Contactor cooling device and contactor arrangement having contactor cooling device

Abstract

The invention relates to a contactor cooling device (10) and to a contactor arrangement (1) having a contactor cooling device (10) according to the invention. The contactor cooling device (10) according to the invention is configured to establish an electrical connection between electrical contacts (21, 22) of an electrical conductor, in particular of a high-voltage network, and contactor contacts (31, 32) of a contactor (30). The contactor cooling device (10) comprises a connection section (13) configured to establish a connection between the contactor cooling device (10) and the contactor contacts (31, 32). The contactor cooling device (10) further comprises at least one cooling fluid inlet (11), at least one cooling fluid outlet (12) and at least one cooling fluid channel, wherein the cooling fluid channel (40) is configured to convey a cooling fluid (41) from the cooling fluid inlet (11) to the cooling fluid outlet (12).

Description

Technical Field

[0001] The present invention relates to a contactor / relay (Schütz) cooling device and a contactor arrangement structure / contactor assembly having the contactor cooling device according to the invention. Background Technology

[0002] Contactors (also known as high-voltage contactors) are essential safety components for the operation of electric vehicles / transportation. Contactors are configured to disconnect the high-voltage circuit under certain conditions (such as a control circuit disconnection or fault) to ensure that the energy stored in the battery is not unintentionally released. High-voltage contactors disconnect the high-voltage battery from the vehicle's high-voltage onboard electrical grid through both electrical and potential isolation.

[0003] Within the scope of this application, potential isolation for contactors means that there is no conductive connection between the control circuit and the load circuit (high-voltage vehicle electrical grid) or within the load circuit, thus achieving complete potential isolation, which simple electrical isolation may not fully achieve. Potential isolation prevents dangerous voltages or currents from the load circuit from entering the control circuit. This is particularly important in high-voltage or high-current applications.

[0004] Typically, two main contactors are used—one for the positive terminal of the battery and one for the negative terminal. This allows for full disconnection from the vehicle's electrical grid. The contactors must be able to switch current in both directions to enable both actuation and regenerative braking. As mentioned earlier, these contactors must be able to disconnect upon loss of control signal. Furthermore, sufficient insulation resistance must be maintained in the disconnected state to ensure potential isolation.

[0005] In contactors, potential isolation is typically achieved using an electromagnetic system. A control current activates a coil that generates a magnetic field. This magnetic field then mechanically closes or opens contacts in the load circuit via corresponding connecting elements between the contacts, without a direct electrical connection between the circuits. In the context of this application, the coil is also referred to as a contactor driver.

[0006] As the demand for high-voltage onboard electrical grids in vehicles increases, so does the demand for electricity. Here, all current flows through the contactors in the high-voltage battery. Due to the internal resistance of the contactors themselves, considerable heat is generated at the center of the contactor, and this heat must be dissipated as efficiently as possible to maintain the full power of the high-voltage system.

[0007] Text CN 116 053 081A discloses a contactor for a high-voltage battery in a vehicle, wherein the contactor is connected to the cooling circuit of an electric vehicle drive motor and is heated by means of a cooling medium. The contactor achieves temperature control through an integrated coolant distribution. Text DE 102021 128 966A1 discloses a contactor for a high-voltage battery in a vehicle, wherein the contactor is connected to the cooling circuit of the high-voltage battery and achieves temperature control by means of a cooling medium. The contactor is configured with internal cooling. Text US2022 278 414A1 discloses a contactor for a high-voltage battery in a vehicle, wherein the contactor is indirectly cooled by means of a carrier. The carrier achieves temperature control by means of a cooling medium.

[0008] Text US2022 119 121A1 discloses a contactor for an electric motor in an aircraft, wherein the contactor is connected to a cooling circuit and temperature control is performed by means of a cooling medium. Temperature control of the contactor is indirectly implemented via a cooling plate. Text US2018 062 226A1 discloses a contactor for a high-voltage battery in a vehicle. Text US2022077 699A1 discloses a contactor for a high-voltage battery in a vehicle. Text EP 3 972 114 A1 discloses a contactor for a high-voltage battery in an aircraft, wherein the contactor is connected to a cooling circuit of an electric motor and temperature control is performed by means of a cooling medium. Summary of the Invention

[0009] In view of the prior art presented, the objective of the present invention is to provide a contactor cooling device and a contactor arrangement structure having the contactor cooling device according to the invention, thereby ensuring the possibility of efficient and feasible cooling of the contactor.

[0010] This objective is achieved through the subject matter of the independent claims. Advantageous embodiments of the invention are disclosed in the dependent claims.

