink can be integrated at end 2 of conductor (where end 2 connects to components 12, 14) is that the conductor can serve as a heat sink for components 12, 14. Therefore, by providing an integrated heat sink 11, the desired conductor mass / surface area can be reduced to ensure adequate heat removal from components 12 / 14.

[0193] Figure 7 The illustration shows a conductor with a heat sink 11 according to an embodiment of the present invention. The heat sink 11 is preferably integrally formed with the conductor 1 to take into account the airflow direction within the cabinet where the conductor is mounted. The corrugated heat sink 11 ensures optimal airflow above the conductor (i.e., on the end sections 2 and 3 and the middle section 4).

[0194] The radiator 11 forms a predetermined flow path, which can be at least partially defined by the radiator and thus can also be used as an air guide. The radiator 11 can be found on both sides of the conductor, so the radiator can be a plate through which the conductor passes.

[0195] Figure 8 The diagram illustrates conductor 1, which can be considered a connecting conductor or transition conductor connected to a heat-generating component 12 (such as an electrical switch). Heat generated by the heat-generating component can be guided away from the end / contact surface of conductor 1 connected to the switch via internal channels and a heat sink 11. The heat sink is located towards the end of the conductor connected to the heat-generating component 12. In this way, heat can be removed from this end / heat-generating component and enter into an opening around the conductor. Furthermore, airflow can be generated or provided by defining channels between the various walls of the heat sink inlet 14, which helps remove heat from the contact surface / conductor.

[0196] The two main busbars, labeled 1a and 1b, can be connected to conductor 1 via terminals labeled 7 and 8. Therefore, as indicated above, the internal channel 11 can also be used as a bolt enclosure or guide, i.e., during installation, the internal channel 11 can accommodate bolts that connect conductor 1 to the busbars.

[0197] This type of busbar can also be considered a heat-generating component 12. Figure 8Heat from the upper busbar 1a can also be removed via the internal channel 11. More specifically, the internal channel 11 is indicated by a pointer pointing outwards. Busbars 1a and 1b indicate two buses, but can also be one.

[0198] It should be noted that, in order to optimize heat distribution and heat exchange with the surrounding air, the outer surface of conductor 1 may also be equipped with a heat sink 11, as shown between terminals 7 and 8.

[0199] As can be clearly seen from the above, the present invention relates to an electrical conductor comprising an integrated heat exchanger. This heat exchanger, and therefore the conductor, can be strategically positioned in an electrical system to remove heat from uncooled components. In this way, the conductor of the present invention with an integrated heat sink is capable of cooling components such as power modules in an electrical system.

[0200] The present invention has been illustrated above with reference to specific embodiments, which are intended to be illustrative rather than limiting. Details of specific embodiments have been provided to facilitate understanding of the objectives of the invention. Please note that detailed descriptions of well-known systems, devices, circuits, and methods have been omitted to avoid unnecessary detail affecting the description of the invention.

[0201] List

[0202] 1. Electrical conductor

[0203] 2. First end

[0204] 3. Second end

[0205] 4. Middle section

[0206] a. First end

[0207] b. Second end

[0208] 5. Conductor branching

[0209] a. Vertical conductor branch b. Transverse conductor branch

[0210] 6. Air gap

[0211] a. Longitudinal air gap (X direction)

[0212] b. Lateral air gap (Y direction)

[0213] c. Vertical air gap (Z direction)

[0214] 7. First terminal

[0215] 8. Second terminal

[0216] 9. Intersections and forks

[0217] 10. Terminal hole

[0218] 11. Radiator

[0219] a. A radiator with an air-permeable geometry. b. A radiator as a protrusion.

[0220] c. The radiator is used as a recess.

[0221] 12. Heating Components

[0222] 13. Additional radiator

[0223] 14. Power electronic components

[0224] 15. Airflow

[0225] 16. Fan

[0226] 17. Electrical System

[0227] 18. Air Inlet

[0228] 19. Air vent

[0229] 20. External air guide

[0230] 21. Fasteners

[0231] 22. Electrical cabinet

[0232] 23. Thermal paste

Claims

1. An electrical conductor (1) comprising at least one first terminal (7) and at least one second terminal (8) separated by an intermediate segment (4), said intermediate segment (4) being configured to support current conduction between said at least one first terminal (7) and said at least one second terminal (8). Its features are, The intermediate section (4) includes at least one integrated heat sink (11).

2. The electrical conductor (1) as claimed in claim 1, wherein, The at least one heat sink (11) is removably attached to the middle section (4) of the electrical conductor (1).

3. The electrical conductor (1) as described in any one of claims 1 or 2, wherein, The at least one heat sink (11) is an integrated portion of the intermediate segment (4) of the electrical conductor (1).

4. The electrical conductor (1) according to any one of the preceding claims, wherein, The electrical conductor includes an integrated fan fastener (12).

5. The electrical conductor (1) according to any one of the preceding claims, wherein, The integrated heat sink (11) is formed from the conductive material of the intermediate section (4).

