Busbar with one contact element

Abstract

Busbar (21, 22, 23) with a contact element, for an electrical functional part (20) with a high-voltage interface (16) for establishing an electrical connection between a stator (25) and high-voltage electronics, wherein an electrical contacting unit (15) is provided in the electrical functional part (20), wherein the electrical contacting unit comprises a plurality of, preferably at least three, high-voltage lines, each of which comprises a contact element (51, 52, 53) at its end, so that the high-voltage lines can be connected to wire connections (61, 62, 63) which are designed to supply electrical phases of the stator with electrical current, wherein the busbar (21, 22, 23) is designed to provide at least one of the high-voltage lines, so that the contact element of the busbar can be connected to the associated wire connection, characterized in that the busbar (21, 22, 23) including its contact element (51, 52,53) is made of a single piece of pipe material.

Description

[0001] The invention relates to a busbar with a contact element for an electrical functional part with a high-voltage interface for representing an electrical connection between a stator and high-voltage electronics. State of the art

[0002] From the German patent application DE 10 2016 225 342 A1, a stator arrangement of an electrical machine is known with a housing and with a stator which has a stator base body and at least one winding head, wherein the stator base body and the winding head are cast in a heat-conducting epoxy resin.

[0003] From the subsequently published DE 10 2023 203 074.8 it is known to install high-voltage cables in such electrical machines, which protrude from a connection extension of an electrical contacting unit, wherein the connection extension is formed on a centering ring of the electrical contacting unit. Disclosure of the invention

[0004] The inventive, in particular one-piece, busbar has the advantage of providing a simple and cost-effective solution for a high-voltage connection of an electrical machine, in particular an air compressor. Advantageously, a stator busbar is made from a single tube.

[0005] Further advantages, features and details of the invention will become apparent from the following description, in which various embodiments are described in detail with reference to the drawing.

[0006] Advantageously, the tube is flattened in the area subsequently serving as the screw-in area or overmolding area, while it retains its hollow cylindrical shape in the area of ​​a contact element of the busbar for the stator current strands, which can then be given any desired outgoing direction by forming in a simple bending tool. Short description of the drawing

[0007] They show: Fig. 1 a perspective view of a gas conveying device, in particular an air supply device, with a housing comprising an electrical functional part with a high-voltage interface; Fig. 2 the electrical functional part Fig. 1 in a plan view; Fig. 3 a perspective view of an electrical contact unit of the electrical functional part of Fig. 1 without the Fig. 1 temperature control device shown; Fig. 4 a plan view of an electrical functional part, Fig. 5 a plan view of another electrical functional part, Fig. 6 a high-voltage line designed as a busbar and Fig. 7 a top view of a contact unit including the busbars forming its high-voltage lines. Description of the embodiments

[0008] In Fig. Figure 1 shows a perspective view of an air supply device 1. The air supply device 1 is also referred to as an air compressor and is used in a mobile fuel cell system to provide compressed air. The mobile fuel cell system, in turn, is used in a motor vehicle equipped with the fuel cell system to provide electrical energy, which is converted, for example, via an electric motor into drive energy for the motor vehicle.

[0009] The air supply device 1 comprises a multi-part housing 2 with an air connection 3 through which air is supplied, and with an air connection 4 through which compressed air is discharged. To compress the air, the air supply device 1 comprises, for example, a compressor wheel that is rotatable within a compressor volute.

[0010] The compressor wheel is driven by an electric motor located in the housing 2. The electric motor comprises a rotor that rotates within a stator.

[0011] The stator of the electric motor comprises a power connection device 5, via which alternating current is supplied to the stator in three phases. The power connection device 5 is connected to a control connection device 6 via a connecting device 10, which comprises three elongated contact parts 7, 8, 9.

[0012] The control connection device 6 is combined, for example, with a cable outlet 40, which is connected to a separately arranged and Fig. 1 is connected to an inverter not shown. However, the inverter can also be integrated into the housing 2 of the air supply device 1.

[0013] The electrical connection between the stator and the high-voltage electronics is realized by means of an electrical contact unit 15. The electrical contact unit 15 is Fig. 1 only hinted at.

[0014] In Fig. 2, the electrical contact unit 15 is shown in combination with an optional temperature control device 18. The electrical contact unit 15 comprises a high-voltage interface 16 with three plug connections (not shown in more detail) for the Fig. 2 inverter not shown. Inside the temperature control device 18, the stator is indicated only by a reference numeral 25.

