Immersion-cooled automotive high-voltage component

Abstract

Immersion-cooled automotive high-voltage component (10) with a fluid-tight component housing (30) filled with an electrically non-conductive cooling liquid (32), wherein the component housing (30) has a feedthrough section (31) for passing through a signal line (44), wherein the lead-through section (31) is formed by an electrically non-conductive ceramic wall body (52) in a housing metal wall (54), wherein the signal line (44) is embedded in the ceramic wall body (52) and guided through in this way, and wherein the embedded signal line (44) in the ceramic wall body (52) does not run orthogonally to the wall plane.

Description

[0001] The invention relates to an immersion-cooled automotive high-voltage component having a component housing through which a signal line is passed from the outside to the inside in a feedthrough section.

[0002] An immersion-cooled high-voltage automotive component can be, for example, a vehicle traction battery or a vehicle traction motor. Immersion cooling, in this context, refers to the direct liquid cooling of an electrical component with an electrically non-conductive coolant, for example, the cooling of a motor stator, a motor, or battery cells. Immersion cooling allows for the rapid dissipation of large amounts of heat, even in the short term.

[0003] An immersion-cooled drive motor is known from DE 10 2019 125 871 A1. An immersion-cooled traction battery is known from DE 10 2018 133 005 A1.

[0004] Typical immersion-cooled automotive high-voltage components have a component housing made of an electrically conductive metal, such as aluminum. To route a signal line through the component housing to transmit a measured value from a sensor inside the housing, such as a coolant temperature sensor, the component housing must incorporate corresponding connector components, which are complex to manufacture and integrate, and require a relatively large amount of installation space.

[0005] From DE 10 2009 003 958 B4, DE 10 2014 007 562 B4, DE 10 2018 107 561 A1 and DE 10 2020 206 664 A1 various arrangements and methods for embedding an electrical conductor in an electrically non-conductive body are known.

[0006] From US 2011 0 254 147 A1 an immersion-cooled high-performance semiconductor component is known in which the electrical connections are made via lines that are each led orthogonally through a ceramic wall body.

[0007] The object of the invention is to provide an immersion-cooled automotive high-voltage component with a compact, fluid-tight feedthrough of a signal line through the component housing.

[0008] This object is achieved by an immersion-cooled automotive high-voltage component having the features of claim 1.

[0009] The immersion-cooled high-voltage automotive component according to the invention comprises a fluid-tight component housing filled with an electrically non-conductive cooling liquid. The cooling liquid is preferably a cooling oil. A motor stator or a motor rotor, or battery cells, are preferably arranged in the component housing.

[0010] The component housing has a feedthrough section for the passage of one or more signal lines. The feedthrough section is formed by a metal housing wall and an electrically non-conductive ceramic wall body. The ceramic wall body completely and fluid-tightly fills an opening in the metal housing wall, so that the fluidic separation between the inside of the component housing and its outside in this area is achieved exclusively by the ceramic wall body.

[0011] The signal line is embedded in the ceramic wall body, so that the signal line is routed through the component housing in this area.

[0012] The embedded signal line runs non-orthogonally within the ceramic wall body, not orthogonally to the wall plane of the ceramic wall body. This increases the length of the signal line embedded in the ceramic wall body, thus correspondingly lengthening the sealing gap between the outer surface of the signal line and the ceramic wall body, thus increasing the fluid tightness and pressure resistance in this area.

[0013] Particularly preferably, the embedded signal line runs in a meandering fashion within the ceramic wall body, thereby correspondingly extending the length of the signal line embedded in the ceramic wall body. Particularly preferably, the basic direction of the meandering section of the signal line runs parallel to the wall plane of the ceramic wall body. This results in a particularly long embedded signal line.

[0014] Preferably, a sensor is provided in the component housing, which is electrically connected to a controller outside the component housing via the embedded signal line. Particularly preferably, the sensor is a temperature sensor that, for example, determines the temperature of the cooling fluid.

[0015] Preferably, the housing metal wall consists of an electrically conductive metal, particularly preferably of a stainless steel.

[0016] Preferably, the ceramic wall body is manufactured additively, so that the signal line can be embedded particularly easily into the ceramic wall body. Particularly preferably, the embedded signal line can also be manufactured additively.

[0017] In the following, an embodiment of the invention is explained in more detail with reference to the drawing.

[0018] The figure schematically shows an immersion-cooled automotive high-voltage component with a fluid-tight component housing and a feedthrough section for passing a signal line through the component housing.