6. The electrical conductor (1) according to any one of the preceding claims, wherein, The integrated heat sink (11) is the intermediate segment (4) of the electrical conductor (1), wherein the intermediate segment (4) is at least partially formed with an air-penetrating geometry (11a).

7. The electrical conductor (1) as claimed in claim 6, wherein, The air-penetrating geometry (11a) is selected from the following list: spiral-like design, branch-like design, biomimetic design, mesh-like design, honeycomb-like design and sponge-like design.

8. The electrical conductor (1) according to any one of the preceding claims, wherein, The first terminal (7) includes a first end (2), and the second terminal (8) includes a second end (3), wherein the heat sink (11) is integrated in the first end (2) or the second end (3).

9. The electrical conductor (1) according to any one of the preceding claims, wherein, The middle section (4) having the integrated heat sink (11) is a monolithic geometry.

10. The electrical conductor (1) as claimed in claim 9, wherein, The integral geometry includes one or more protrusions (11b) or one or more grooves (11c).

11. The electrical conductor (1) according to any one of claims 9-10, wherein, The one or more protrusions (11b) are integrally integrated with the intermediate section (4) as one or more outwardly extending cooling fins.

12. The electrical conductor (1) according to any one of the preceding claims, wherein, The intermediate section (4) is thermally connected to the heating element (12), wherein the thermal connection is at a physical location on the heating element (12) that is different from the physical location on the heating element (12) that is electrically connected to the electrical conductor (1).

13. The electrical conductor (1) according to any one of the preceding claims, wherein, The integrated heat sink (11) is directly connected to the heat-generating component (12).

14. The electrical conductor (1) according to any one of the preceding claims, wherein, The electrical conductor (1) is configured to supply power to the component (12), and the intermediate segment (4) including the integrated heat sink (11) is configured to remove heat from the component (12) via the integrated heat sink (11).

15. The electrical conductor (1) according to any one of the preceding claims, wherein, The intermediate section (4) is thermally connected to the heat-generating component via an additional heat sink (13).

16. The electrical conductor (1) as claimed in claim 15, wherein, The additional heat sink (13) is at least partially made of a non-conductive material.

17. The electrical conductor (1) according to any one of the preceding claims, wherein, The intermediate section (4) with an integrated heat sink (11) is located at the cold spot in the electrical cabinet (22).

18. The electrical conductor (1) according to any one of the preceding claims, wherein, The intermediate section (4) with an integrated heat sink (11) is located at a hot spot in the electrical cabinet (22).

19. The electrical conductor (1) according to any one of the preceding claims, wherein, The intermediate segment (4) and the integrated heat sink (11) are manufactured at least partially simultaneously by an additive manufacturing process.

20. The electrical conductor (1) according to any one of the preceding claims, wherein, The intermediate section (4) is integrally formed of conductive material.

21. The electrical conductor (1) according to any one of the preceding claims, wherein, The intermediate segment (4) is integrally formed at the first end (4a) with the first end (2) of the electrical conductor (1), and at the second end (3) with the second end (4b) of the electrical conductor (1).

22. The electrical conductor (1) according to any one of the preceding claims, wherein, The intermediate segment (4) includes multiple conductor branches (6).

23. The electrical conductor (1) according to any one of the preceding claims, wherein, The electrical conductor (1) has a resonant frequency of at least 5 Hz, for example at least 20 Hz, for example at least 30 Hz, for example at least 70 Hz, for example at least 150 Hz, for example at least 300 Hz, for example at least 500 Hz.

24. An electrical conductor manufactured according to any one of the preceding claims by the method of claims 25-26.

25. A method for cooling a power electronic component (14) by physically connecting it to an electrical conductor (1), wherein, The electrical conductor (1) includes an intermediate section (4) having an integrally integrated heat sink (11), wherein the method includes the step of providing an airflow (15) through the integrated heat sink (11).

26. The method of claim 25, wherein, The airflow is generated by a fan (16).

27. A high-power electrical system (17), comprising: - An electrical cabinet (22) including an air inlet (18) and an air outlet (19), - A plurality of electrical conductors (1), wherein at least one of the plurality of electrical conductors includes a first end (2), and -At least one heating element (12) included in the electrical cabinet (22), At least one of the plurality of electrical conductors (1) includes at least one integrated heat sink (11). The radiator (11) is thermally connected to the at least one heat-generating electrical component (12) at a first location. Wherein, the first end (2) of the electrical conductor (1) is electrically connected to the at least one heating electrical component (12) at a second position, wherein the first position and the second position are different positions.

28. The system of claim 27, wherein, The fan (16) is configured to establish an airflow (15) between the air inlet (18) and the air outlet (19), and wherein at least one of the plurality of electrical conductors (1) includes an intermediate section (4) in which the integrated heat sink (11) is located, and wherein the integrated heat sink (11) is located in the airflow (15).

29. The system of claim 27 or 28, wherein, The airflow is guided through the middle section (4) by an external air guide (20).

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