POWER BUSBAR WITH COOLING MOUNT

Abstract

busbar (100), wherein the busbar (100) forms a receptacle (102) for a cooling cell (104) and the cooling cell (104) is arranged in the receptacle (102), wherein the receptacle (102) is configured to thermally couple the cooling cell (104) to the busbar (100) and the cooling cell (104) is configured to temperature-control the busbar (100), wherein in the area of ​​the receptacle (102) two electrically insulating spacers (202) are arranged between the cooling cell (104) and the busbar (100), wherein a gap (200) formed by the spacers (202) between the cooling cell (104) and the busbar (100) is filled with an electrically insulating and thermally conductive paste.

Description

Technical field

[0001] The present invention relates to a busbar with a cooling cell. State of the art

[0002] The present invention is described below mainly in connection with a high-voltage distribution system of a vehicle.

[0003] In an electrically powered vehicle, drive energy can be transmitted via busbars. Busbars are solid strips of sheet metal made of a metal material with good electrical conductivity. The busbars provide a large conductor cross-section to minimize power loss.

[0004] Especially when charging a vehicle's traction battery, increasingly higher power levels are used to quickly increase the battery's charge level. This can cause even busbars with large conductor cross-sections to heat up.

[0005] DE 10 2019 117 649 A1 discloses a connector part for connection with a mating connector part comprising at least a bridge element with a cooling line receptacle for the heat-conducting system with a coolant line of a cable, a plug contact provided on the bridge element and electrically connectable to an electrical line of the cable and a heat sink which is in thermally conductive contact with the bridge element and which forms a coolant channel to which the coolant line can be connected.

[0006] US Patent 2022 / 0337006A1 discloses a charging connector and a liquid-cooled charging cable, wherein the liquid-cooled charging cable comprises a plurality of conductors for supplying charging current and at least two fluid channels for supplying and returning liquid coolant. The charging connector comprises a plurality of busbars and a plurality of contacts, and the charging connector includes an area made of a thermally conductive and electrically insulating material to which the busbars are attached and with which the fluid channels are thermally connected, so that heat generated in the contacts during charging can be dissipated by the liquid coolant.

[0007] CN 1 03 959 513 A discloses a busbar connected to or attached to a terminal part of a battery pack and fixedly mounted to a battery pack housing, wherein the busbar comprises a current input part located at one end of the busbar, such that the current input part is connected to or attached to an output terminal part of the battery pack, and a power output part located at the other end of the busbar, such that the power output part is connected to or attached to an input terminal part of the battery pack. The busbar further comprises a plate-shaped body connected between the current input part and the current output part, wherein the plate-shaped body contains a vapor chamber and a fastening element formed on the current input part for securing the busbar to the battery pack housing.

[0008] DE 10 2017 113 920 B4 discloses a charging port cooler for mechanically contacted charging ports of electrically powered vehicles, wherein at least two supply lines of a first cross-section, coming from a charging socket of an electric vehicle and leading to the charging port cooler, are received in a housing of the charging port cooler, wherein the supply lines are led from the charging socket of the electric vehicle into a housing of the charging port cooler, wherein these are electrically contacted directly or indirectly via contacts with leads from the charging port cooler, wherein the leads are led out of the housing of the charging port cooler, wherein the leads have a second cross-section that is smaller than the first cross-section of the supply lines, and furthermore the contacts of the supply and drain lines are surrounded by an electrically insulating and at the same time highly thermally conductive material.and the housing encloses the thermally conductive material and directly touches this material, and a cooling device is arranged on the housing in a thermally conductive manner.

[0009] DE 10 2020 111 685 A1 discloses a cooling device for a power electrical component of a motor vehicle. The cooling device has a plastic holder with a guide for a busbar.

[0010] DE 10 2017 103 271 A1 discloses an electrical charging arrangement in a motor vehicle comprising an electrical coupling and at least one conductor. A cooling element is arranged on the rear side of the electrical coupling facing the conductor, so that the electrical coupling can be cooled from the rear. Description of the invention

[0011] One object of the invention is therefore to provide an improved busbar using the simplest possible design means. An improvement in this regard could, for example, involve a reduced temperature of the busbar, particularly during the charging of the traction battery.

[0012] The problem is solved by the subject matter of the independent claims. Advantageous embodiments of the invention are specified in the dependent claims, the description, and the accompanying figures.

[0013] In the approach presented here, a cooling cell is thermally coupled to the busbar. Interfaces between the busbar and adjacent components are also thermally connected to the cooling cell via the busbar.

[0014] The approach presented here allows the power losses generated during charging of the traction battery to be absorbed in the busbar. Furthermore, increased power losses at the interfaces, resulting from potentially higher contact resistance, can be conducted through the busbar to the cooling cell and also absorbed there. This allows the temperature of the busbar, the interfaces, and ideally also adjacent components to be limited during charging.

[0015] According to one aspect of the invention, a busbar is presented, wherein the busbar forms a receptacle for a cooling cell and the cooling cell is arranged in the receptacle, wherein the receptacle is designed to thermally couple the cooling cell to the busbar and the cooling cell is designed to temperature-control the busbar.

[0016] According to a second aspect of the invention, a busbar pair with two busbars according to the first aspect of the invention is presented, wherein the busbars are electrically isolated from each other and at least one cooling cell in the area of ​​the mountings is thermally coupled to both busbars.

[0017] A busbar can be a strip of sheet metal. The busbar provides a conductor cross-section for transmitting electrical power across its width and thickness. The busbar can be made of materials such as copper, aluminum, or iron, like steel.

[0018] The power rail can, for example, be located between a charging socket of an electric vehicle and the vehicle's traction battery. In particular, the power rail can be located in the vicinity of the charging socket.

