A flexible electrical conductor

Abstract

The invention relates to an electrical conductor comprising a first end segment and a second end segment spaced apart by a middle segment in a longitudinal direction of the electrical conductor. The middle segment comprising a plurality of conductor branch elements which are made of electric conductive material. At least part of at least two of the plurality of conductor branch elements are spaced apart by an airgap in a longitudinal direction of said electrical conductor.

Description

A FLEXIBLE ELECTRICAL CONDUCTORField of the invention

[0001] The invention relates to a flexible electrical conductor.Background of the invention

[0002] In the art electrical conductors are known in the form of cables and busbars. These however are heavy and difficult to handle manually when dimensioned to conduct currents above 16 to 32 amps. Thus, mounting such electrical conductors in electrical panels is difficult and time consuming.

[0003] An example of what in this document is referred to as a traditional cable may be found in prior art document GB 2120836. Here a multicore electric cable in which each core comprises a plurality of insulated conductors assembled together are illustrated.

[0004] Similarly various examples of what in this document is referred to as electric busbars may be found on a search on the Internet. Such prior art cables and busbars may be massive or hollow and by their construction not flexible.

[0005] Prior art document KR20210113001 discloses a hybrid flexible busbar comprising a braided wire and a thin plate laminate structure installed across the braided wire with terminal parts fixed to both ends of the braided wire.

[0006] A drawback with prior art busbars and cable is that they are generic in that the same design is used in a variety of different applications.Summary of the invention

[0007] The inventors have identified the above-mentioned problems and challenges related to flexibility of electrical conductors and solved these problems by the present invention as described below. Hence, an electrical conductor according to the present invention is flexible and thereby easy to manoeuvre i.e. deform so that it fits to the application to which it is designed (and maintain a given posture in relaxed state i.e. when no external force is applied (except from gravitational force)), it uses less material, cooling capacity is increased leading to an optimization of ability to conduce current per material weight, etc. In addition, only one manufacturing steps is required because of the additive manufacturing process.

[0008] In an aspect, the invention related to an electrical conductor comprising: a first end segment and a second end segment spaced apart by a middle segment in a longitudinal direction of said electrical conductor, wherein said middle segment comprising a plurality of conductor branch elements, wherein said plurality of conductor branch elements are made of electric conductive material, wherein at least part of at least two of said plurality of conductor branch elements are spaced apart by an airgap in a longitudinal direction of said electrical conductor.

[0009] This is advantageous in that it has the effect, that the geometry of the electrical conductor is able to change upon applying a force. The force may be applied by a person or a component mechanically connected / in contact with the electrical conductor. In this way a flexible electrical conductor is provided which is easy to mount and may absorb vibrations.

[0010] A change in geometry lead to a change of position and / or orientation in space of at least one of the ends of the electrical conductor.

[0011] The airgap should be understood as a space between part of two conductor branch elements. The airgap is ensuring that the two parts of the two conductor branch elements are not in physical contact when the electrical conductor is in a resting position i.e. when there is no forces acting on the electrical conductor.

[0012] It could be argued that gravitational force is always acting on the electrical conductor. Hence if e.g. the first end segment is relatively long compared to the middle segment and the electrical conductor is fixed in the second end segment, then the gravitational force may be sufficient to change geometry of the electrical conductor by pulling the end segment towards ground.

[0013] The airgap(s) are spacing apart parts of the conductor branch elements in the longitudinal direction of the electrical conductor. Hence, such airgap may be defined from a position at a part of one conductor branch element to a position on a part of another conductor branch element in the direction towards one of the two end segments (where the conductor branch element is connected to end segment).

[0014] In an exemplary embodiment of the invention said plurality of conductor branch elements are formed by one conductor branch.

[0015] One conductor branch may be designed and subsequently produced in a harmonica-like shape, spiral-like shape, etc. leading to a plurality of airgaps between parts of the same electrical conductor.

[0016] The plurality of conductor branch elements may be one unique conductor branch. It should be mentioned that an electrical conductor may be built from a mix of conductor branch elements formed by individual conductor branches and by one (or more) conductor branch(es) forming two or more conductor branch elements.

[0017] In an exemplary embodiment of the invention said plurality of conductor branch elements are formed by two or more conductor branches.

[0018] In an exemplary embodiment of the invention said electrical conductor is monolithic.

[0019] A monolithic electrical conductor include connection part, end segment and middle segment in one and the same piece without having to physically connect two or more of these elements. Thereby the manufacturing of the electrical conductor can be done in one process step i.e. an additive manufacturing step.

[0020] In an exemplary embodiment of the invention, said electrical conductor (1) is at least partly manufactured by an additive manufacturing process.

