Control unit, in particular an in-vehicle charger for an electrically powered vehicle, method for producing the control unit and method for operating the control unit

Abstract

The invention relates to a control unit (10), in particular an in-vehicle charger (15) for an electrically powered vehicle, a method for producing the control unit (10), and a method for operating the control unit (10), comprising a control device (30) with a heat source (65), a housing (35), a heat sink (40), and a connecting layer (45). The control device (30) is arranged in a housing interior (60) of the housing (35) and bears against a first connecting side surface (110) of the connecting layer (45). The heat sink (40) is arranged outside the housing interior (60) and bears against a second connecting side surface (115) of the connecting layer (45), which is arranged opposite the first connecting side surface (110). The connecting layer (45) thermally and mechanically connects the control device (30) to the heat sink (40) for cooling the heat source (65).wherein the connecting layer (45) comprises a connecting material which is designed to melt from a solid phase state in the event of a thermal overload of the control device (30) and to cool the control device (30) by melting from the solid phase state into a liquid phase state.,

Description

The invention relates to a control device, in particular an in-vehicle supercharger for an electrically driven vehicle according to patent claim 1, a method for producing the control device according to patent claim 15 and a method for operating the control device according to patent claim 16.In-vehicle loaders for electric-powered automobiles are known. The vehicle-internal charger serves to convert the electrical energy provided at a charging connection of the vehicle, which is usually provided as an alternating current, into a direct current for charging the electrical energy store, which is in particular designed as a traction battery. The in-vehicle supercharger has numerous components, in particular semiconductor components, which warm up during operation. In order to keep the heating within the scope of tolerable heating, the charger is preferably actively cooled.It is an object of the invention to provide an improved control device, in particular an in-vehicle supercharger for an electrically driven motor vehicle. It is a further object of the invention to provide an improved method for producing the control unit, in particular the in-vehicle supercharger, and an improved method for operating the control unit, in particular the in-vehicle supercharger.This object is achieved by means of the features of claim 1 and of claims 15 and 16. Advantageous embodiments are given in the dependent claims.It has been recognized that an improved control device for a vehicle, in particular an improved in-vehicle supercharger for an electrically driven vehicle, may be provided in that the control device, in particular the in-vehicle supercharger, has a control device having a heat source, a housing, a heat sink, and a connection layer. The control device is arranged in a housing interior of the housing. The control device abuts a first connecting side surface of the connecting layer. The cooling body is arranged outside the housing interior and abuts a second connecting side surface of the connecting layer arranged opposite the first connecting side surface. The connecting layer thermally and mechanically connects the control device to the cooling body for cooling the heat source. In addition, the connecting layer can also connect individual components of the control device to one another. The connecting layer comprises a connecting material which is configured to melt from a solid phase state in the event of thermal overloading of the control device and to cool the control device from the solid phase state into a liquid phase state by the melting.This embodiment has the advantage that further mechanical fastening means for connecting the cooling body to the control device can be dispensed with and a reliable heat transfer between the cooling body and the control device, in particular the heat source of the control device, can also be provided.Furthermore, due to the melting of the connecting layer in the event of an overload, for example when the control device heats up at least locally to a temperature of greater than 220° C., a further temperature rise is prevented during the melting of the connecting material, so that additional time is provided in order to deactivate the control device and to prevent overheating or further damage to further components of the control device.In a further embodiment, the control device has a first collecting container, wherein the first collecting container is arranged offset to the heat sink and delimits a first collecting volume, wherein the first collecting container is open on the side facing the connecting layer and is designed to receive melted connecting material of the connecting layer. This configuration has the advantage that emission of the connecting material into an environment or into other regions of the vehicle is avoided. In particular, contamination into the environment of the vehicle is avoided.In a further embodiment, the control device has a sensor device with at least one first sensor. The first sensor is designed to detect the connecting material located in the first collecting volume and to provide a sensor signal as a function of the detected connecting material. The sensor signal can be provided to the control device, for example, so that the control device is deactivated or deactivated when connecting material located in the first collecting volume is detected, and further heating of the control device is thereby avoided in order to avoid further damage to the control device.It is particularly advantageous here if the first sensor is arranged in the first collection volume. It would also be possible for the first sensor to be arranged outside the first collecting container. Additionally or alternatively, the first sensor may be embedded in the bonding layer. The first sensor can be sensitive to the connecting material, for example.In a further embodiment, the connecting material of the connecting layer can be reversibly transferred from the solid phase state to the liquid phase state essentially in a non-destructive manner. A melting point of the bonding material may be in a range of from 7 °60C to 120 °C inclusive. Due to a melting point in this specified range, the connecting material is suitable as a phase change material and / or as a latent heat store.In a further embodiment, the bonding layer comprises at least one of the following bonding materials: aliphatic hydrocarbon, preferably having 16 or 17 or 18 carbon atoms, salt, microencapsulated hard paraffin, hard paraffin, wax, natural