[0011] The contactor cooling device according to the invention is configured to establish an electrical connection between the electrical contacts of an electrical conductor, particularly in a high-voltage power grid, and the contactor contacts of a contactor. For this purpose, the entire contactor cooling device is configured to be conductive, or the entire contactor cooling device includes at least one conductive section configured to electrically connect the corresponding contactor contacts to the electrical contacts. In the context of this application, a distinction is made between electrical contacts and contactor contacts. Electrical contacts always describe the contacts of an electrical conductor, while contactor contacts describe the contacts within a contactor. According to the prior art, contactor contacts and the electrical contacts of conductors are directly connected to each other.

[0012] The contactor cooling device includes a connection section configured to establish a connection between the contactor cooling device and a contactor contact. In the context of this application, the expression "establish a connection" means to establish / establish physical contact. This may involve one component (here, the contactor cooling device) being attached to another component (here, the contactor contact). The contactor cooling device also includes at least one cooling fluid inlet, at least one cooling fluid outlet, and at least one cooling fluid passage, wherein the cooling fluid passage is configured to deliver cooling fluid from the cooling fluid inlet to the cooling fluid outlet.

[0013] The contactor arrangement according to the invention includes a contactor having a first contact and a second contact that are electrically connected and electrically isolated, particularly by potential isolation, by means of a connecting element that can be moved by means of a contactor driver. Furthermore, at least one contactor cooling device according to the invention is provided, connected to at least one contactor contact and configured to establish an electrical connection between an electrical contact of an electrical conductor and a contactor contact of the contactor to which the electrical conductor is connected. Additionally, the contactor arrangement includes a cooling fluid passage configured to provide cooling fluid at a cooling fluid inlet of the contactor cooling device and to receive cooling fluid at a cooling fluid outlet of the contactor cooling device. The cooling fluid passage specifically includes different separate sections. The section providing cooling fluid at the cooling fluid inlet is different from the section receiving cooling fluid at the cooling fluid outlet.

[0014] Therefore, a contactor cooling device is designed to be positioned between the electrical contacts of the conductor and the contactor contacts. The contactor cooling device is configured to be conductive and capable of transmitting cooling fluid, thereby cooling and dissipating heat from the contactor contacts. This avoids direct contact between the electrical contacts or contactor contacts and the cooling fluid, as the cooling fluid only passes through the contactor cooling device. In the event of a failure, the contactor cooling device can be easily replaced. Therefore, the replacement of the electrical contacts or contactor contacts can be avoided.

[0015] In an advantageous embodiment of the contactor cooling device, the connecting section is configured as a threaded portion or partially threaded. The connecting section is configured to screw into a corresponding mating thread on the contactor contact. Thus, in an advantageous embodiment of the contactor arrangement, the connecting section is at least partially screwed into the contactor contact and is therefore secured to the contactor contact by means of a threaded connection. Preferably, the contactor cooling device extends at least partially into the contactor contact. This ensures particularly efficient cooling of the contactor contact. The threaded connection ensures easy assembly, disassembly, and replacement of the contactor cooling device, while also ensuring a mechanical and secure connection for establishing electrical contact.

[0016] In another advantageous embodiment of the invention, the cooling fluid channels are arranged at least partially in a spiral pattern within the contactor cooling device. Therefore, the residence time of the cooling fluid within the contactor cooling device is increased, and thus the heat transfer to the cooling fluid is increased, thereby enhancing the cooling capacity.

[0017] In another advantageous embodiment of the invention, the cooling fluid channel is constructed as a cavity within the contactor cooling device, particularly a cavity supported by a support column. In this embodiment, the channel should not be understood as a conduit for the cooling fluid, but rather as a volumetric space in the form of a chamber, wherein the support column preferably supports the volumetric space to ensure the structural integrity of the contactor cooling device. This volumetric space is thus filled with cooling fluid, wherein a cooling channel inlet introduces the cooling fluid into the volumetric space, and the cooling fluid is guided out of the volumetric space via a cooling channel outlet.

[0018] In another advantageous embodiment of the contactor cooling device according to the invention, the contactor cooling device has a bolt shape. In the context of this application, the bolt shape should be understood as a body consisting of two monomers, one monomer having a cylindrical or slightly conical shape, also referred to as a threaded section, and the other monomer being axially adjacent to the cylindrical or slightly conical monomer and extending radially beyond it, also referred to as a bolt head. Here, the bolt head of this bolt shape need not necessarily be circular.