[0021] In an exemplary embodiment of the invention said, said airgap is defined by a distance, wherein said distance is the shortest distance between a conductor branch element of a first conductor branch and a conductor branch element of a second conductor branch in the longitudinal direction of said electrical conductor.

[0022] In an exemplary embodiment of the invention said airgap is defined by a distance, wherein said distance is the shortest distance between two conductor branch elements of one conductor branch in the longitudinal direction of said electrical conductor.

[0023] Accordingly, when referring to an airgap size, this size may be the distance between elements / parts of two conductor branches or of the same conductor branch. More specifically, the largest spatial separation between two given conductor branches or conductor branch element. The size of an airgap may be measured in the longitudinal direction or in a transversal direction of the electrical conductor.

[0024] In an exemplary embodiment of the invention said airgap is below 1cm, preferably below 0,5cm, most preferably below 0.25cm.

[0025] In an exemplary embodiment of the invention said airgap is below 20cm, preferably below 15cm, most preferably below 10cm.

[0026] In an exemplary embodiment of the invention said airgap is between 0,01cm and 40cm.

[0027] As can be understood, the size of the airgap is a design choice which may depend on the size of the electrical installation in which the conductor is installed and the required degree of flexibility. Thus, the smaller electric installation, the smaller size of the airgap and the larger installations such as connection of building or panels, the larger airgaps.

[0028] In an exemplary embodiment of the invention said airgap is configured to change geometry as consequence of a force applied to said electrical conductor.

[0029] A change in geometry may include a change is distance between two points in one way or the other i.e. the distance between two conductor branch elements may either increase or decrease. If the airgap is a closed airgap defined by e.g. four parts of two or more conductor branch elements, the airgap may be a rhomb-like form. Such rhomb-like form may change geometry by changing distance between the diagonal corners of the rhomb-like form.

[0030] In an exemplary embodiment of the invention said airgap geometry is configured to change by deformation of said at least two of said plurality of conductor branch elements.

[0031] It should be mentioned that the deformation creating the change in geometry of the airgap may happen distant from the parts between which the airgap is established. Hence, the parts between which the airgap is established may be straight parts between bended parts of the conductor branch elements. Thus, the deformation may happen at the bended parts and not at the straight parts.

[0032] In an exemplary embodiment of the invention a plurality of airgaps is established between said plurality of conductor branch elements in the longitudinal direction of said electrical conductor.

[0033] This is advantageous if a highly flexible / deformable electrical conductor is required in that the more airgaps, the more flexible, the electrical conductor is.

[0034] In an exemplary embodiment of the invention said plurality of conductor branch elements is configured to deform so as to change geometry of one subset of said plurality of airgaps differently from a second subset of said plurality of airgaps.

[0035] While a first subset of airgaps is increased in size e.g. the distance between two conductor branch elements is increased, the distance between a second subset of airgaps is decreased in size e.g. the distance between two conductor branch elements is decreased.

[0036] In an exemplary embodiment of the invention said airgap is extending between said at least two conductor branches and separates said at least two conductor branches in the longitudinal direction of said conductor branch between said first end segment and said second end segment.

[0037] In an exemplary embodiment of the invention at least two of said plurality conductor branch elements meet in an intersection point and wherein at least two conductor branch elements branches off from said intersection point.

[0038] This is advantageous in that it has the effect, that an electrical conductor is established that maintain a desired strength (determined yield point) with a minimum of material. Thereby reducing the cost of material which as mentioned is electric conductive and therefor relatively expensive.

[0039] It should be mentioned that the two conductor branch elements meeting in the intersection point may be the same two conductor branch element leaving that intersection point. Alternatively, two other conductor branch elements may leave the intersection point, however this may be a question of definition of a conductor branch element.

[0040] In an exemplary embodiment of the invention, at least one of said plurality conductor branch elements (5a-l, 5a-2, 5a-3; 5b-l, 5b-2...) branches off from an intersection point (11) into at least two conductor branch elements (5a-l, 5a-2, 5a-3; 5b-l, 5b-2...).

[0041] In an exemplary embodiment of the invention said plurality of conductor branch elements forming a plurality of airgaps are implemented as a web-like structure.

[0042] In an exemplary embodiment of the invention said plurality of conductor branch elements forming a plurality of airgaps are implemented as a bionic structure.

[0043] Web-like structure and bionic structure are advantageous in that they both provide the necessary strength and current conducting capability required by the electrical conductor. A bionic designed structure should be understood as a structurewith a design that technically implements abstracted principles of nature. Bionic design may at first glance look unpredictable, but is in essence an optimized minimalistic and logic structure optimised according to strength, structure, cooling, use of material, conductance of current, etc. An example could be a support structure or electric conductor that is computer generated to comply with certain requirements leading to a structure / design that is not possible or very difficult and time consuming for a person to establish.