wax, thermochemical heat accumulators. Additionally or alternatively, the bonding layer comprises at least one of the following stiffening materials embedded in the bonding material: aluminum nitride (AlN), fiber material (preferably with long and / or short fibers) such as basalt, carbon, nylon, hemp, flax, aramid and / or glass fiber (preferably with long and / or short fibers)), mercerized cellulose, vegetable powder, carbon nanofilament, cellulose nanofilament, nanocellulose microfibrils, nanofibrils. A proportion of vegetable powder may be up to 74 volume percent. Alternatively, a level of microfibrils may be up to 91 volume percent.In a further embodiment, the housing has a through-opening, wherein the cooling body is arranged on the through-opening and the connecting layer fluidically seals the through-opening. This embodiment has the advantage that additional sealing means can be dispensed with. In particular, it is possible to dispense with seals encircling additional housing covers and mechanical means for fastening the housing cover to the housing, with the result that the control device is of particularly simple and cost-effective design by means of the sealing at the passage opening by means of the connecting layer.In a further advantageous embodiment, the cooling body is mechanically fastened to the control device, preferably exclusively, by means of the connecting layer in a materially bonded manner. The control device is in turn fastened in the housing. This can also be effected, for example, by the connecting layer. This embodiment has the advantage that the cooling body is thus only indirectly connected to the housing. Further mechanical connecting means, in particular screws, clamping means or the like, can be dispensed with or they can be provided in a reduced numberIn a further embodiment, the first collecting container closes the passage opening at least in sections.In a further embodiment, the housing has a housing underside, wherein the heat sink is arranged on the housing underside. The connecting layer is arranged below the control device. The heat sink is arranged below the connecting layer. The heat sink is designed to become detached when the connecting material of the connecting layer melts and to separate from the control device. This configuration has the advantage that in the event of damage to the control unit, if the control device produces so much waste heat that the connecting layer melts and the melting connecting layer has to cool the control device in the event of damage, additional cooling is provided by the separation of the cooling body, in particular if the passage opening to the control device is opened at the housing bottom side.In a further embodiment, the control device has a second collecting container with a second collecting volume, wherein the second collecting container is arranged offset with respect to the first collecting container and the cooling body. The second collecting container delimits the second collecting volume. The second collecting container is open on the side facing the connecting layer and is designed to receive melted connecting material of the connecting layer. This configuration has the advantage that the connecting layer can be configured to be particularly thick and, as a result, good electrical insulation can be provided between the cooling body and the control device. In the event of damage, i.e. when the connecting material is melted, the connecting material of the connecting layer can be collected both by the first collecting container and by the second collecting container in a sufficient quantity, so that contamination of the environment of the vehicle or of an interior of the vehicle can be avoided.In a further embodiment, the connecting layer has a clearance surface which is arranged on a side facing away from the control device. The free surface is arranged laterally spaced apart from the cooling body and preferably from the first collecting container. The free surface is uncovered. This embodiment has the advantage that in the event of repair a thermal energy can be introduced into the connecting layer via the flank, for example by means of laser radiation, in order to melt the connecting layer and separate the cooling body from the control device.In a further embodiment, the connecting material is reversibly separable from the control device in a non-destructive manner in the liquid phase state. As a result, contamination of the control device by the connecting material can be avoided during recycling of the control device.In a further embodiment, after the separation from the control device, the connecting material can be reused. This allows recycling of the connecting material in a pure type. In particular, the connecting material can be inserted again in order to connect the control device to the cooling body.An improved method for producing the above-described control device is provided in that the control device is introduced into the housing interior. The bonding material of the bonding layer is applied to the control device in a liquid phase state. The heat sink is arranged on the liquid connecting material. The heat sink cools the liquid connection material, so that the liquid connection material is transferred into the solid phase state to the connection layer and the connection layer thermally and preferably mechanically connects the heat sink to the control device. This configuration has the advantage that additional fastening means for connecting the cooling body to the control device, in particular screws, clamps or the like, can be dispensed with and the method for producing the control device, in particular the in-vehicle charger, is thereby particularly cost-effective. Furthermore, the connecting layer and the reversible melting and cooling of the connecting material which are possible several times make it possible to produce a readily repairable control device in which the heat sink can be removed in a simple manner.An improved method for operating the control unit, in particular the in-vehicle supercharger, can be provided in that, in a control operation, the control device generates heat with the heat source, wherein, in the control operation, the heat source reaches a first maximum temperature which is lower than a melting temperature of the connecting material. The heat is dissipated from the heat source to the cooling body via the connecting layer for cooling the heat source. In the event of a fault, the heat source heats up to a second maximum temperature which is greater than the melting temperature of the connecting material. The bonding material melts and is converted to the liquid phase state. The liquid compound material flows into the first collection volume. The method has the advantage that the melting can be detected at an early stage