ELECTRICAL UNIT WITH A WINDING AND METHOD FOR MANUFACTURING SUCH A UNIT

Description

[0001] The invention relates to an electrical component with a winding, in particular a machine component such as a stator, with conductor sections inserted into a receiving body and electrically conductive connection structures adjoining these at their ends for the production of the winding, which are at least partially formed by a conductor track structure inserted into an electrically insulating support structure, wherein the support structure is composed of several support structure parts which are plate-like and stacked on top of each other in the normal direction to the plate plane to form a support structure package and are provided with overlapping passages for receiving end-end connection sections of the conductor sections, which are contacted with corresponding connecting conductor elements of the conductor track structure to produce the desired turns of the winding.as well as a method for manufacturing such a machine assembly unit with a winding.

[0002] US Patent 6,538,356 B1 discloses such an electrical assembly with a winding, namely an electric machine with a rotor and a stator, in which axially extending conductive plates serving as windings are connected to the stator windings via end disks with embedded conductor sections. The end disks are ring-shaped and made of insulating material, for example, a ceramic with an aluminum content of 96%.

[0003] Another such electrical component with a winding, namely a stator for an electric motor, is shown in US 2015 / 0145358 A1.

[0004] In the article by Brunner D. G et al.: "Foil casting, sintering and applications of aluminum nitride", SPRECHSAAL, Vol. 121, No. 3, March 1, 1988 (1988-03-01), pages 181-186, XP001263640, a ceramic substrate material made of aluminum nitride is described and compared to classic oxide ceramic substrate materials. Various applications, e.g., in the field of electronics, are mentioned.

[0005] US patent 2009 / 207568 A1 shows a layered printed circuit board arrangement with cooling channels.

[0006] DE 10 2005 032 965 A1 shows stator windings with rod-shaped conductors and components of electrical power electronics on a front-facing circular circuit board in a motor housing.

[0007] Another electrical component designed as a stator of an electric machine, as well as a method for its manufacture, are described in US 2014 / 0319960 A1. In this known electrical component and method, base plate units are mounted on the end faces of a stator unit into which rod-shaped conductor sections are inserted. These base plate units connect the conductor sections of the stator in a preselected manner. The right and left base plate units are themselves constructed from two base plates insulated from each other and from the stator body by ring-shaped insulating elements. The base plates consist of an insulating carrier body with metallic connecting tracks inserted into grooves within it. These connecting tracks are, in turn, connected to each other via connecting pins to form a coil. The terminal ends of the conductor sections of the stator are guided through corresponding through-holes in the base plates.This design results in relatively complex connection structures on the two base plates with the interposed ring-shaped insulating elements.

[0008] US Patent 2014 / 0014390A1 discloses a component with a stator for a multiphase electric machine, featuring several axially stacked annular busbars. Dome-shaped mounting pins with shoulder-shaped steps are provided in a housing-like support body for positioning the busbars. The annular busbars are contacted laterally, connecting the different phases.

[0009] WO 2015 / 092 192 A2 also shows a stator assembly in which the winding heads are equipped with ring conductors. Connections for phase connections are positioned radially on the outside of the ring conductors.

[0010] WO 2014 / 129 288 A1 describes a radially layered ring conductor in an insulating support. Another electrical component with a winding and a method for its manufacture, specifically in the form of a stator for an electric machine, is described in WO 2015 / 158508 A1. In this electrical component, as is typical for such stators, a winding with multiple coils and turns is electrically insulated and inserted into slots in a stator lamination stack. The conductor sections inserted into the slots of a supporting body are electrically connected at their end faces to the coils of the winding by a winding head. Various methods are described for manufacturing the winding head, in which two conductor ends are electrically connected to each other, for example, by directly twisting the conductor ends together, directly soldering them, or soldering them to a connecting conductor.The winding is encased in insulating material in the area of ​​the winding head. Such winding heads typically have a relatively large size and occupy a relatively high proportion of the assembly's installation space. Furthermore, a relatively large amount of power is consumed during operation due to significant heat generation in this area.

[0011] Such disadvantages are also addressed in DE 10 2012 206 442 A1 and DE 10 2015 218 929 A1, which propose special measures for heat dissipation by embedding the winding heads. For example, DE 10 2012 206 442 A1 proposes a ceramic matrix material for lining with insulating material, in which, for example, silver or copper particles are embedded. DE 10 2015 218 929 A1 shows several ring-shaped elements embedding the winding heads, as well as liquid cooling in a support structure of the stator housing. The heat conduction device is designed, for example, with an aluminum nitride ceramic.