[0044] In an exemplary embodiment of the invention said airgap is an axial airgap.

[0045] An axial airgap should be understood as an airgap that is following conductor branches / conductor branch elements forming a tubular electrical conductor around the tubular perimeter. In this way, two conductor branches may extent between the end segments along a path that is not the shortest therebetween and all along this path the axial airgap is separating the two conductor branches. This is advantageous in that such design of an electrical conductor is flexible i.e. elastically deformable.

[0046] In an exemplary embodiment of the invention said airgap separate said at least two conductor branch elements in a transversal direction of said electrical conductor.

[0047] In an exemplary embodiment of the invention at least one of said first end segment and said second end segment is terminating in a connection part.

[0048] In an exemplary embodiment of the invention said connection part is a fastener hole.

[0049] This is advantageous in that it has the effect, that the connection of the electrical conductor to a neighbouring component is possible e.g. by a threaded bolt.

[0050] It should be mentioned that the connection part may also be implemented as a protrusion suitable for being connected in a terminal of an electric panel.

[0051] In an exemplary embodiment of the invention, at least one of said plurality of conductor branch elements is longer than the shortest distance between said first andsecond end, and wherein said electrical conductor is configured to change geometry by a deformation of said one or more conductor branch elements.

[0052] A conductor branch element or conductor branch being longer than the shortest distance between the distal ends of the electrical conductor is advantageous in that it has the effect, that the electrical conductor is flexible enabling the electrical conductor to absorb vibrations and allows for flexible mounting to mounting points of an electric component that is not completely aligned with fastener holes of the first and second end segments.

[0053] A further advantage is that the amount of material of which the electrical conductor is made is optimized e.g. reduced or material is used for cooling fins or the like while at the same time sufficient conductivity is maintained of the electrical conductor. The reduction of material is leading to a reduction of weight of the conductor and thereby of the panel in which it is mounted. When referring to a reduction of weight / material, this is compared to a traditional busbar capable of conductor a similar current under similar conditions.

[0054] As indicated, a removal of material of the electrical conductor may lead to a reduction of conductivity. However, the design of an electrical conductor according to the present invention is optimized to conduct a particular current. More specifically, the sum of the cross-sectional areas of the conductor branches together complies with requirements to conduction of the particular / required current. Both due to the multiple individually spaced conductor branches and the increased cooling capability hereof, a significant reduction of material can be obtained while maintaining the electrical conductors capability to conduct the required current.

[0055] The change of geometry should be understood as physically stretching, twisting, bending, etc. of the electrical conductor as consequence of a force being applied to part of the electrical conductor. Such change of geometry has the effect that the distance between the first and second end segments is changing, orientation in space of the first and second end segments relative to each other is changing, rotationaround a longitudinal axis of the electrical conductor of one of the first and second end segments relative to the other, etc.

[0056] Deformation should be understood as a change in geometry the conductor itself. As a non-limiting example, the conductor is able to bend leading to a deformation of the conductor. The deformation may result in an elongation of the distance between the two ends of the conductor along the outer side of the conductor (the side away from the centre of the circle, the bended conductor form part of).

[0057] The force applied to the electrical conductor is typically applied to one of its two ends, more specifically to the terminals connecting the electrical conductor to another electric part e.g. in an electric panel. The force can be applied from any orientation e.g. perpendicular to the longitudinal axis of the electrical conductor which will result in a bend of the electrical conductor. Alternative, the force may be applied parallel to the longitudinal axis of the electrical conductor which will result in a compression of the electrical conductor. Alternative, the force may be applied between parallel and perpendicular to the longitudinal axis leading to a mix of bend and compression of the electrical conductor. The force can also come from the weight of the conductor itself by gravitation.

[0058] In an exemplary embodiment of the invention said plurality of conductor branch elements are implemented as one or more conductor branches and wherein one of said one or more conductor branches is longer than the shortest distance between said first and second end segments, and wherein said electrical conductor is configured to change geometry by a deformation of said one or more conductor branches.

[0059] It should be noted, that in an embodiment the plurality of conductor branch elements are implemented as what may be referred to as a plurality of individual conductor branches. Hence, the electrical conductor may include a conductor branch that is longer than the shortest distance between two points one of the first segment and one of the second end segment, and wherein the electrical conductor is configured to change geometry by a deformation of the one or more conductor branches.