by means of a sensor device, for example, and as a result, when the melting and the presence of the liquid connecting material in the first collecting volume are detected, the control device can be deactivated in order to avoid a further heat development without errors.In a further embodiment, a presence of connecting material in the first collecting volume is checked. When connecting material is detected in the first collecting volume, the control device is deactivated. This can quickly prevent overheating of the control unit.The invention is explained in more detail below with reference to figures. The following are shown: FIG. 1 shows a perspective illustration of a control unit for a motor vehicle; FIG. 2 shows a further perspective illustration of the control unit shown in FIG. 1 ; FIG. 3 shows a schematic illustration of a sectional view along a sectional plane A-A shown in FIG. 1 by the control device shown in FIG. 1 ; FIG. 4A is a perspective detail of an illustration of the control device shown in FIGS. 1 to 3 ; FIG. 4B is a perspective view of the control device shown in FIGS. 1 to 3; FIG. 5 is a flow chart of a method for manufacturing the control device shown in FIGS. 1 to 4; FIG. 6A is a schematic side view of the control device; FIG. 6B shows a plan view of the control device before a first method step; FIG. 7 shows a schematic illustration of the control device and of the housing during a third method step; FIG. 8 shows a schematic illustration of the control unit during a fourth method step; and FIG. 9 shows a detail of a perspective bottom view of the control device shown in FIGS. 1 to 4.In the following figures, reference is made to a coordinate system for ease of understanding. The coordinate system has an x-axis (longitudinal direction), a y-axis (transverse direction) and a z-axis (height direction). The coordinate system is designed here as a right-hand system, for example.FIG. 1 shows a perspective illustration of a control unit 10 for a motor vehicle.The control device 10 is configured as an in-vehicle supercharger 15 for an electric driven vehicle, for example, in the embodiment. The vehicle can be designed, for example, as a hybrid vehicle or as a fully electric vehicle having an electrical energy store (not shown in FIG. 1 ) for providing drive energy for driving the vehicle.The in-vehicle supercharger 15 has an input side 20, an output side 25, and a controller 30 (schematically indicated by a dashed line in FIG. 1 ).The housing 35 delimits a housing interior 60. At least the control device 30 is arranged in the housing interior 60. The control device 30 can have power electronics. The control device 30 comprises, by way of example, at least one heat source 65, which generates heat during operation of the control device 30. The heat is to be transported away from the housing interior 60 and from the control device 30 in order to protect the control device 30 in order to avoid overheating of the control device 30.The input side 20 and the output side 25 are each electrically connected to the controller 30. In this case, the input side 20 can be electrically connected, for example, to a charging connection (not illustrated in FIG. 1 ) of the vehicle. The output side 25 can be electrically connected to the electrical energy store of the vehicle, for example. When electric energy, for example an alternating current, is provided at the charging connection, the control device 30 converts the electrical energy provided, for example, into a direct current which is provided on the output side 25 for charging the electrical energy store. In this case, the control device 30, in particular the heat source 65, heats up.The housing 35 has, for example, a housing top side 75 and a housing bottom side 80 arranged opposite the housing top side 75 in the z direction. In FIG. 1, the view is directed at the housing bottom side 80. The housing top side 75 and the housing bottom side 80 result in the installed state of the control unit 10 in the vehicle. The housing bottom side 80 is arranged on a side facing the wheels and the housing top side 75 is arranged on a side facing away from the wheels. The housing top side 75 and the housing bottom side 80 are each connected to one another by means of side surfaces 85, 86, 87, wherein, for example, the input side 20 and the output side 25 can be arranged on one of the side surfaces 85, 86, 87.On the housing bottom side 80, the housing 35 has a through opening 70. The through opening 70 extends completely through the housing underside 80 and opens into the housing interior 60. the through opening 70 can extend, for example, completely over the housing underside 80.Adjoining the first side surface 85 in the transverse direction is the first collecting container 50. Opposite the first collecting container 50 in the transverse direction, the second collecting container 55 can be arranged on the housing 35. The second collecting container 55 reduces, for example, an opening cross section of the through opening 70. the first collecting container 50 and the second collecting container 55 are each arranged in the z direction on the housing bottom side 80. In this case, the first collecting container 50 and / or the second collecting container 55 can be mechanically connected to the housing 35, for example by means of a screw connection. The first collecting container 50 delimits a first collecting volume 90 on a side facing the housing interior 60. Both the first collecting container 50 and the second collecting container 55 can be designed in the manner of a shell or trough. The first collecting volume 90 and the second collecting volume 95 open at the through opening 70.It is particularly advantageous if the first collecting container 50 is arranged substantially flush with a first side surface 85, and the second collecting container 55 is arranged opposite the first collecting container 50 in the transverse direction flush with a second side surface 86.In the transverse direction, the cross-sectional area of the through-opening 70 visible from below is limited by the first collecting container 50 and the second collecting container 55. In this case, in the embodiment, the cooling body 40 is arranged, by way of example, laterally offset with respect to the first collecting container 50 and the second collecting container 55. In particular, the cooling body 40 can be arranged between the first collecting container 50 and the second collecting container 55 in such a way that, for example, only a small gap 100 is arranged between the first collecting container 50 and the cooling body 40 and / or the second collecting container 55 and the cooling body 40. A gap-free arrangement of the cooling body 40 between the first collecting container 50 and the cooling body 40 and / or the cooling body 40 and the second collecting