[0012] JP 2002 329938 A shows a plate-shaped component support made of ceramic material with high thermal conductivity and a cooling channel arrangement for coolant to dissipate heat.

[0013] The present invention is based on the objective of providing an electrical component, in particular a mechanical component such as a stator, of the type mentioned above, which results in the most efficient operation possible with the smallest possible installation space, and of providing a method for manufacturing such a component.

[0014] This problem is solved with regard to the structure of the assembly unit with the features of claim 1 and with regard to the manufacturing process with the features of claim 5.

[0015] For the design of the electrical component, it is provided that at least one connection structure is formed by a conductor track structure embedded in an electrically insulating support structure. These measures achieve a small installation space with advantageous design possibilities for the component, particularly the machine component, which also results in advantages for efficient operation. For example, the measures according to the invention can be applied both when the conductor sections are inserted axially and radially into the slots of the receiving body. The formation of the connection structure by means of the support structure and the conductor track structure embedded therein results in a compact design in the area of ​​the winding heads, since the support structure can be made thin and the dimensions of the winding head can be kept small. This also allows for a high power density.This arrangement also allows for a high copper fill factor and thus high efficiency of the machine built with it.

[0016] The manufacturing process, in which an electrically insulating support structure with an integrated conductor track structure is produced and provided to form at least one connection structure, and in which the conductor sections inserted into the receiving body are contacted at their ends with the relevant conductor elements, allows for a wide variety of design possibilities with simple measures, whereby the conductor sections can be easily connected to windings and, via the support structure and the conductor track structure, to coils of the winding.

[0017] In the present design according to the invention, which also offers different adaptation possibilities to respective circumstances, the support structure is built from several support structure parts, which are combined to form a support structure package.

[0018] The support structure components are designed in a plate-like manner and are stacked on top of each other in the normal direction to the plate plane to form the support structure package.

[0019] Further measures according to the invention for the construction consist in the fact that the support structure parts are provided with overlapping passages for receiving end-side connection sections of the conductor sections and that the conductor sections are contacted with relevant connecting conductor elements of the conductor track structure to produce the desired turns of the winding.

[0020] The inventive measure contributes to efficient operation with a compact design by making the support structure from a material with high thermal conductivity, wherein the support structure is made entirely or partially, to more than 50%, from a material with a thermal conductivity in the range of 100 to 400 W / (m•K).

[0021] The inventive measure also contributes to high efficiency by incorporating a cooling channel arrangement with a connection arrangement for coolant into at least one support structure part.

[0022] According to the invention, conductor elements are formed by metallic inserts integrated into the support structure parts.

[0023] Advantageous embodiments of the invention are specified in claims 2 to 4.

[0024] Further advantages for the design and function result from the fact that at least one component of power electronics for controlling an electric machine built with the machine component is integrated into at least one support structure part.

[0025] Another advantageous measure is that the support structure is made of a material with a thermal conductivity in the range of 150 to 300 W / (m•k).

[0026] A design advantageous for the structure and function consists of the support structure being made at least partially from a highly thermally conductive ceramic material, for example, aluminum nitride. Alternatively, an aluminum oxide material or another ceramic material with good electrical insulation and simultaneously good thermal conductivity can also be advantageously used.

[0027] The invention is explained in more detail below with reference to exemplary embodiments and the drawings. The drawings show: Fig. 1 shows an electrical component, namely a stator, with a central part and lateral winding heads according to the prior art, in a perspective view; Fig. 2 shows a support structure part for constructing a support structure in the end region of a winding in an axial top view; Fig. 3 shows an extended arrangement of several support structure parts according to Fig. 2 with inserted ladder sections in perspective view, Fig. 4, consisting of several support structure parts according to Fig. 3 layered support structure package in perspective view and Fig. 5 an electrical machine construction unit in the form of a stator with support structures arranged on both end faces to form a connecting structure of winding heads.