[0019] The figure schematically illustrates a high-voltage automotive component 10, which in this case is part of an electric high-voltage traction motor. The high-voltage automotive component 10 has a fluid-tight component housing 30, in which, in this case, a motor stator 20 of the traction motor, comprising, for example, three coil strands 22, is arranged and permanently immersion-cooled by an electrically non-conductive cooling liquid 32. The cooling liquid 32 is, in this case, a cooling oil.

[0020] The motor stator coil strands 22 are electrically controlled by motor electronics 24 external to the housing.

[0021] The component housing 30 with the cooling liquid 32 is part of a cooling circuit, which is further formed by a housing-external cooling liquid pump 34 and a housing-external cooler 36.

[0022] The component housing 30 is essentially formed from an electrically conductive housing body, for example, a housing body made of die-cast or extruded aluminum. The component housing 30 has a feedthrough section 31 for passing through a signal line 44, which electrically and wiredly connects a housing-internal sensor 42 to a housing-external controller 40. In this case, the housing-internal sensor 42 is a temperature sensor that determines the temperature of the cooling fluid 32.

[0023] The controller 40 controls the entire cooling circuit and is further connected via signal connections to the radiator 36, the coolant pump 34 and, if applicable, also to the engine electronics 24. The controller 40 controls the entire cooling circuit depending on the coolant temperature determined by the sensor 42.

[0024] In the feedthrough section 31, an electrically non-conductive ceramic wall body 52 is embedded in a housing opening of an electrically conductive housing metal wall 54 in a fluid-tight manner. In this area, the ceramic wall body forms the relevant housing wall entirely and entirely. In this case, the housing metal wall 54 is made of stainless steel. The housing metal wall 54 of the feedthrough section 31 can be integrated into the remaining aluminum component housing 30 in a fluid-tight manner, for example, by friction stir welding.

[0025] The signal line 44 is embedded in the ceramic wall body 52, with the embedded signal line 44 running in a meandering manner in this area. The basic direction of the meander formed by the signal line 44 lies in the wall plane of the ceramic wall body 52, so that the embedded signal line 44 has a line length that is at least three times the wall thickness d of the ceramic wall body 52.

[0026] The complete signal connection between the housing-internal sensor 42 and the housing-external controller 40 is formed by a housing-internal signal line section 44", the embedded signal line 44 and a housing-external signal line section 44'.

[0027] In this case, the ceramic wall body 52 is manufactured using an additive manufacturing process, by which the signal line 44 in this area has been embedded layer by layer into a layered ceramic body 50. The embedded signal line 44 itself can also be formed using an additive manufacturing process. The wall thickness d of the ceramic wall body 52 is identical to the wall thickness d of the housing metal wall 54 adjacent to the ceramic wall body 52.

Claims

[1] Immersion-cooled automotive high-voltage component (10) with a fluid-tight component housing (30) filled with an electrically non-conductive cooling liquid (32), wherein the component housing (30) has a feedthrough section (31) for passing through a signal line (44), wherein the lead-through section (31) is formed by an electrically non-conductive ceramic wall body (52) in a housing metal wall (54), wherein the signal line (44) is embedded in the ceramic wall body (52) and guided through in this way, and wherein the embedded signal line (44) in the ceramic wall body (52) does not run orthogonally to the wall plane. [2] Immersion-cooled automotive high-voltage component (10) according to claim 1, wherein the embedded signal line (44) runs in a meandering manner in the ceramic wall body (52). [3] Immersion-cooled automotive high-voltage component (10) according to one of the preceding claims, wherein a sensor (42) is provided in the component housing (30) and is electrically connected to a controller (40) outside the component housing (30) via the embedded signal line (44). [4] Immersion-cooled automotive high-voltage component (10) according to claim 3, wherein the sensor (42) is a temperature sensor. [5] Immersion-cooled automotive high-voltage component (10) according to one of the preceding claims, wherein the housing metal wall (54) is electrically conductive and particularly preferably consists of stainless steel. [6] Immersion-cooled automotive high-voltage component (10) according to one of the preceding claims, wherein the ceramic wall body (52) is additively manufactured. [7] Immersion-cooled automotive high-voltage component (10) according to one of the preceding claims, wherein the embedded signal line (44) is additively manufactured. [8] Immersion-cooled automotive high-voltage component (10) according to one of the preceding claims, wherein the cooling liquid (32) is a cooling oil. [9] Immersion-cooled automotive high-voltage component (10) according to one of the preceding claims, wherein a motor stator (20), a motor rotor or battery cells are arranged in the component housing (30).

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