container 55 would also be possible.In addition, the connecting layer 45 may have a clearance surface 135. The free surface 135 can be arranged, for example, in the transverse direction between the first collecting container 50 and the second collecting container 55. In the longitudinal direction, the clearance surface 135 in FIG. 1 is situated, for example, between the cooling body 40 and the first side surface 85. The gap 100 can end at the clearance surface 135. The clearance surface 135 is formed wider in the longitudinal direction than a maximum gap width of the gap 100. The clearance surface 135 is arranged laterally offset from the collecting container 50, 55 and from the cooling body 40 due to the arrangement between the first and second collecting containers 50, 55.FIG. 2 shows a further perspective illustration on the control unit 10 shown in FIG. 1, in particular of the in-vehicle supercharger 15, looking at the housing underside 80 of the housing 35 of the control unit 10.In FIG. 2, the receiver 50, 55 and the cooling body 40 are not shown. It can be clearly seen in FIG. 2 that the through-opening 70 extends substantially completely over the housing underside 80 in the transverse direction. The through-opening 70 can also extend completely over the housing bottom side 80 of the housing 35 in the longitudinal direction.The control device 30 adjoins the housing bottom side 80 and the through-opening 70 in the z-direction. In particular, the control device 30 can extend substantially over the entire cross-sectional area of the through-opening 70. The control device 30 can have a printed circuit board 105, for example. The circuit board 105 may support and electrically connect the heat source 65. In particular, the heat source 65 can be arranged on the printed circuit board 105 on a side facing away from the through-opening 70. On the side facing the housing bottom side 80 and thus the through-opening 70, the printed circuit board 105 can be designed to be substantially planar, for example. The printed circuit board 105 can be designed to be thermally conductive at least in regions.Schematically indicated by dashed lines in FIG. 2 shows how the cross-sectional area of the passage opening 70, which is arranged between the and second collecting containers 50, 55, is reduced by the collecting container 50, 55.FIG. 3 shows a schematic illustration of a sectional view along a sectional plane A-A shown in FIG. 1 through the control device 10 shown in FIG. 1, in particular the in-vehicle charger 15. On the side facing the housing bottom side 80, the printed circuit board 105 is covered by the connecting layer 45, so that the printed circuit board 105 abuts a first connecting side surface 110. In particular, the printed circuit board 105 is connected to the first connecting side surface 110 in a materially integral manner, for example.The cooling body 40 abuts on the connecting layer 45 on a second connecting side surface 115 which is arranged opposite the first connecting side surface 110 in the z direction, preferably over the full surface. The second connecting side surface 115 can be substantially planar. Furthermore, the cooling body 40 is connected to the second connecting side surface 115 in a materially integral manner. As a result, the connecting layer 45 not only serves to thermally connect the control device 30 via the connecting layer 45 to the cooling body 40 but also to mechanically fasten the cooling body 40 to the control device 30.The control device 30 can be mechanically fastened to the housing 35, for example by screwing the printed circuit board 105 to the housing 35. Due to the cohesive connection of the cooling body 40 via the connecting layer 45 to the control device 30, in particular to the printed circuit board 105, further mechanical fastening means for fastening the cooling body 40 to the housing 35 can be dispensed with. In particular, screwing the heat sink 40 to the housing 35 is dispensed with here, with the result that the control device 10, in particular the in-vehicle supercharger 15, can be produced particularly easily.In a control operation of the control device 10, for example, when the control device 10 as the in-vehicle charger 15 charges the electric energy storage device with electric energy provided at the charging port, the heat source 65 heats up. The heat source 65 generates heat Q due to, for example, ohmic resistance of the heat source 65, for example, when the heat source 65 is configured as a semiconductor device. The heat Q is dissipated from the heat source 65 via the thermally conductive printed circuit board 105. The circuit board 105 can serve, for example, as a heat spreader. The heat Q is introduced from the circuit board 105 into the connection layer 45 at the first connection side surface 110. The connecting layer 45 is formed to be heat-conductive and conducts the heat Q in the direction of the heat sink 40. the heat Q exits from the connecting layer 45 via the second connecting side surface 115 and is introduced into the heat sink 40.The cooling body 40 can be designed, for example, as a passive cooling element with ribs, wherein the heat Q is emitted to an environment of the control unit 10 via convection. By configuring the heat sink 40 as a passive cooling element, it is possible to dispense with connecting the control unit 10, in particular the in-vehicle supercharger 15, to a liquid cooling system of the vehicle, so that the outlay on assembly of the in-vehicle supercharger 15 for assembly in the vehicle is reduced.It would of course also be possible for the heat sink 40 to be designed as an active cooling element and / or as a heat exchanger, the secondary side of which is incorporated into the cooling system of the vehicle.It is of particular advantage if the bonding layer 45 has at least one of the following bonding materials: aliphatic hydrocarbons, preferably having 16 or 17 or 18 carbon atoms, salt, microencapsulated hard paraffin, hard paraffin, thermochemical heat accumulators.In addition, at least one of the following stiffening materials can be embedded in the connecting material of the connecting layer 45: aluminum nitride (AIN), fiber material such as basalt, carbon, nylon, hemp, flax, aramid and / or glass fiber (preferably with long and / or short fibers)), mercerized cellulose, vegetable powder, carbon nanofilament, cellulose nanofilament, nanocellulose microfibrils, nanofibrils. A proportion of vegetable powder may be up to 74 volume percent. Alternatively, a level of microfibrils may be up to 91 volume percent. Aluminum nitrite may have a proportion by volume of 5% to 80% inclusive. The fiber material can be long-fiber and / or short-fiber, for example. The stiffening material is configured to increase an elastic modulus of the connection layer 45 compared to an elastic modulus