[0019] A cooling cell can have a housing made of a thermally conductive material. The housing can be made of a metal, in particular. The cooling cell can be active or passive. In an active cooling cell, a cooling medium is circulated through the cell to dissipate the heat energy generated by the power rail's loss. In a passive cooling cell, a heat storage medium can be located within the housing. This heat storage medium can absorb heat energy during the charging process and release it again afterward. This allows a predefined amount of energy to be stored before the power rail reaches a predefined temperature. In particular, the heat storage medium can have a higher heat capacity than the material of the power rail, thus absorbing and storing more heat energy per unit volume than the power rail itself.The material of the heat storage medium typically differs from the material of the housing surrounding it and generally has a significantly higher heat capacity. For example, the specific heat capacity of the heat storage medium can be more than 50%, more than 100%, or even more than 200% higher than that of the busbar or housing material.

[0020] A mounting bracket can be adapted to the contour of the cold storage unit, providing the largest possible heat transfer surface between the busbar and the cold storage unit. The cold storage unit can be cylindrical or prismatic, for example.

[0021] The busbars of a busbar pair can be at different electrical potentials during operation. The busbars can be electrically isolated from each other. Air gaps and creepage distances can be maintained between the busbars.

[0022] The busbars of a busbar pair can be arranged symmetrically to each other. A symmetrical arrangement allows the electromagnetic emissions of the busbars to cancel each other out. This symmetrical arrangement reduces the overall emissions of the busbar pair.

[0023] The cooling cell of the busbar pair can have two electrically isolated subcells. Each subcell and busbar can be electrically connected to each other. The subcells can be at different electrical potentials. The electrical separation of the subcells allows for good heat transfer from the busbar to the respective subcell, as no electrical insulation is required there.

[0024] The cold storage unit can be electrically isolated from the busbar. If an electrically conductive cooling medium flows through the cold storage unit, electrical isolation between the unit and the busbar can prevent current flow through the cooling medium. To electrically isolate the cold storage unit from the busbar, a thermally conductive insulating material can be placed between the unit and the busbar. Additionally, air and creepage distances can be maintained between the cold storage unit and the busbar. Alternatively, an electrically insulating cooling medium can be used.

[0025] In the area of ​​the installation, two electrically insulating spacers are positioned between the cooling cell and the busbar. A gap formed by the spacers between the cooling cell and the busbar is filled with an electrically insulating and thermally conductive paste. This electrically insulating and thermally conductive paste can be referred to as a gap filler. The gap filler is configured to compensate for any tolerances and resulting air gaps, ensuring optimal heat transfer. The edges of the gap can be sealed to contain the paste. A spacer can seal at least one side of the gap. The spacers can be positioned on opposite sides of the gap. The edges of the gap between the spacers can be sealed with electrically insulating plugs.

[0026] The cold storage unit can be positioned between two electrically insulating protective caps. The protective caps can act as spacers. The protective caps can be made of a plastic material, for example. They can provide the necessary air and creepage distances for electrically insulating the cold storage unit. The spacers can be positioned along an edge of the protective caps.

[0027] In the area of ​​the intake, an electrically insulating film can be placed between the cooling cell and the busbar. This film can be used as additional protection against short circuits, alongside the insulating paste, between the cooling cell and the busbar.

[0028] A sensor can be positioned between the cold storage unit and the power rail to measure the temperature in the area being measured. This sensor can, for example, be a printed circuit embedded in the foil. Alternatively, the sensor can be integrated into the spacer. The sensor can be used to regulate the cooling capacity of the cold storage unit. It can also limit the current flow through the power rail when a temperature threshold is exceeded.

[0029] The busbar can have at least one tab in the mounting area for attaching the cold storage unit to the busbar and / or for attaching the busbar to a structural component. A tab can be an extension of the busbar. Alternatively, the tab can also be part of the electrically insulating spacer. The tab can protrude from the busbar and provide space for attachment next to the busbar.

[0030] Alternatively, the cold storage unit can be electrically connected to the busbar. If the cold storage unit is cooled by an electrically insulating cooling medium or is designed as a passive cold storage unit, it can be directly connected to the busbar and be at the same electrical potential. This electrically conductive connection allows for simple and cost-effective installation. The electrically conductive connection also exhibits low thermal resistance. This direct connection enables the cold storage unit to absorb heat energy particularly efficiently.

[0031] The busbar can, in the area of ​​the recording, at least partially replicate the contour of the cold storage unit. The busbar can be a negative form of at least a section of the cold storage unit's contour. By replicating the contour, the largest possible heat transfer surface between the busbar and the cold storage unit can be achieved.

[0032] The busbar can encircle the cold storage unit by more than 180° in the mounting area. This allows the cold storage unit to mechanically lock into the mounting. The busbar can be elastically deformed in the mounting area during this locking process. For example, the busbar can have a slightly smaller bending radius in the mounting area than the contour of the cold storage unit. This slightly pre-tensions the busbar, resulting in a restoring force that presses against the housing of the locked-in cold storage unit. The resulting surface pressure allows for a low thermal resistance between the mounting and the cold storage unit.

[0033] The busbar can have at least one retaining element located in the area of ​​the mounting. The cold storage unit can be positioned between the retaining element and the busbar. The retaining element can at least partially conform to the contour of the cold storage unit and at least partially enclose it. A retaining element can be attached to the busbar. The retaining element can, for example, be made of a plastic material. The retaining element can enclose the portion of the contour that is not enclosed by the mounting. The retaining element can fix the cold storage unit within the mounting.

[0034] The retaining element can form the mounting and be positioned between the busbar and the cold storage unit. The retaining element can at least partially enclose the cold storage unit. In particular, the retaining element can completely enclose the contour of the cold storage unit. The retaining element can be made of a thermally conductive, electrically insulating material. The retaining element can electrically isolate the cold storage unit from the busbar. The retaining element allows the busbar to have a simplified geometry.

[0035] The busbar can form at least one wall of the cold storage unit in the area where it is mounted. The busbar can be an integral part of the cold storage unit. The cold storage unit can then be located directly adjacent to the busbar. This direct connection results in very good heat transfer from the busbar to the cold storage unit.

[0036] Connections for the cold storage unit can run through the busbar. Inlet and outlet for the cooling medium can be located in openings through the busbar. By arranging the connections within the busbar, the cold storage unit can be designed very simply.