[0015] Three high-voltage lines 21, 22, 23 are connected to the stator 25, which are Fig. 2 protrude from the inside of a connection extension 29 of the electrical contact unit 15. The electrically conductive wire connection between the high-voltage lines and the stator is in Fig. 2 not shown in detail, but in the Fig. 4 and Fig. 5. The Fig. In this context, Figure 2 shows only the contact elements 51, 52 and 53, which are assigned to the respective high-voltage lines 21, 22 and 23. The contact elements have a spatial orientation in the plane under consideration, which is Fig. 4 and Fig. 5 is described in more detail. The contact elements form the connection of a respective wire connection to the stator (see Fig. 4 and Fig. 5). The connection extension 29 is formed on a centering ring 28 of the electrical contact unit 15. The temperature control device 18 comprises a temperature control sleeve 24, which surrounds the stator 25 in a temperature-regulating, in particular cooling, manner. The electrical contact unit 15 comprises, for example, two sensor lines 26, 27, which are assigned to sensors (not shown) in or on the stator 25.

[0016] The centering ring 28 and the connection extension 29 are integrally connected to one another in an injection-molded part, which serves to represent the electrical contact unit 15. A frictional connection geometry 30 is formed on an inner circumference 37 of the centering ring 28. The frictional connection geometry 30 comprises, for example, a total of six support bodies, of which Fig. 2 only five supporting bodies 31 to 35 are visible.

[0017] The support bodies 31 to 35 are raised inwardly on the inner circumference 37. To create a press fit, the support bodies 31 to 35 rest against an outer circumference 38 of the temperature control sleeve 24. This easily enables a stable press fit between the electrical contact unit 15, which is designed as an injection-molded part, and the temperature control device 18.

[0018] In Fig. 3, the electrical contact unit 15 is shown in perspective and without the high-voltage lines 21 to 23 and without the sensor lines 26, 27. The centering ring 28 with the frictional connection geometry 30 and the connection extension 29 is advantageously formed as an injection-molded part made of a suitable plastic material. Fig. The high-voltage cables 21 to 23 shown in Figure 2 and the sensor cables 26, 27 can, depending on the design of the injection-molded part, be overmolded with it.

[0019] The Fig. 4 and Fig. 5 each show an electrical contact unit 15 corresponding to the illustrations in the Fig. 1 to 3. These contact units also have contact elements 51, 52, and 53, which at one end are each part of the high-voltage lines 21, 22, and 23, respectively. The contact elements 51, 52, and 53 are each firmly connected at the other end to wire connections 61, 62, and 63, respectively. These wire connections are guided inward into the air supply device 1, where they are electrically connected, in a manner not shown in detail, to the respective electrical phase of the stator of the electric motor of the gas conveying device.

[0020] The contact elements 51, 52, and 53 are each arranged in a defined orientation relative to the respective high-voltage line in order to ensure the routing of the wire connections and their connection to the contact elements with low mechanical stress. Furthermore, the defined orientation and the angular position described below ensure an optimal distance between the wire connections 61, 62, and 63.

[0021] In the Fig. 4 and Fig. 5, α (“Alpha”) is the angle between contact elements 52 and 53. B (“Beta”) is the angle between contact elements 51 and 53. And γ (“Gamma”) is the angle between contact elements 51 and 52.

[0022] Alpha, Beta and Gamma lie between 2 degrees and 95 degrees or between 120 degrees and 178 degrees. For example, Fig. 4 shows a situation where all three angles are between 2 degrees and 95 degrees. Fig. Figure 5 shows an example of a situation where the angle gamma is between 2 degrees and 95 degrees, but the angles alpha and beta are between 120 degrees and 178 degrees.

[0023] Fig. 6 shows a single high-voltage cable 21, 22, or 23 in the form of a busbar, which can be manufactured cost-effectively using a simple process. The busbar has an elongated, flat region 131, which transitions into the contact element 51, 52, or 53 via a bent region 130. The contact element has a cylindrical, in particular a circular-cylindrical, cross-section 100 with a tubular opening for connection to an electrical wire. In the transition region between the contact element and the bent region 130, there is a vent opening 120, which serves to provide an escape route for gases generated when the contact element is soldered or hot-crimped to a wire. At the end of the flat region 131 facing away from the bent region 130, a hole 110 is provided for further connection to a current-carrying element or for forming a high-voltage interface 16.