[0028] Fig. 1 Figure 1 shows an example of an electrical assembly 1' with a winding, namely a stator of an electric machine (electric motor, generator), with a receiving body 2 in the central stator section 20 that accommodates the conductor sections of a winding, and two winding heads 21 projecting from its end faces. The conductor sections are inserted axially or radially into receiving grooves on the inner circumference of the receiving body 2 and are electrically connected to one or more coils of the winding via the winding heads 21. Such machine assemblies 1' are state of the art, with the lateral winding heads requiring a relatively large installation space and also being subject to relatively high temperatures during operation, as described above.

[0029] To solve these problems, the invention provides, as shown below with reference to the Fig. 2 bis 5 described, a support structure 5 (cf. Fig. 5 ) provided, which is composed of several, in particular more than two, for example more than 4 or 6, support structure parts 3, such as the Fig. 2 bis 4 show.

[0030] Fig. 2 Figure 1 shows a support structure part 3 in an axial top view with respect to a machine component 1 (not shown in this figure), such as a stator. The support structure part 3 is designed as a plate in the form of a circular disk and has a conductor track structure 30 as well as intermediate passages 31 for inserting end sections of the conductor sections 22, as can be seen from the Fig. 3 and 4This is evident. For example, the openings 31 for the conductor sections 22 are designed as rectangular openings extending radially in the longitudinal direction, corresponding to the cross-sectional shape of the conductor sections, between which the conductor track structure 30 is arranged. The conductor track structure 30 is itself formed on or in an electrically insulating substrate material, preferably a ceramic material, such as aluminum nitride with a high specific thermal conductivity λ, e.g., in the range of 180 to 220 W / (m•K). Other substrate materials, such as aluminum oxide material and general ceramic material with good electrical insulation properties and the highest possible thermal conductivity, can also be used.

[0031] According to the invention, the conductor track structure 30 is formed by incorporating receiving areas, as recessed depressions, at predetermined locations in the respective carrier structure part 3. Metallic inserts, preferably made of copper, are inserted or integrated into these recesses as conductor elements. Advantageously, the predetermined locations or the recesses are coated with a metallic layer that provides a strong adhesive and thermally conductive bond between the inserts and the carrier material. The depressions, as well as the through-holes 31, can be formed in the carrier structure part 3 in the green body, i.e., before a sintering process, by a suitable forming process, such as machining (cutting, milling, etc.). The metallization or the incorporation of the metallic layer or the insert can advantageously take place after sintering.During this processing phase, circuit components of an electronic system can also be integrated into one or more carrier structure parts, as described below. For simple electrical insulation with good thermal conductivity, for example, a one-sided application of the metallic inserts to the individual carrier structure parts 3 is advantageous; however, a two-sided application can also be achieved with suitable, thermally conductive insulation.

[0032] Inside the substrate material, a cooling channel arrangement 60 is incorporated into the substrate structure part 3 shown, which may, for example, be thicker than the other substrate structure parts 3. Cooling fluid can be supplied to this cooling channel arrangement via a connection arrangement 61. With the highly thermally conductive substrate material and the optionally present cooling channel arrangement 60 with flowing cooling fluid, even a large amount of heat generated can be dissipated with high efficiency from the conductor track structure 30 and the conductor sections 22.

[0033] As from the Fig. 3 and 4As can be seen, the end sections of the conductor sections 22 can be advantageously electrically contacted to the respective turns of a coil via the conductor track structure 30, for example, via the integrated conductor elements, and the coils can be advantageously electrically contacted to the winding arranged in the machine component. A conductor section bundle with several mutually insulated conductor sections 22 can be guided through a passage 31, as shown from Fig. 4 As can be seen. The specified structure allows for different connections of the conductor sections 22, depending on the desired configuration.

[0034] As the Fig. 3 and 4As can be seen, three different conductor structures 30 are arranged in the individual stacked carrier structure parts, with which the end sections of the conductor sections 22 are electrically contacted. The contacting is carried out, for example, by soldering the conductor structure 30 to the corresponding end sections of the conductor sections 22 at the relevant points, such as the relevant metallic inserts, e.g., by soft soldering or hard soldering. For this purpose, at least the end sections of the conductor sections 22 are surrounded with a sufficiently temperature-resistant insulating material, with only the ends to be contacted being exposed. The contact points of the conductor structure 30 or the metallic inserts can advantageously be provided with a suitable flux, as is known, for example, from SMD or SMT technology.The heat energy required for the soldered joint can be supplied inductively, for example.