[0037] The busbar can have a connection field adjacent to the mounting point for a charging socket pin. The busbar can also have an interface adjacent to the mounting point for the vehicle's high-voltage distribution system. The busbar can be located directly behind the charging socket. The busbar can be referred to as an adapter busbar and forms a connection between the charging socket and the high-voltage distribution system. Due to its close proximity to the charging socket, heat generated within the socket due to contact resistance can be efficiently dissipated.

[0038] The connection panel can be designed to accommodate different pins. These different pins may be required for different charging socket standards. Thanks to the universal connection, the busbar can be a single, identical component for different charging socket standards.

[0039] The cold storage unit can have fins facing the interior. These fins can increase the heat transfer surface area to a cooling medium or a heat storage medium inside the unit. This increased heat transfer surface area allows for improved cooling performance.

[0040] The cold storage unit can have at least one fin running through its interior. A fin can provide additional heat transfer surface area to a cooling medium or a heat storage medium within the interior. This additional heat transfer surface area can increase cooling capacity. The fin can be flat or curved. The fin can also stiffen the cold storage unit.

[0041] At least one lamella can be held by the ribs. The ribs can be aligned in one direction of the lamella. The lamella can be inserted between at least two of the ribs. The ribs can be slightly elastically deformed by the lamella, clamping it with a resulting restoring force.

[0042] At least one fin can define a flow path for the cooling medium from the inlet to the outlet within the interior. The cooling medium can flow in opposite directions on opposite sides of the fin. The fin can lengthen the flow path. Likewise, the cross-sectional area for the cooling medium can be reduced, which can lead to an increased flow velocity and improved heat transfer to the cooling medium.

[0043] At least one fin can have flow-through openings for the cooling medium. In this case, the cooling fin can extend through the entire interior space. The cooling medium can flow from one side of the fin to the other via these flow-through openings.

[0044] Alternatively, at least one fin can be shorter than the interior space to create a flow path for the cooling medium. The cooling medium can then flow around an edge of the fin from one side to the other.

[0045] The cooling cell can have at least two fins inside. These cooling fins can extend into the interior from opposite sides. By having fins on opposite sides, the flow path can be designed in a serpentine pattern. This allows the flow path to be lengthened and the flow cross-section to be reduced.

[0046] The louvers allow the fluid dynamics within the cold storage cell to be modified or optimized. Their shape, form, surface, as well as targeted protrusions and openings, can be used to deliberately create more laminar or turbulent flow patterns.

[0047] The heat storage medium can be a phase-change material. A phase-change material can also be called a latent heat storage material. This material can absorb or release thermal energy at a substantially constant temperature while undergoing a phase change. For example, a paraffin or salt material can absorb or release large amounts of thermal energy at its melting point. The temperature only rises or falls again once the phase change is essentially complete. The amount of thermal energy that can be absorbed can be adjusted by changing the volume of the phase-change material. The melting point, or melting temperature, can be adjusted by changing the material composition of the phase-change material. The phase-change material allows the temperature of the busbar to be maintained within a predetermined temperature range during the charging process.The heat energy can be released slowly after the charging process.

[0048] At least one of the fins may have equalization openings. These openings allow the fill level of the heat storage medium within the cooling cell to equalize. The fin also prevents the liquid heat storage material from sloshing back and forth.

[0049] The heat storage medium may not completely fill the interior. Partial filling of the cold storage cell allows for the thermal expansion of the heat storage medium to be accommodated.

[0050] The remaining volume of the interior can be filled with a noble gas. A noble gas can at least slow down or even prevent chemical changes in the heat storage medium over time. This can give the cold storage unit a long service life. Brief character description

[0051] An advantageous embodiment of the invention is explained below with reference to the accompanying figures. These show: Fig. 1 a representation of a busbar according to an exemplary embodiment; Fig. 2 a sectional view of a prismatic cooling cell on a busbar according to an exemplary embodiment; Fig. 3 a representation of a passive cooling cell for a busbar according to an exemplary embodiment; Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8, Fig. 9 to Fig. 10 illustrations of cold storage cells in photographs of busbars according to exemplary embodiments; Fig. 11 a representation of a busbar pair according to an exemplary embodiment; Fig. 12 a sectional view of a cooling cell for a pair of busbars according to an exemplary embodiment; and Fig. 13 to Fig. 14 illustrations of cooling cells in photographs of busbar pairs according to exemplary embodiments.

[0052] The figures are schematic representations and serve only to illustrate the invention. Identical or equivalent elements are consistently identified by the same reference numerals. Detailed description

[0053] Fig. Figure 1 shows a representation of a busbar 100 with a receptacle 102 for a cold storage unit 104 according to an exemplary embodiment. The receptacle 102 for the cold storage unit 104 is formed by a three-dimensional contour of the busbar 100. The receptacle 102 thermally couples the cold storage unit 104 to the busbar 100. The cold storage unit 104 acts as a heat sink and cools the busbar 100. The busbar 100 is essentially a stamped and bent strip of sheet metal. The conductor cross-section of the busbar 100 results from the material thickness of the busbar 100 and the width of the busbar at its narrowest point.

[0054] In one embodiment, the busbar 100 has a connection panel 106 for a pin 108 of a vehicle charging socket and an interface 110 to a high-voltage distribution system 112 of the vehicle. This allows the cooling cell 104 to absorb heat loss generated at connection points during a vehicle charging process. The connection panel 106 and the interface 110 are angled relative to a central section of the busbar 100. Pin 108 is, for example, replaceable. In particular, the busbar 100 can thus be used as an adapter busbar for different charging socket standards (country variants).

[0055] The mounting bracket 102 with the cooling cell 104 is located in the central section between the connection panel 106 and the interface 110. The busbar 100 connects pin 108 and the high-voltage distribution system 112 both electrically and thermally. Both pin 108 and the high-voltage distribution system 112 are thermally coupled to the cooling cell 104 via the mounting bracket 102. The cooling cell 104 can thus dissipate heat from the charging socket and at least part of the high-voltage distribution system.