[0019] Preferably, the threaded section of the bolt-shaped contactor cooling device is configured to extend into the contactor contact to which the contactor cooling device is connected, and the bolt head of the bolt-shaped contactor cooling device is configured to contact the electrical contact. Specifically, the cooling fluid inlet and / or cooling fluid outlet are located in the bolt head of the bolt-shaped contactor cooling device. This geometry of the contactor cooling device ensures efficient cooling while saving space. Similarly, this implementation is easy to assemble and disassemble.

[0020] In an advantageous embodiment of the contactor arrangement, the first and second contactors of the contactor are connected to their respective contactor cooling devices, which are further connected by a cooling fluid passage, such that cooling fluid supplied by the cooling fluid passage is conveyed from the cooling passage outlet of one contactor cooling device to the cooling passage inlet of the other. In other words, the contactor cooling devices are connected in series via the cooling fluid passage. Therefore, the contactor cooling devices are part of the same cooling system and are supplied with the same cooling fluid. Consequently, the complexity of the cooling system can be simplified, as only one cooling loop needs to be implemented.

[0021] Preferably, the contactor cooling device extends at least partially into the contactor contacts. This ensures the best possible heat transfer from the contactor contacts to the cooling fluid, thus improving cooling performance.

[0022] Furthermore, in embodiments of the contactor arrangement, the contactor cooling device has a bolt shape. The contactor cooling device is arranged such that a threaded section extends into the contactor contact to which the contactor cooling device is connected, and the bolt head of the bolt-shaped contactor cooling device contacts or connects to the electrical contact. Attached Figure Description

[0023] In the following text, see the appendix. Figure 1 The invention will be explained in more detail below.

[0024] Figure 1 A schematic diagram of an embodiment of the contactor arrangement structure 1 according to the present invention is shown in cross-section. Detailed Implementation

[0025] The contactor arrangement 1 includes a contactor 30. This contactor further includes a contactor housing 35, a contactor driver 34 in the form of a coil that generates a magnetic field, two contactor contacts 31 and 32 extending from the contactor housing 35, and a connecting element 33. The connecting element 33 is configured to connect the two contactor contacts 31 and 32 (i.e., the first contactor contact 31 and the second contactor contact 32) when the contactor driver 34 is powered on, allowing current to flow between the two contactor contacts 31 and 32. If the contactor driver 34 is not powered on, the connecting element 33 moves, so that there is no electrical connection between the contactor contacts 31 and 32. Here, the control current of the contactor driver 34 is separate from the power supply circuit to be disconnected by the contactor 30.

[0026] Furthermore, the contactor arrangement 1 includes two contactor cooling devices 10, each connected to one of the contactor contacts 31 and 32. The contactor cooling device 10 is bolt-shaped, with a connecting section 13 corresponding to a threaded section of this bolt shape. The connecting section 13 includes a threaded portion that screws into and thus extends into the corresponding contactor contacts 31 and 32. Therefore, the contactor cooling device 10 is fixedly connected to the contactors 31 and 32.

[0027] The bolt heads of the contactor cooling device 10 extend beyond the contactor contacts 31 and 32, respectively, and contact the electrical contacts 21 and 22 of the power supply circuit. The electrical contacts 21 and 22 lead to a high-voltage on-board electrical network, such as the vehicle's high-voltage on-board electrical network, which can be disconnected from the high-voltage battery (not shown) via the contactor 30. The electrical contacts 21 and 22 can be electrically isolated by the contactor 30.

[0028] The contactor cooling device 10 is designed to be conductive, so that in Figure 1 In the diagram shown, current can be conducted from the first electrical contact 21 through the contactor cooling device 10, the first contactor contact 31, the connecting element 33, the second contactor contact 32, and another contactor cooling device 10 to the second electrical contact 22.

[0029] Furthermore, a cooling fluid passage 40 is provided for conveying cooling fluid 41. The cooling fluid reaches a cooling fluid inlet 11 in the bolt head of a contactor cooling device 10 connected to a first contactor contact 31 via the cooling fluid passage 40. Thus, the cooling fluid 41 is conducted within the contactor cooling device 10 in the cooling fluid passage, allowing it to absorb heat from the contactor cooling device 10 and therefore from the first contact 31. Once the cooling fluid 41 has passed through the cooling passage, it reaches a cooling fluid outlet 12 in the contactor cooling device 10, also located in the bolt head. The cooling fluid then enters a middle section 42 of the cooling fluid passage and flows further toward a cooling fluid inlet 11 of another contactor cooling device 10 connected to a second contactor contact 32. Here, the cooling fluid again passes through this contactor cooling device 10 via the cooling fluid passage and returns to the cooling fluid passage 40 via the cooling fluid outlet 12. Along its path, the cooling fluid 41 has absorbed heat from the contactor cooling device 10, particularly from the contactor contacts 31, 32, thereby cooling them.