of the connection material and preferably to increase a thermal conductivity of the connection layer 45 compared to a thermal conductivity of the connection material. This has the advantage that the connecting layer 45 is particularly well formed mechanically and thermally and thus both a good mechanical and thermal connection of the cooling body 40 to the control device 30 is ensured.It is particularly advantageous if the printed circuit board 105 is covered with the connecting layer 45 preferably over the entire surface, but to an extent of at least 80%, on the side facing the housing bottom side 80. In particular, the connecting layer 45 can be formed wider than the cooling body 40 both in the longitudinal direction and in the transverse direction, for example. Thus, in the transverse direction in FIG. 3, the connecting layer 45 protrudes beyond the cooling body 40 and is at least partially closed by the connecting layer 45 at the passage opening 70 on the top side of the first and second collecting containers 50, 55. In this case, the collecting container 50, 55, in particular on the side facing the cooling body 40, can bear against the connecting layer 45, with the result that the connecting layer 45 seals the passage opening 70 together with the collecting container 50, 55 in a fluid-tight manner and a liquid is prevented from entering the housing interior 60, in particular toward the control device 30, for example via the gap 100. The fluid-tight seal by the connecting layer 45 is achieved in that the connecting layer 45 has at least one layer thickness of 0.8 mm to 10 mm inclusive and the connecting layer 45 is formed closed, that is to say without interruption and without a connection between the first connecting side surface 110 and the second connecting side surface 115.In addition, the control device 10, in particular the in-vehicle supercharger 15, may include a sensor device 120. The sensor device 120 has at least one first sensor 125 and preferably a second sensor 130. The first sensor 125 is arranged, for example, on the first collecting container 50 in the first collecting volume 90. It is of course also conceivable for the first sensor 125 to be arranged outside the first collecting volume 90. The second sensor 130 may be disposed in the second collection volume 95. Alternatively, it is also conceivable for the second sensor 130 to be arranged outside the second collecting volume 95. The sensor device 120 can be connected to the control device 30 in terms of data and / or electrical technology. A data connection is possible, for example, via a CAN bus of the vehicle. The first sensor 125 and / or the second sensor 130 are directly and / or indirectly sensitive to the connecting material. For example, the first sensor 125 and / or the second sensor 130 can be designed as a capacitive sensor.FIG. 4A shows a perspective detail of a representation of the control device 10 shown in FIGS. 1 to 3 ; FIG. 4B shows a perspective representation of the control device 10 shown in FIGS. 1 to 3, in particular of the in-vehicle charger 15, wherein the representation of the cooling body 40 and the collecting containers 50, 55 is omitted.It is particularly advantageous here if the connecting layer 45 extends in the transverse direction and the longitudinal direction respectively as far as the side surface 85, 86, 86 and in the process completely closes the through-opening 70.The connecting layer 45 preferably independently completely closes the through-opening 70. the connecting layer 45 can bridge gaps, cracks or interruptions in, for example, the printed circuit board 105 and / or between the printed circuit board 105 and the housing 35.FIG. 5 shows a flow chart of a method for producing the control device 10 shown in FIGS. 1 to 4, in particular the in-vehicle supercharger 15. FIG. 6A shows a schematic side view of the control device 30, and FIG. 6B shows a schematic plan view of the control device 30 before a first method step 205. FIG. 7 shows a schematic illustration of the control device 30 and of the housing 35 during a third method step 215. FIG. 8 shows a schematic illustration of the control unit 10 during a fourth method step 220.In a first method step 205, the control device 30 and preferably the housing 35 are provided (cf. FIGS. 6A, 6B ).In a second method step 210 following the first method step 205, the control device 30 is inserted into the housing interior 60. In addition, the control device 30 can be mechanically fastened to the housing 35. The mechanical fastening can be effected, for example, by means of connecting means, such as, for example, clamps, screws or the like.In a third method step 215 following the second method step 210, the connecting material and, if appropriate, the stiffening material embedded in the connecting material are applied in the liquid phase state to the control device 30, in particular the printed circuit board 105 (cf. FIG. 7 ). The application of the connecting layer 45 can be effected, for example, in a spray application to the control device 30, in particular to the printed circuit board 105. Additionally, gaps, cracks, or openings in the circuit board 105 and / or between the circuit board 105 and the housing 35 may be bridged in the spray application and by the stiffening material embedded in the connection material. As a result of the spray application, the through-opening 70 can thereby be closed in a particularly simple and cost-effective manner and a fluid-tight seal of the control device 30 in the housing interior 60 at the through-opening 70 with respect to the environment can thereby be ensured.In a fourth method step 220 (see FIG. 8 ) following the third method step 215, preferably as long as the connecting material is still in the liquid phase state, the cooling bodies 40 are placed at a defined distance on the printed circuit board 105 into the injected connecting material and the possibly embedded stiffening material of the cooling bodies 40 (see FIG. 8 ). In this case, the cooling body 40 preferably bears over its full surface against the second connecting side surface 115.In a fifth method step 225 following the fourth method step 220, which can also be carried out simultaneously with the fourth method step 220, the connecting material present up to then in the liquid phase state is cooled below the melting point, so that the connecting material changes to the solid phase state and forms the connecting layer 45.In addition, the position of the cooling body 40 during the solidification of the connecting material of the connecting layer 45 can be secured by the cooling body 40 being held at a defined distance from the printed circuit board 105 or from the control device 30, for example by means of a robot arm or another device.The holding of the cooling body 40 or the fixed positioning of the