[0056] The cold storage unit 104 is aligned along the conductor rail 100. The mounting bracket 102 therefore consists of two tabs 114 projecting laterally beyond a side edge of the conductor rail 100. The tabs 114 are bent out from a main plane of extension of the conductor rail 100 in the area of ​​the mounting bracket 102 and rest against a surface 116 of the cold storage unit 104. The tabs 114 enclose a large portion of the surface 116. Thus, the mounting bracket 102 has a large heat transfer surface area to the cold storage unit 104.

[0057] Depending on the available space, the cold storage unit 104 can have different shapes. For example, it can be cylindrical or prismatic. Mounting bracket 102 is adapted to the shape of the cold storage unit 104. Here, for example, the cold storage unit 104 is cylindrical.

[0058] The cold storage unit 104 can be connected to a cooling system. In that case, the cold storage unit 104 can be referred to as an active cold storage unit. The cold storage unit 104 can also be designed passively and provide a defined heat storage capacity.

[0059] In the active cooling cell 104, a cooling medium is circulated through an interior space of the cooling cell 104 via connections 118. For example, during the charging process, the cooling medium transports heat from the power rail 100 to a heat sink in the vehicle.

[0060] For example, depending on the requirements, oil, coolant, or refrigerant can be circulated through the cooling cell 104. The cooling cell 104 can be connected to its own cooling circuit. It can also be connected to the cooling circuit of a traction battery in the vehicle. Likewise, the cooling cell 104 can be connected to the vehicle's air conditioning system.

[0061] In a passive cooling cell 104, a heat storage medium is arranged inside the cooling cell 104. This heat storage medium absorbs heat, for example, during the charging process and releases it again some time later. The heat storage medium can have a large heat capacity. For example, the heat storage medium can be a phase-change material. During a phase change at an approximately constant temperature, the phase-change material can absorb and release large amounts of heat as latent heat.

[0062] Fig. Figure 2 shows a sectional view of a prismatic cooling cell 104 on a busbar 100 according to an exemplary embodiment. The busbar 100 essentially corresponds to the busbar in Fig. 1. The cold storage cell 104 has a rectangular cross-section. In contrast to Fig. In Figure 1, the cold storage cell 104 is oriented transversely to the busbar 100, and the busbar 100 is bent around the cold storage cell 104 to form the receptacle 102. In this embodiment, the receptacle 102 surrounds the cold storage cell 104 on three of its four sides.

[0063] Here, the cooling cell 104 is galvanically isolated from the busbar 100. For this purpose, a thermally conductive insulator is arranged between the cooling cell 104 and the busbar 100 in the area of ​​the mounting 102.

[0064] In one embodiment, the insulator is designed as a paste-like material arranged in a gap 200 between the cooling cell 104 and the busbar 100. This paste-like material can be referred to as a gap filler. The material is shown transparently here. The gap 200 is created by a spacer 202 of the receptacle 102. The spacer 202 seals one side edge of the gap 200 and prevents the paste-like material from spreading laterally, as well as preventing the busbar 100 from making direct contact with the cooling cell 104.

[0065] In one embodiment, the cooling cell 104 is further enclosed by an electrically insulating film 204 to reliably prevent breakdowns through the insulator.

[0066] In one embodiment, the cooling cell 104 has ribs 210 projecting from a wall 206 of the cooling cell 104 into an interior space 208 of the cooling cell. The wall 206 is, for example, an extruded profile made of an aluminum material. The ribs 210 increase the heat transfer surface area of ​​the wall 206 to the medium arranged in the interior space 208.

[0067] In one embodiment, 208 fins 212 are arranged in the interior. The fins 212 divide the interior 208 into sub-areas 214. The fins 212 also increase the heat transfer surface area to the medium.

[0068] In an active version of the cooling cell 104, the louvers 212 define a flow path for the medium through the interior 208. In a passive version of the cooling cell 104, the louvers 212 act as baffles and prevent the medium from sloshing back and forth in the interior 208.

[0069] In one embodiment, the ribs 210 are arranged in pairs, with the space between the ribs 210 of a pair corresponding to the thickness of the lamellae 212. The lamellae 212 are inserted between each pair of ribs 210 on opposite sides.

[0070] In one embodiment, the ribs 210 are aligned radially to a central axis of the interior 208. The lamellae 212 are arcuate.

[0071] Fig. Figure 3 shows a representation of a passive cooling cell 104 for a busbar according to an exemplary embodiment. The cooling cell 104 essentially corresponds to the representation in Figure 3. Fig. 1. Here, a heat storage medium 300 is arranged in the interior space 208. The heat storage medium 300 fills the interior space 208 up to a predefined fill level 302. A remaining volume of the interior space 208 is empty. This remaining volume can be filled, for example, with air or a noble gas 304. A negative pressure can be set in this volume. The empty volume allows the heat storage medium 300 to expand unhindered when heated.

[0072] In one embodiment, the heat storage medium 300 is a phase change material 306. The phase change material 306 is, for example, a salt material or a paraffin material. The phase change material 306 is solid when cold and liquid when heated. During the phase change from solid to liquid, the phase change material 306 absorbs heat of fusion until it is completely melted without significantly changing its temperature. During the phase change from liquid to solid, the phase change material 306 releases heat of solidification until it is completely solidified without significantly changing its temperature. The phase change material 306 can therefore absorb and release large amounts of thermal energy during the phase change at an approximately constant temperature.

[0073] In one embodiment, fins 212 are connected to at least one cover 308 of the cooling cell 104 and project into the interior 208. The fins 212 increase the heat transfer surface area to the heat storage medium 300. Here, the fins 212 are shorter than the interior 208. This results in a gap between one end of the fins 212 and an opposite cover 308 of the cooling cell 104.

[0074] In one embodiment, louvers 212 are arranged on both covers 308. The louvers 212 project alternately from both covers 308 into the interior 208.

[0075] In one embodiment, the fins 212 have compensating openings 310. Through these compensating openings, the liquid heat storage medium 300 can compensate for level differences within the cooling cell 104.

[0076] Fig. 4, Fig. 5, Fig. 6, Fig. 7, Fig. 8, Fig. 9 to Fig. Figure 10 shows representations of cooling cells 104 in photographs 102 of busbars 100 according to exemplary embodiments.