[0030] The cooling fluid 41 and the cooling fluid channel 40 can be configured as part of an existing cooling circuit (e.g., part of a battery) or as a separate cooling circuit.

[0031] In the event of a failure in the cooling system or in one of the contactor cooling devices 10, the contactor can be simply replaced without having to replace the contactor 30 itself or other components.

[0032] List of icon numbers

[0033] 1. Contactor Layout

[0034] 10. Contactor cooling device

[0035] 11 Cooling fluid inlet

[0036] 12 Cooling fluid outlet

[0037] 13 Connecting Section

[0038] 21 First electrical contact

[0039] 22 Second electrical contact

[0040] 30 contactor

[0041] 31 First contactor contact

[0042] 32 Second contactor contact

[0043] 33 Connecting elements

[0044] 34 Contactor Driver

[0045] 35 Contactor housing

[0046] 40 Cooling fluid passage

[0047] 41 Cooling fluid

[0048] 42. Intermediate section of cooling fluid passage

Claims

1. A contactor cooling device (10) for establishing an electrical connection between electrical contacts (21, 22) of an electrical conductor and contactor contacts (31, 32) of a contactor (30), the contactor cooling device comprising: A connection section (13) configured to establish a connection between the contactor cooling device (10) and the contactor contacts (31, 32), and Cooling fluid inlet (11), cooling fluid outlet (12) and cooling fluid passage (40), wherein the cooling fluid passage (40) is configured to deliver cooling fluid (41) from the cooling fluid inlet (11) to the cooling fluid outlet (12).

2. The contactor cooling device (10) according to the preceding claim, wherein the connecting section (13) is configured as a threaded portion and is configured to be screwed into the corresponding mating threaded portion at the contactor contacts (31, 32).

3. The contactor cooling device (10) according to any one of the preceding claims, wherein the cooling fluid passage is arranged at least partially in a spiral manner in the contactor cooling device (10).

4. The contactor cooling device (10) according to any one of the preceding claims, wherein the cooling channel is configured as a cavity inside the contactor cooling device (10), particularly a cavity supported by a support column.

5. The contactor cooling device (10) according to any one of the preceding claims, wherein the contactor cooling device (10) has a bolt shape.

6. The contactor cooling device (10) according to the preceding claim, wherein the bolt-shaped threaded section is configured to extend into the contactor contacts (31, 32) to which the contactor cooling device (10) is connected, and the helical bolt head is configured to contact the electrical contacts (21, 22).

7. The contactor cooling device (10) according to any one of the preceding two claims, wherein the cooling fluid inlet (11) and / or the cooling fluid outlet (12) are located in the bolt head of the bolt shape.

8. A contactor arrangement structure (1), the contactor arrangement structure comprising: A contactor (30) having a first contactor contact (31) and a second contactor contact (32) that can be electrically connected and electrically isolated and potential isolated by means of a connecting element (33), the connecting element being movable by means of a contactor driver (34). At least one contactor cooling device (10) according to any one of the preceding claims, the at least one contactor cooling device being connected to at least one contactor contact (31, 32) and configured to establish an electrical connection between the electrical contact (21, 22) of an electrical conductor and the contactor contact (31, 32) of the contactor (30) to which the electrical conductor is connected, and A cooling fluid passage (40) is configured to provide cooling fluid (41) at a cooling fluid inlet (11) of the contactor cooling device (10) and receive cooling fluid (41) at a cooling fluid outlet (12) of the contactor cooling device (10).

9. The contactor arrangement structure (1) according to the preceding claim, wherein the contactor cooling device (10) is fixed to the contactor contacts (31, 32) by means of threads.

10. The contactor arrangement structure (1) according to any one of claims 8 or 9, wherein the first contactor contact (31) and the second contactor contact (32) of the contactor (30) are connected to a respective contactor cooling device (10), the two contactor cooling devices (10) being connected by the cooling fluid passage (40) such that the cooling fluid (41) conveyed by the cooling fluid passage (40) is conveyed from the cooling passage outlet (12) of one contactor cooling device (10) to the cooling passage inlet (11) of the other contactor cooling device (10).

11. The contactor arrangement structure (1) according to any one of claims 8 to 10, wherein the contactor cooling device (10) extends at least partially into the contactor contacts (31, 32).

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