cooling body 40 in relation to the control device 30 is not canceled until the connecting material of the connecting layer 45 has solidified at least partially, in particular predominantly, preferably completely.In particular, during the cooling and curing of the connecting material, the stiffening material, if it is applied during the application, is embedded in the connecting material, so that the stiffening material and the connecting material form an integrally formed connecting layer 45.In a sixth method step 230 following the fifth method step 225, the first collecting container 50 and, if appropriate, the second collecting container 55 are fastened to the housing 35. The fastening can be effected, for example, by means of clamps or screws. In addition, it is also conceivable that instead of the sixth method step 230, the first and / or second collecting container 50, 55 is fastened to the housing 35 during the fourth method step 220, so that the collecting container 50, 55 dips into the still liquid connecting layer 45 on the side facing the cooling body 40 and a fluid-tight seal is thereby formed on the collecting container 50, 55 by the connecting layer 45.It is emphasized that additional connecting means for fastening the cooling body 40, in particular for a direct mechanical connection between the cooling body 40 and the housing 35, are dispensed with, and the cooling body 40 is only indirectly connected to the housing 35 via the connecting layer 45 and the control device 30.As already explained in the context of FIG. 3, the control device 30 is passively cooled in the control mode by the heat transfer of the heat Q via the connecting layer 45 by means of the cooling body 40. In addition to regular control operation, damage can also occur. In the event of damage, it is to be avoided that the control device 30 and its components further overheat. In particular, in the event of damage, increased cooling of the control device 30 must be ensured in order to prevent further damage from the components of the control device 30 and to be able to easily repair the usually relatively expensive control device 30.When a damage occurs, the heat source 65 generates an increased amount of the heat Q. The heat Q causes the heat source 65 to heat strongly and the heat Q is transferred to the bonding layer 45 via the circuit board 105. The heat Q heats the bonding layer 45 above the melting point of the bonding material, so that the bonding material is melted. The connecting material acts as a phase change material or latent heat store. During the melting, heat Q is further absorbed. The melting of the connecting layer 45 has the effect that the control device 30 is additionally cooled and a temperature increase (for a short time) does not take place. The melted connecting material flows into the first and / or second collecting volume 90, 95 of the collecting container 50, 55.The melted connecting material and the stiffening material, which may be embedded in the melted connecting material, flow along the channel 145 into the first and / or second collecting containers 50, 55, which are empty in the initial delivery state of the control unit 10, and are stored in the first and / or second collecting volumes 90, 95. Because the first and / or second collecting container 50, 55 is not incorporated in the heat flow between the control device 30 and the cooling body 40, but is arranged offset from the heat flow, the collecting container 50, 55 is generally, but also in the event of damage, significantly cooler than the cooling body 40 and the heat source 65.The sensor 125, 130 detects the presence of connecting material in the respective associated collecting volume 90, 95 and provides a corresponding sensor signal depending on the detected connecting material, which is detected by the control device 30. The control device 30 interrupts, for example, a charging process and thus an electrical connection between the input side 20 and the output side 25 if at least one of the two sensors 125, 130 detects connecting material in the collecting volume 90, 95. The interruption, for example of the charging process, aims at preventing further heating of the heat source 65.Nevertheless, in the event of damage, the case may occur that the heat source 65 heats up very quickly and provides a high heat Q. In this case, the heat Q ensures that the connecting layer 45 is melted to such an extent that the connecting layer 45 can no longer mechanically hold the cooling body 40 on the control device 30 and the cooling body 40 is detached. As a result, the through-opening 70 between the first and second collecting containers 50, 55 is opened, and the control device 30 is cooled particularly strongly from the environment by the air flowing via the through-opening 70. In particular, this prevents further local heating, in particular any smoldering that may begin, in the housing interior 60 and creates a extinguishing possibility for extinguishing the control device 30. Furthermore, the charging process is interrupted by the control device 30 and the detection of the melting connecting layer 45 by the first and / or second sensor 125, 130.The descending cooling body 40 can be secured, for example, by means of a safety strap. Alternatively, it is also conceivable for the heat sink 40 to fall into a corresponding receptacle, for example on the vehicle floor.FIG. 9 shows a detail of a perspective bottom view of the control device 10 shown in FIGS. 1 to 4.It is particularly advantageous if, as shown in FIG. 9, the melting connecting material flows on the basis of channels 145 present in the collecting container 50, 55, in order to thus ensure a reliable flow toward the sensor 125, 130.The above-described configuration has the advantage that a simple and mechanical fastening of the cooling body 40 to the control device 30 can be ensured via the connecting layer 45. The above-mentioned connecting materials are also particularly well suited for the mechanical connection of the cooling body 40 to the control device 30, in particular to the printed circuit board 105, since these are vibration-damping and as a result mechanical shocks between the cooling body 40 and the control device 30 are only damped and are thus only partially transmitted.Furthermore, thermal shocks within the control device 30 are avoided by the heat storage capacity of the connecting layer 45. This configuration has the advantage that the printed circuit board 105 can be formed to have a particularly large surface area, in particular can be formed to be integral and multilayer, without thermal stresses occurring within the printed circuit board 105 during the regulating operation.The connecting layer 45 and the above-mentioned connecting materials are resistant in particular to numerous chemicals, liquid, moisture and thus ensure