[0035] The connection of two conductor sections 22 to form a winding is achieved via a conductor element of the conductor track structure 30. How Fig. 3 This also shows, for example, that a star point connection of phases can be achieved with a conductor track structure 30 arranged on a carrier structure part 3 (see second carrier structure part 3 from the left).

[0036] How Fig. 5As shown, the support structure 5, which is formed from the support structure package 4 with the layered support structure parts 3, is mounted on the end face of the receiving body 2, which carries the conductor sections 22. Preferably, such a support structure 5 is arranged on each end face. The support structure 5 results in a compact design, and the heat generated by the described design with the cooling channels 60 can be effectively dissipated. The support structure 5 offers advantageous adaptation possibilities for the design of the assembly or machine unit and to the receiving body 2 with the conductor sections 22. The receiving body 2 can be housed together with the support structure 5 in a common casing. The compactly designed support structure 5 can also be attached to the receiving body 2, for example, by gluing or by means of clamps.

[0037] A further advantageous embodiment of the support structure 5, constructed as described and shown, consists in the fact that, as mentioned above, at least one support structure part 3 is provided with a power electronics component for controlling an electric machine built with the component. This allows the power electronics, or one or more heat-generating components, to be advantageously housed without additional installation space and simultaneously cooled by the cooling device within the support structure 5. The power electronics components can advantageously be arranged, for example, on support structure parts located further out on the axis. In addition to connecting the end sections of the conductor sections 22, the support structure 5 fulfills further interconnection functions and offers advantageous expansion possibilities, with the resulting three-dimensional structuring providing additional advantages for a compact design.

Claims

1. Electrical subassembly (1), in particular a stator, for an electric machine, comprising a winding, comprising conductor portions (22) introduced into a receiving body (2) and electrically conductive connecting structures that connect to said conductor portions at their ends to produce the winding, which structures are at least partially formed by a conductor track structure (30) introduced in an electrically insulating support structure (5), the support structure (5) being composed of a plurality of support structure parts (3) which are plate-like in design and are layered on top of each other in the normal direction to the plate plane to form a support structure package (4) and are provided with mutually aligned passages (31) for receiving connection portions of the conductor portions (22), the connection portions being located at the ends, which conductor portions are contacted by corresponding connecting conductor elements of the conductor track structure (30) to produce turns of the winding that are to be achieved, the conductor track structure (30) being formed by receiving regions being introduced as recessed depressions at predetermined locations in each support structure part (3), into which regions metal inserts are inserted as conductor elements, characterized in that the support structure (5) is produced entirely or partially, to an extent of more than 50%, from a material with high thermal conductivity in the range of 100 to 400 W / (m•K), and in that a cooling channel arrangement (60) comprising a connection arrangement (61) for coolant is incorporated into at least one support structure part (3), the cooling channel arrangement (60) being arranged inside the support material of at least one support structure part (3).

2. Subassembly according to any of the preceding claims, characterized in that at least one component of a power electronics system for controlling an electric machine built with the machine subassembly is integrated into at least one support structure part (3).

3. Subassembly according to any of the preceding claims, characterized in that the support structure (5) is produced entirely or partially, to an extent of more than 50%, from a material with a thermal conductivity in the range of 150 to 300 W / (m•k).

4. Subassembly according to any of the preceding claims, characterized in that the support structure (5) is produced at least partially from highly thermally conductive ceramics material, for example aluminum nitride material.

5. Method for producing an electrical subassembly (1) for an electric motor or generator, comprising a winding, according to any of the preceding claims, in which method the conductor portions (22) are introduced into the receiving body and the electrically conductive connecting structures, to said conductor portions at their ends to produce a winding, are connected, the electrically insulating support structure (5) comprising the introduced conductor track structure (30) being produced and provided to form at least one of the connecting structures, and the conductor portions (22) introduced into the receiving body being contacted at their ends by the corresponding conductor elements, the conductor track structure (30) being formed by receiving regions being introduced as recessed depressions at the predetermined locations in each support structure part (3), into which regions metal inserts are inserted as conductor elements, characterized in that the support structure (5) is produced entirely or partially, to an extent of more than 50%, from a material with a thermal conductivity in the range of 100 to 400 W / (m•K), and in that the cooling channel arrangement (60) comprising the connection arrangement for coolant is incorporated into at least one support structure part, the cooling channel arrangement (60) being arranged inside the support material of at least one support structure part (3).