[0077] In Fig. In Figure 4, the cold storage unit 104 is cylindrical and positioned lengthwise alongside the conductor rail 100. The mounting 102 consists of a single tab 114 projecting laterally from the conductor rail 100. The tab 114 is bent in a hook shape. At a transition to the flat conductor rail 100, the tab 114 is angled transversely to the conductor rail 100 and from there extends in an arc around the cold storage unit 104. The mounting 102 thus largely replicates the contour of the cold storage unit 104 and has a wrap angle of more than 180°. The wrap angle can, for example, be between 190° and 230°. Here, the wrap angle is approximately 210°. When the cold storage unit 104 is mounted in the mounting 102, the tab 114 is elastically deformed and springs back after deformation. This securely holds the cooling cell 104 in the receptacle 102. The arc of the tab 114 can also have smaller dimensions than the cooling cell 104 when empty.This pre-tensions the tab 114 during assembly, clamping the cooling cell 104 with a resulting preload. This ensures good thermally conductive contact between the receptacle 102 and the cooling cell 104.

[0078] In Fig. In section 5, the tab 114 is not angled and extends in an arc around the cooling cell 104 until one end of the tab 114 rests against the busbar 100. The receptacle 102 thus has a wrap angle of 270°. A flange 500 is arranged at the end of the tab 114 and is attached to the busbar 100 or to one end of the tab 114.

[0079] In one embodiment, the tab 114 has a bending area 502 with reduced bending resistance to simplify the assembly of the cold storage unit 104. The bending area 502 allows the receptacle 102 to be opened with reduced force, enabling the cold storage unit 104 to be positioned within the receptacle 102. The cross-sectional area of ​​the tab 114 is reduced in the bending area 502. A series of openings 504 are arranged in the tab 114 within this bending area 502.

[0080] The cold storage cell 104 is an active cold storage cell with connections 118. The connections 118 are located in one of the lids 308 of the cold storage cell 104.

[0081] The 100 power rail in Fig. 6 essentially corresponds to the busbar in Fig. 4. Here, the busbar 100 has an additional retaining element 600. The retaining element 600 is connected to the receptacle 102. The retaining element 600 complements the receptacle 102. The receptacle 102 and the retaining element 600 each have a wrap angle of 180° around the cooling cell 104. Together, the receptacle 102 and the retaining element 600 have a wrap angle of 360°. The retaining element 600 is connected to the receptacle 102 and the busbar 100, respectively, via flanges 500.

[0082] The 100 power rail in Fig. 7 essentially corresponds to the busbar in Fig. 5. In addition, the busbar 100 has a retaining element 600 as shown in Fig. 5. The retaining element 600 is connected to the receptacle 102 via a flange 500. The receptacle 102 and the retaining element 600 together have a wrap angle of 360° around the cooling cell 104. The retaining element 600 is specifically a plastic part made of a thermally conductive plastic. The retaining element 600 has thickenings 700 for attachment to the flange 500 and the busbar 100.

[0083] In Fig. Figure 8 shows that the receptacle 102 is completely formed by the retaining element 600. The retaining element 600 completely encloses the outer surface 116 of the cooling cell 104. The retaining element 600 has a foot 800 that rests flat against the busbar 100.

[0084] In Fig. The cold storage unit 104 has a cuboid shape and rests with one flat side lengthwise on the conductor rail 100. Two tabs 114, arranged on opposite sides of the conductor rail 100, are oriented transversely to the conductor rail 100 and form the receptacle 102. The receptacle itself acts as a spacer to the rail and may have a recess facing the rail. This recess can be filled, for example, with gap filler. The tabs 114 rest against opposite narrow sides of the cold storage unit 104. A retaining element 600 rests on the second flat side of the cold storage unit 104 and secures the cold storage unit 104 in the receptacle 102.

[0085] Is the cold storage room like in Fig. As shown in Figure 9, the tabs 114 can also be used, if necessary, to fix one or more busbars 100 to the surroundings, e.g. to the body or adjacent components.

[0086] In one embodiment, the connections 118 of the cold storage cell 104 are arranged on opposite end faces of the cold storage cell 104. The retaining element 600 has recesses 900 for the connections 118.

[0087] In Fig. In the area of ​​the mounting point 102, the busbar 100 forms a base 1000 of the cooling cell 104. The cooling cell 104 is thus materially connected to the busbar 100. This direct contact results in a low thermal resistance to the cooling cell 104.

[0088] In one embodiment, the terminals 118 of the cold storage unit run through the busbar 100. This allows the busbar 100 to be installed even in confined spaces. Alternatively, the terminals 118 can also be located opposite each other.

[0089] Fig. Figure 11 shows a representation of a busbar pair 1100 according to an exemplary embodiment. The busbar pair 1100 consists of two busbars 100, each with a receptacle 102. The busbars 100 essentially correspond to the busbars in the preceding figures. In contrast, here a single cooling cell 104 is thermally coupled to both busbars 100. For this purpose, the cooling cell 104 is arranged between the two receptacles 102. The receptacles 102 are arranged symmetrically about a central plane of the cooling cell 104. Since the busbars 100 are at different electrical potentials, the cooling cell 104 is galvanically isolated from at least one of the busbars 100, and appropriate air and creepage distances are maintained. The receptacles 102 thus encircle the cooling cell 104 by less than 180° each.

[0090] The cold storage cell 104 is aligned along the busbars. The busbars 100 lie side by side in a common plane before and after the mounting points 102. Shortly before and after the mounting points 102, the busbars 100 are twisted by approximately 90°. In the area of ​​the mounting points 102, the busbars 100 are deformed approximately into half-shells, which essentially correspond to the contour of the cold storage cell 104.

[0091] In one embodiment, the cold storage cell 104 has touch protection caps 1102. The touch protection caps 1102 cover both lids of the cold storage cell 104 and each form a spacer 202. The spacers 202 rest against opposite ends of the receptacle 102 and form the gap 200 between the busbars 100 and the cold storage cell 104. The gap 200 is filled with the electrically insulating, thermally conductive material.