[0024] The busbar is made of an electrically conductive, preferably metallic tube. The tube is flattened where the flat area 131 is to be created. This is the area in which the busbar can be connected or screwed to a current-carrying element, i.e., the area of ​​the hole 110, and in which the busbar can be overmolded with an electrically non-conductive material, which then forms the connection extension 29, as shown in Fig.7. The latter is preferably the area between the area of ​​the hole and the bent area 130. At the end of the busbar facing away from the hole 110, which is also intended to serve as the connection area and thus subsequently forms the contact element, the cross-section of the tube remains cylindrical or circular-cylindrical. The bent area can be shaped as desired to create the desired angle of the contact element to the flat area 131. In this way, different outlet directions of the connection geometry can be produced cost-effectively, depending on the design of the busbar as a high-voltage cable 21, 22, or 23. The vent opening 120, which is required for hot-squeezing or hot-crimping stator strands to the contact element, can be easily provided during the production of the busbar, i.e., during the forming of the tube starting material.

[0025] The busbar is preferably made of copper tubing and is preferably tinned over its entire surface to prevent corrosion, particularly in the area of ​​the hole 110 and the contact element 51, 52 or 53.

[0026] Due to manufacturing and design considerations, the busbar has rounded edges, meaning no separate removal is required. This is beneficial when overmolding the busbar with the material of the connection extension. Rounded edges reduce stresses in the plastic at the busbar edges, increasing the robustness of the plastic overmolding and significantly reducing the risk of cracking. QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2016 225 342 A1

[0002] DE 10 2023 203 074.8

[0003]

Claims

[1] Busbar (21, 22, 23) - for an electrical functional part (20) with a high-voltage interface (16) for forming an electrical connection between a stator (25) and high-voltage electronics, wherein an electrical contacting unit (15) is provided in the electrical functional part (20), wherein - the electrical contacting unit comprises several, preferably at least three, high-voltage lines, each of which comprises a contact element (51, 52, 53) at its end, so that the high-voltage lines can be connected to wire connections (61, 62, 63) which are designed to supply electrical phases of the stator with electrical current, wherein the busbar (21, 22, 23) is designed to provide at least one of the high-voltage lines, characterized by that the busbar (21, 22, 23) including its contact element (51, 52, 53) is made of a one-piece tubular material. [2] Busbar according to claim 1, characterized by that the pipe material in its original form has a cylindrical, in particular a circular cylindrical, cross-section. [3] Busbar according to claim 2, characterized by that the contact element (51, 52, 53) is formed from one end of the tube material, wherein the contact element is designed for the introduction and fastening of electrical wire, in particular stranded wire. [4] Busbar according to one of the preceding claims, characterized by that it has a flat region (131) at the end facing away from the contact element (51, 52, 53), which is produced by flattening the one-piece tube material at the end facing away from the contact element. [5] Busbar according to claim 4, characterized by that a vent opening (120) is arranged at the end of the contact element facing the flat area. [6] Busbar according to claim 4 or 5, characterized bythat a curved region (130) is arranged between the contact element (51, 52, 53) and the flat region (131). [7] Busbar according to one of the preceding claims, characterized by that it is made of copper material. [8] Busbar according to one of the preceding claims, characterized by that it is tinned. [9] Method for producing a busbar according to one of the preceding claims, characterized by that it is made from a one-piece tubular material which is flattened at one end to provide a flat area (131) of the busbar. [10] Electrical functional part (20) with a high-voltage interface (16) for forming an electrical connection between a stator (25) and high-voltage electronics, wherein an electrical contacting unit (15) is provided in the electrical functional part (20), wherein the electrical contacting unit comprises at least three high-voltage lines (21, 22, 23), each of which comprises a contact element (51, 52, 53) at its end, so that the high-voltage lines can be connected to wire connections (61, 62, 63) which are designed to supply electrical phases of the stator with electrical current, characterized by that the high-voltage lines are each formed by a busbar according to one of claims 1 to 8. [11] Electrical functional part according to claim 10, characterized by that the contact elements (51, 52, 53) have a defined spatial orientation such that the wire connections can be guided to the stator with low mechanical stress. [12] Electrical functional part according to claim 11, characterized by that the contact elements each have a longitudinal extension, with defined angles (α, β, γ) lying between the respective longitudinal extensions, while the flat regions (131) of the busbars are arranged parallel to one another. [13] Electrical functional part according to claim 12, characterized by that these angles lie in one plane. [14] Air supply device (1) with a stator (25) and with an electrical functional part (20) according to one of claims 10 to 13.

Images