a corrosion-proof seal of the housing interior 60 with respect to the environment.The use of the connecting materials also ensures additional electrical insulation of the printed circuit board 105 with respect to the cooling body 40 and / or the collecting container 50, 55, such that these can be formed from an electrically conductive material, for example, and further electrical insulation means on the printed circuit board 105 can be dispensed with.The thermal conductivity can be additionally increased by means of the above-mentioned stiffening materials. Aluminum nitrides (AlN) embedded in the bonding material are particularly suitable for increasing the thermal conductivity of the bonding layer 45.In order, for example, to easily separate the cooling body 40 in the event of repair and, for example, to repair the control device 30, the connecting layer 45 can be heated and melted, for example by means of laser radiation, via the clearance surface 135 (cf. FIG. 1 ) in order to remove the cooling body 40. As a result, the control device 30 is particularly easily accessible. The melted connecting layer 45 can also be recycled.The connecting layer 45 is also suitable in particular for improving the thermal management of the control unit 10, in particular of the internal charger 15, since thermal regulation and stabilization for the components of the control device 30 takes place during operation by the abovementioned use of connecting materials which in this case function as heat accumulators.As explained above, the mechanical stiffness can be increased by means of the above-mentioned stiffening materials, in particular by means of the stiffening material embedded in the connecting material.Furthermore, vibrations can be avoided since the connecting layer 45 within the control unit 10 acts as a mechanical vibration damper.Furthermore, additional connecting means, such as tapes, snap connections or welded connections, for example, for connecting the control device 30 to the heat sink 40 can be dispensed with. As a result, the control device 10, in particular the in-vehicle supercharger 15, can be manufactured particularly easily.Furthermore, the control device 10 is particularly repairable, since the connecting layer 45 can easily be separated by its melting and the heat sink 40 can be removed.Furthermore, recrystallization or resolidification of the joining material after it has been liquefied can be used to allow the two components to be joined, the control device 30 and the heat sink 40, to be reused. Reuse is even possible several times.Furthermore, it is possible to dispense with the use of casting materials and / or steps for casting the control device 30 in the housing interior 60, with the result that the control device 10 can be produced particularly quickly and cost-effectively. This is advantageous in particular for mass production.Furthermore, surface treatment, in particular of the control device 30, with respect to, for example, entering liquids, moisture and for corrosion avoidance or for protection against chemicals can be avoided, so that the control device 30 can be produced particularly cost-effectively.Furthermore, the method described above for producing the control unit 10 for connecting the control device 30 to the cooling body 40 by means of the connecting layer 45 is particularly simple.The connecting material of the connecting layer 45 has a defined melting temperature or a defined resolidification temperature, so that these temperatures can be used in a targeted manner for liquefying or solidifying the connecting material in the production method and in the operating method. Furthermore, the behavior within the scope of the operation of the control unit 10 can be defined and predictable in a controlled manner both as a rule and in the event of a fault.It is pointed out that, in order to increase sustainability, the connecting materials can be of natural origin and can be produced in particular with bio-quality, so that the sustainability of the control unit 10 is increased.This makes it possible to dispense with plastics (both recycled and newly produced) for connecting the heat sink 40 to the control device 30, and furthermore this increases a recycling capability of the control device 10.A connection should likewise be necessary at another point of the control unit 10 if the connecting material used for connecting the cooling body 40 to the control device 30 can also be used at another point, as a result of which the control unit 10 is particularly simple to produce and a recycling capability for the control unit 10 is particularly high.Furthermore, the abovementioned connecting materials make it possible to dispense with the addition of additives or catalysts for producing the fluid-tight seal of the passage opening 70 and for ensuring the adhesive properties of the connecting layer 45.Furthermore, the electrically insulating properties of the connecting material ensure electrical insulation of the cooling body 40 with respect to the control unit 10, in particular with respect to the printed circuit board 105.Furthermore, a housing cover arranged on the underside can be dispensed with and the housing cover can be replaced by the connecting layer 45.List of reference characters10 Control device 15 in-vehicle supercharger 20 Input side 25 Output side 30 Control device 35 Housing 40 Heat sink 45 Connection layer 50 First collecting container 55 Second collecting container 60 Housing interior 65 Heat source 70 Through opening 75 Housing upper side 80 Housing lower side 85 First side surface 86 Second side surface 86 Third side surface 90 First collecting volume 95 Second collecting volume 100 Gap 105 Circuit board 110 First connection side surface 115 Second connection side surface 120 Sensor device 125 First sensor 130 Second sensor 135 Exposed surface 145 Channel 205 First method step 210 Second method step 215 Third method step 220 Fourth method step 225 Fifth method step 230 Sixth method step Q Heat

Claims