[0092] In one embodiment, each of the two covers has a connection 118 for cooling medium. The connection 118 penetrates the protective cap 1102. At the point where the connection passes through, the protective cap has a protective collar 1104 to maintain air and creepage distances.

[0093] Fig. Figure 12 shows a sectional view of an active cooling cell 104 for a pair of busbars according to an exemplary embodiment. The cooling cell 104 is divided into two electrically isolated subcells 1200. An insulator 1202 is arranged between the subcells 1200. Each subcell 1200 can thus be at its own electrical potential.

[0094] Each subcell 1200 has a connection 118 for an electrically insulating cooling medium. A flow channel 1204, connecting the subcells 1200, runs through the insulator 1202. This ensures that both subcells 1200 are subjected to the same volume flow but are electrically isolated from each other.

[0095] In one embodiment, two fins 212 are arranged in the interior 208 of each subcell 1200. The fins 212 are shorter than the interior 208 and project into the respective interior 208 from opposite sides. The fins 212 form a meandering flow path 1206 for the cooling medium. The flow path 1206 extends from the respective connection 118 to the overflow channel 1204. Both interior spaces 208 are completely permeated by the cooling medium flow through the fins 212.

[0096] If the lamellae 212 are as long as the interior space 208, the lamellae 212 can have overflow openings. The overflow openings connect the spaces between the lamellae 212 and form the flow path 1206.

[0097] Fig. 13 to Fig. Figure 14 shows illustrations of cooling cells 104 in photographs 102 of busbar pairs 1100 according to exemplary embodiments.

[0098] In Fig. 13 is a cold storage cell 104 with electrically insulated sub-cells 1200 as in Fig. 12 are arranged transversely between the busbars 100 of the busbar pair 1100. The subcells 1200 are at the respective electrical potential of the busbars 100. The busbars 100 essentially correspond to the representation in Fig. 2. In contrast, the cooling cell 104 is cylindrical here, and the inlets 102 are therefore arc-shaped as in Fig. 4. The receptacles 102 each encompass more than half of the circumference of the subcells 1200. The cooling cell 104 is held in the receptacle 102 by one retaining element 600 per power rail 100.

[0099] The busbars 100 are approximately identical here and run essentially parallel to each other from connection fields 106 for pins of a charging socket to interfaces 110 of a high-voltage distribution system 112. In the area of ​​the interfaces 110, the busbars 100 have a height offset to allow a parallel arrangement of busbars of the high-voltage distribution system 112.

[0100] In Fig. 14 is the cold storage cell 104 as in Fig. 13 are arranged transversely to the conductor rails 100. In contrast, the conductor rails 100 are, as in Fig. 11 electrically insulated from the cold storage cell 104 using spacers. The busbars 100 run along opposite sides of the cold storage cell 104 in the area of ​​the mountings 102 and cross each other there without touching. The mountings 102 each enclose less than half the circumference of the cold storage cell 104 in order to maintain the required clearances and creepage distances.

[0101] Possible embodiments of the invention are summarized below or presented using slightly different wording.

[0102] Modular and scalable cooling units will be presented.

[0103] Charging systems basically consist of a charging socket, a cable, and a junction box on or in the battery. The battery is charged using direct current (DC) or alternating current (AC). The charging power is many times higher with DC than with AC.

[0104] For charging with direct current and the associated power transfer, cables, components, and interfaces are dimensioned accordingly larger. Currently, power levels of approximately 700 amps at approximately 800 volts are possible.

[0105] However, the current trend shows that the current is increasing disproportionately, and with it the power loss in the form of heat is increasing exponentially. One possibility is to further adjust or increase the cross-sections; another is to cool the system in a targeted manner.

[0106] To design an effective cooling system, it's crucial to understand where heat can be generated within the system. The primary sources of heat are contact and line resistance. Contact resistance always occurs at interfaces, such as between the charging port outlet and the cable, or between the pin and the socket. Line resistance increases with decreasing cable cross-section and increasing temperature within the cable itself.

[0107] The effort required to cool individual components in the system's charging path varies considerably. This is due, on the one hand, to the topology and complexity of the component itself, and on the other hand, to the available flexibility regarding packaging, accessibility, and material mix.

[0108] A good example is the cooling of a cable. Active cooling allows for a reduction in cross-section – meaning less weight and cost, as well as a smaller package. However, the cooling process itself can negate these advantages, as costs increase, the package size doesn't decrease, and the complexity and robustness may be higher and potentially lower.

[0109] Another aspect in the context of effort and benefit is the requirement to avoid developing highly individualized systems and components down to the last detail.

[0110] The Cool Cells approach presented here introduces a modular, scalable, active or passive portfolio of cooling units that can be integrated into the hotspots of a charging system with minimal customization. To this end, areas and parts within components are identified whose design or cost-effective adaptation enables this approach and unlocks its potential.

[0111] The connection panel offers the potential to redesign the rail for each country variant. Its rear-facing position also provides good accessibility for servicing. Furthermore, the connection panel is in close proximity to power losses generated by contact resistances, for example, at pins and the transition to the high-voltage distribution system (HVDS - high-voltage double rail). Therefore, a design and modification of the rail (DC bar) to accommodate a standardized, modular, and scalable cooling module is proposed. The cooling module can be implemented as either an active or passive cooling module and can be either potentialally isolated or galvanically isolated from the rail.

[0112] The cooling module can be designed as a cylinder or cube and, due to its 2D and / or point symmetry and / or multiple 3D axial symmetry, offers a high degree of flexibility and a high potential for identical parts. The bending and stamping process generally offers a high degree of flexibility for integrating a cooling module.

[0113] A section of the cooling module, for example the cylindrical surface, is partially enclosed or connected to the bent-and-punched grid, thus dissipating heat. The cooling module can be directly fixed in place by the bent-and-punched grid.

[0114] For the design and integration method, it is important to consider the type of cooling circuit, whether it is inside or outside the vehicle. Cooling systems with a non-insulating, i.e., electrically conductive, coolant generally require insulation between the Cool Cell and the current-carrying component (section). Such a coolant is, for example, a water-glycol mixture, such as that used in the battery cooling circuit.

[0115] Cooling systems based on mineral, synthetic, or similar oils are non-conductive. In these systems, cooling can be applied directly to the potential or the current-carrying component. However, during integration, air and creepage distances to other components must be observed.

[0116] Another very effective option is to integrate the CoolCell as a "consumer" of the air conditioning refrigerant circuit. In this case, the CoolCell is cooled by a fluid cooled by the air conditioning system or compressor. Since the temperature differences between the CoolCell and the heat source are relatively large, this method would be very efficient.

[0117] A cooling source can be used for thermal management. The cooling source can be located inside or outside the vehicle. Inside the vehicle, a cooling module can be supplied, for example, by the vehicle's S-Box, a high-voltage storage system, the air conditioning system's cooling circuit, or it can operate independently. From outside the vehicle, the cooling module can be supplied, for example, by the charging station.

[0118] Alternatively, the Cool Cell / s can be integrated into a standalone cooling circuit system. This requires the integration of the necessary pipes, a heat exchanger, a reservoir or expansion tank, and a pump.

[0119] Cool cells can therefore be integrated into various types of cooling circuits. They can be integrated individually or in multiples into components or groups.

[0120] Multiple cooling modules can be connected in series or parallel. The series and parallel connections can be combined according to the required heat output.

[0121] Similarly, cooling modules can be operated via different, independent circuits. In this case, the systems would not overlap, especially if the fluids used are different.

[0122] The module consists of three basic shapes: round, cubic, and flat. The appropriate shape can be chosen depending on the integration method. For simplicity, the examples shown in the figures mostly depict the round shape. However, the construction and integration can largely be applied to the other shapes.

[0123] All forms share the characteristic that the outer surface is largely in contact with the heat source for heat transfer or cooling. Depending on the dimensions and length of the Cool Cell itself, the end face may be more suitable. A fundamental distinction is made between cooling at potential, where the module is energized, and isolated cooling, where the module has no conductive contact with the potential, i.e., it is galvanically isolated from it.

[0124] In a finned profile heat sink, the module has one or more guide fins, depending on the design. These fins direct the cooling medium through the module. The aim is to maximize the flow length and optimize the fluid flow mechanics without modifying the standardized base body, thus making optimal use of the medium's heat absorption capacity.

[0125] The fins are inserted and guided and secured by the cooling fins themselves. The fins have a gap to the heat sink or openings through which the medium can flow.

[0126] In a passive design, the module is closed on both sides; there are no inlets or outlets. Inside, the module is filled with a heat storage medium. This heat storage medium is, for example, a latent heat storage medium or phase-change material (PCM).

[0127] On the end faces, i.e., on the lids, ribs can be applied to improve heat transfer. These can have equalization holes to achieve a uniform fill level across the cell. The volume expansion of, for example, a PCM is accounted for by a fill level of approximately 70-90%, thus utilizing the compressibility of the gas or air. The ratio of PCM volume to heat transfer surface area can be adjusted depending on the application. For example, in the case of a steep temperature gradient, the number of heat transfer surfaces can be increased to better "activate" the PCM.

[0128] In an active design, a fin, e.g., made of sheet metal, can be fixed to the cover between the connections. This fin is designed so that it does not cover the inlet or outlet. Ideally, the fin forms two equally sized, preferably separate sections through which a cooling medium flows completely at both the inlet and outlet. The fin ensures complete flushing of the module by allowing backflow or reversal of the flow only at the end. If an extruded profile with integrated cooling fins is used as the base body, the fin is simply pushed into two optimally positioned, opposing cooling fins. One or more "stoppers" prevent the fin from "sagging," i.e., they hold the fin in position. Alternatively, the length of the fin corresponds to the internal length of the module and it has at least one opening for flow. Calculations and / or...Simulations with multiple penetrations can be used to determine optimal flow (fluid mechanics).

[0129] Alternatively, at least one fin, e.g., made of sheet metal, can be fixed to the cover next to each of the two connections. This fin is designed so that it does not cover the inlet or outlet. Together, the fins form three separate sections of approximately equal size, through which a cooling medium flows completely at both the inlet and outlet. The fins ensure complete flushing of the module. If an extruded profile with integrated cooling fins is used as the base body, the fin is inserted into two cooling fins. If the cooling fins are oriented towards the center, as shown here, the fin can be bent or bendable, or have the corresponding contour, to create the aforementioned sections.

[0130] Two modules can be connected side-by-side in parallel, i.e., combined, to cool two potentials with a single unit. An insulator between the modules is designed to seal and secure each module while also acting as an insulator.

[0131] For galvanic isolation, films, gap fillers, and spacers are used, either individually or in combination. In a preferred embodiment, a polyimide film with an elastic top layer is used. Due to the high dielectric strength of polyimide (approx. 150 to 200 kV / mm), insulation can be ensured with a wall thickness of approximately 25 to 40 µm. The elastic top layer is approximately 0.5 to 1.5 mm thick and preferably consists of silicone with ceramic fillers. This allows for an ideal compromise between elasticity and thermal conductivity. The film completely encloses the module's surface and ensures that the requirements for high-voltage / low-voltage isolation are met.

[0132] The film can have printed or fully / partially integrated temperature sensors. Alternatively, the sensors can be integrated into the spacer, where conventional SMD sensor chips can also be used. The sensors allow for direct monitoring of the system.

[0133] The spacer, here part of the cap, ensures that the gap filler is not displaced by the DC-Bar busbar, thus maintaining the necessary distance. The spacer's contour is designed so that the gap filler is pressed between the spacer and the foil during assembly.

[0134] The electrical insulation consisting of foil, gap filler and spacer can also be applied to cubic shapes.

[0135] The module can be used as in Fig. The module is enclosed by the DC bar (busbar). The outer surface (M) can be essentially an open semicircle of >180° and secure the body by allowing the bar to yield briefly during installation. The module can then be clipped into the DC bar.

[0136] The module can be used as in Fig. 6. It can also be completely enclosed by a second element of the rail. The second element is connected to the DC bar by welding, bolting, riveting, etc.