Control device (10) for a vehicle, in particular in-vehicle supercharger (15) for an electrically driven vehicle, - having a control device (30) having a heat source (65), a housing (35), a heat sink (40) and a connecting layer (45), - wherein the control device (30) is arranged in a housing interior (60) of the housing (35) and bears against a first connecting side surface (110) of the connecting layer (45), - wherein the heat sink (40) is arranged outside the housing interior (60) and bears against a second connecting side surface (115) of the connecting layer (45) arranged opposite the first connecting side surface (110), - wherein the connecting layer (45) thermally and mechanically connects the control device (30) to the heat sink (40) for cooling the heat source (65), - wherein the connecting layer (45) has a connecting material which is designed to connect the control device (30) to the heat sink (65), in the event of a thermal overloading of the control device (30), it is possible to melt the control device (30) from a solid phase state and to cool the control device (30) from the solid phase state into a liquid phase state by the melting.Control device (10) according to Claim 1, - having a first collecting container (50), - wherein the first collecting container (50) is arranged offset with respect to the cooling body (40) and delimits a first collecting volume (90), - wherein the first collecting container (50) is designed to be open on the side facing the connecting layer (45) and is designed to receive melted connecting material of the connecting layer (45).Control device (10) according to Claim 2, - having a sensor device (120) having at least one first sensor (125), - wherein the first sensor (125) is designed to sense the connecting material located in the first collecting volume (90) and to provide a sensor signal as a function of the sensed connecting material.Control device (10) according to Claim 3, - wherein the first sensor (125) is arranged in the first collecting volume (90) or outside the first collecting container (50) - and / or, - wherein the first sensor (125) is embedded in the connecting layer (45).Control device (10) according to one of the preceding claims, - wherein the connecting material of the connecting layer (45) can be reversibly transferred from the solid phase state to the liquid phase state essentially in a non-destructive manner, - wherein a melting point of the connecting material is in a range from 100°C to 280°C inclusive.Control device (10) according to one of the preceding claims, - wherein the connecting layer (45) has at least one of the following connecting materials: - aliphatic hydrocarbon, preferably having 16 or 17 or 18 carbon atoms, - salt, - microencapsulated hard paraffin, - hard paraffin, - wax, - natural wax, - biodegradable wax - oxidized wax, - lipid, - thermochemical heat store, - wherein the connecting material is able to be recycled, - and / or - wherein the connecting layer (45) has at least one of the following stiffening materials, which is embedded in the connecting material: - aluminum nitride (AlN), - mercerized cellulose, - vegetable powder, - carbon nanofilament, - cellulose nanofilament - nanocellulose - microfibrils, - nanofibrils, - glass fiber, - basalt fiber, Hemp fiber, flax, aramid fiber, nylon fiber, carbon fiber.Control device (10) according to one of the preceding claims, - wherein the housing (35) has a through-opening (70), - wherein the cooling body (40) is arranged on the through-opening (70) and the connecting layer (45) fluidically seals the through-opening (70).Control device (10) according to one of the preceding claims, - wherein the cooling body (40) is mechanically fastened to the control device (30), preferably exclusively, in a materially bonded manner by means of the connecting layer (45), - wherein the control device (30) is fastened in the housing (35).Control device (10) according to one of Claims 2 to 8, - wherein the first collecting container (50) closes the passage opening (70) at least in sections.Control device (10) according to one of Claims 2 to 9, - wherein the housing (35) has a housing underside (80), - wherein the heat sink (40) is arranged on the housing underside (80), - wherein the connecting layer (45) is arranged below the control device (30), - wherein the heat sink (40) is arranged below the connecting layer (45), - wherein the heat sink (40) is designed to release and separate from the control device (30) when the connecting material of the connecting layer (45) melts.Control device (10) according to one of Claims 2 to 10, - having a second collecting container (55) with a second collecting volume (95), - wherein the second collecting container (55) is arranged offset with respect to the first collecting container (50) and the cooling body (40), - wherein the second collecting container (55) delimits the second collecting volume (95), - wherein the second collecting container (55) is designed to be open on the side facing the connecting layer (45) and is designed to receive molten connecting material of the connecting layer (45).Control device (10) according to one of the preceding claims, - wherein the connecting layer (45) has a clearance surface (135) which is arranged on a side facing away from the control device (30), - wherein the clearance surface (135) is arranged laterally spaced apart from the cooling body (40) and preferably from the first collecting container (50), - wherein the clearance surface (135) is uncovered.Control device (10) according to one of the preceding claims, - wherein the connecting material in the liquid phase state can be reversibly separated from the control device (30) in a non-destructive manner.Control device (10) according to one of the preceding claims, - wherein the connecting material can be reused after the disconnection from the control device (30).Method for producing a control unit (10) according to one of the preceding claims, - wherein the control device (30) is introduced into the housing interior (60), - wherein the connecting material of the connecting layer (45) is applied to the control device (30) in the liquid phase state, - wherein the cooling body (40) is arranged on the liquid connecting material and the cooling body (40) cools the liquid connecting material, such that the liquid connecting material is transferred into the solid phase state to the connecting layer (45) and the connecting layer connects the cooling body (40) to the control device (30) thermally, and preferably mechanically.Method for operating a control unit (10) according to one of Claims 2 to 14, - wherein, in a regulating operation, the control device (30) generates a heat with the heat source (65), - wherein, in the regulating operation, the heat source (65) reaches a first maximum temperature which is lower than a melting temperature of the connecting material, - wherein the heat is dissipated via the connecting layer (45) from the heat source (65) to the cooling body (40) for cooling the heat source (65), - wherein, in the event of a fault, the heat source (65) heats up to a second maximum temperature which is greater than the melting temperature of the connecting material, - wherein the connecting material melts and is converted into the liquid phase state, - wherein the liquid connecting material flows into the first collecting volume (90).Method according to Claim 16, - wherein a presence of connecting material in the first collecting volume (90) is checked, - wherein the control device (10) is deactivated on detection of connecting material in the first collecting volume (90).

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