[0137] The module can be used as in Fig. 7. They are secured by one or more additional retaining elements. The retaining element is ideally made of a material with optimized thermal conductivity, e.g., thermally conductive plastic.

[0138] The DC bar can power the module as shown in Fig. 5. Enclose the DC bar in such a way that it is fixed in place. For example, the DC bar can have a tab at its end to secure the end to itself at another point. The DC bar can have local weakenings, such as beads, notches, and / or cutouts, to allow for local movement during module installation.

[0139] The retaining element can hold the cell as in Fig. 8. They also fully enclose the components, thus completely handling heat conduction and fixation. Galvanic isolation from the DC bar is therefore directly achieved.

[0140] The module can also be oriented laterally. This variant allows for direct coupling of two cooling modules to the other DC pin or potential. The arrangement has the advantage that the DC bar, by forming a depression, 'holds' the module.

[0141] The cooling module can be used as described in Fig. Alternatively, 10. the components are not 'contacted' at the outer surface, but thermally coupled via the end face, i.e., via the caps of the cooling unit. Fixing is achieved, for example, using screws, circumferential welding, or clips.

[0142] The inlet and outlet can be positioned on either side, in which case the DC bar requires the necessary cutouts for the inlet and outlet. The end face is either directly connected to potential or galvanically isolated via spacers, gap fillers, etc.

[0143] A flat, elongated cooling unit can be used as in Fig. 9. The bracket is placed directly onto the DC bar. A mounting bracket is designed to form the spacer and the gap filler area around the entire perimeter. Lateral tabs facing the DC bar ensure sufficient clearance. The bracket is then attached to the housing or other components.

[0144] A cap is designed to hold the cooling unit in position and ensure even pressure on the rail. The cap is attached to the bracket, for example, by clipping, screwing, or welding.

[0145] The cooling module can be used as described in Fig. The cooling module must be fully integrated, meaning it is partially bonded and sealed to the DC bar. This bonding is achieved, for example, by friction or laser welding. Other methods are possible depending on the design and material pairing. The cooling module can be integrated from the front. Alternatively, it can be integrated from the rear. The connections can be located on the back or through the DC bar itself. Press-fitting, welding, or screwing of the inlet and outlet is possible. Fins can be integrated on the DC bar and / or in the cooling module.

[0146] The cooling module can be used as described in Fig. 11. The module is also partially enclosed and fixed by two DC bars at different potentials. The DC bars enclose the module in such a way that creepage distances are maintained. This type of integration reduces EMC emissions.

[0147] The cooling module can be used as described in Fig. 14. The DC bars can also be oriented horizontally or transversely. The two potentials do not completely and symmetrically encompass the module. The DC bars can be stacked for EMC optimization. The outputs of the DC bars can also be positioned next to each other for optimized connection. REFERENCE MARK LIST 100 busbar 102nd entry 104 Cold storage room 106 Connection panel 108 pin 110 interface 112 High-voltage distribution system 114 tab 116 Surface area 118 connection 200 gap 202 spacers Slide 204 206 Wall 208 Interior 210 rib 212 lamella 214 Sub-area 300 heat storage medium 302 Filling level 304 Noble gas 306 Phase change material 308 lids 310 Compensation opening 500 flange 502 Bending range 600 retaining elements 700 thickening 800 feet 900 recess 1000 floors 1100 busbar pair 1102 Touch protection cap 1104 Touch protection collar 1200 subcells 1202 Insulator 1204 Overflow channel 1206 Flow path

Claims

busbar (100), wherein the busbar (100) forms a receptacle (102) for a cooling cell (104) and the cooling cell (104) is arranged in the receptacle (102), wherein the receptacle (102) is configured to thermally couple the cooling cell (104) to the busbar (100) and the cooling cell (104) is configured to temperature-control the busbar (100), wherein in the area of ​​the receptacle (102) two electrically insulating spacers (202) are arranged between the cooling cell (104) and the busbar (100), wherein a gap (200) formed by the spacers (202) between the cooling cell (104) and the busbar (100) is filled with an electrically insulating and thermally conductive paste. busbar (100) according to claim 1, wherein the cooling cell (104) is arranged between two electrically insulating touch protection caps (1102), wherein the spacers (202) are formed by the touch protection caps (1102). busbar (100) according to one of the preceding claims, wherein an electrically insulating film is arranged between the cooling cell (104) and the busbar (100) in the area of ​​the receiving (102). busbar (100) according to one of the preceding claims, wherein a sensor for mapping a temperature in the area of ​​the recording (102) in a temperature value is arranged between the cooling cell (104) and the busbar (100). busbar (100) according to one of the preceding claims, wherein the busbar (100) has at least one tab (114) in the area of ​​the receptacle (102) for attaching the cooling cell (104) to the busbar (100) and / or for attaching the busbar (100) to a structural component. busbar (100) according to one of the preceding claims, wherein the busbar (100) in the area of ​​the receiving (102) at least partially reflects a contour of the cooling cell (104). busbar (100) according to claim 6, wherein the busbar (100) surrounds the cooling cell (104) in the area of ​​the receiving (102) by more than 180°. busbar (100) according to one of the preceding claims, with at least one retaining element (600) arranged in the area of ​​the receiving (102), wherein the cooling cell (104) is arranged between the retaining element (600) and the busbar (100). busbar (100) according to one of the preceding claims, wherein the busbar (100) forms at least one wall (206) of the cold storage cell (104) in the area of ​​the receiving (102). busbar (100) according to claim 9, the connections (118) of the cold storage cell (104) run through the busbar (100). busbar (100) according to one of the preceding claims, with a connection field (106) adjacent to the receptacle (102) for a pin of a charging socket. A pair of busbars (1100) with two busbars (100) according to one of the preceding claims, wherein the busbars (100) are electrically insulated from each other and at least one cooling cell (104) in the area of ​​the receptacles (102) is thermally coupled to both busbars (100). Busbar pair according to claim 12, wherein the busbars (100) are arranged symmetrically to each other. busbar pair (1100) according to one of claims 12 to 13, wherein the cooling cell (104) has two electrically isolated subcells (1200), wherein one subcell (1200) and one busbar (100) are electrically connected to each other.

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