[0060] The distance between the two end segments should be understood as the length of the middle segment extending between the two end segments. This length may not be the same over the cross-sectional area of the end segment(s) in that the end segments may be twisted or tilted leading to a longer distance between two point of one side of the end segment than between two points of the other side.

[0061] In an exemplary embodiment of the invention, said deformation is an elastic deformation.

[0062] An elastic deformation is advantageous in that the electrical conductor can be adapted to fit in different configurations and still be able to return (deform back) to its originally form / geometry. Thus, the electrical conductor is configured to reshape to its original geometry as consequence of removal of the deforming force.

[0063] In an exemplary embodiment of the invention, said electrical conductor is configured to elastically deform when a force is applied to said electrical conductor, wherein said force generates a stress within the electrical conductor which is less than the yield point of the material of the electrical conductor.

[0064] The force required to elastically deform the electrical conductor is depending on one of the cross-sectional area, length, geometry, etc. of the conductor branches. Further, designing an electrical conductor utilizing a plurality of branches / branch elements will provide a more flexible component than if it was designed in the traditional way, i.e. with one solid cross-section. Thus, the force needed to flex, i.e. elastically deform, the electrical conductor of the present invention is less than to deform a traditional electrical conductor complying with the same requirements to current conductance. It should be mentioned that the force required to reach the level of stress corresponding to the material yield point is a design choice and therefore the force required to elastically deform an electrical conductor is typically a design choice and thus often individual from one electrical conductor to the other.

[0065] In an exemplary embodiment of the invention, said force is below 400N

[0066] A force below 400N is producible by most persons working with electrical conductors. Thus, designing an electrical conductor according to the present invention to deform (elastic or plastic) when a force below 400N is applied is advantageous in that most such persons would be able to deform the electrical conductor and thereby route and mount it in an electric system (e.g. in an electric panel).

[0067] It should be noted that electrical conductors may be designed to deform above 400N such as when a force between 400N and 1000N is applied to the conductor.

[0068] As mentioned, the gravitational force may be sufficient to elastically deform an electrical conductor of the present invention. Hence, forces between 10N and 40N may be sufficient and advantages in that a person mounting a conductor in a panel may deform it easily while mounting. With this said electrical conductors may be designed to elastically or plastically deform in a predetermined orientation if forces between 40N and 400N such as 100N, 200N or 300N is applied to them from a predetermined direction.

[0069] It should be mentioned that an electrical conductor according to the present invention is typically less than 200cm. Even though it could be longer it is typically less than 100cm and it is in this context a force below 400N is sufficient to elastically deform the electric conductor of the present invention. One example is applying force below 200N when mounting an electrical conductor in an electric panel.

[0070] It should be noted that when discussing applying a force in the context of deforming an electrical conductor in this document, the forces mentioned is applied directly on the electrical conductor i.e. without a lever arm.

[0071] In an exemplary embodiment of the invention, said deformation is a plastic deformation.

[0072] Allowing a plastic deformation is advantageous in that the electrical conductor then can be adapted to fit in configurations that, if no deformation of the electrical conductor was made, did not allow use of the electrical conductor. The reason for this could size / geometry of such configurations. Hence, a conductor of thepresent invention may be partly mounted or inserted in a panel, then plastically deformed e.g. behind or beside other components of the panel, to make it fit to the space allowed for the electrical conductor. Put in another way, the geometry of an electrical conductor according to the present invention can be offset providing flexibility relative to a new relaxed shape. Configuration in this context should be understood as electric systems in general.

[0073] In an exemplary embodiment of the invention, said electrical conductor is configured to plastically deform when a force is applied to said electrical conductor, wherein said force results in stresses above the yield point of the material of the electrical conductor.

[0074] This is advantageous in that it has the effect, that several identical electrical conductors may be shaped differently by applying a force resulting in stress above the material yield point to fit in to the footprint of one or mor electric panels.

[0075] Note that one electrical conductor may be designed to have more than one point where it plastically deforms when exposed to a force leading to a stress above the material yield point.

[0076] In an exemplary embodiment of the invention at least one of said one or more conductor branches is designed with a geometry comprising a plurality of airgaps, wherein said plurality of airgaps decrease non-uniformly as consequence of a force applied to said at least one of said one or more conductor branches.

[0077] This is advantageous in that it has the effect that the flexibility of an electrical conductor can be increased by increasing the number of “turns” of the single conductor branch and thereby increase the length of the single conductor branch. Thus, if two parts of such conductor branch are physically touching, then the electrical conductor may continue to flex by changing another of the plurality of airgaps. As an example, a spiral like geometry could be mentioned as a geometry where this is especially advantageous.

[0078] In an exemplary embodiment of the invention said electrical conductor is configured to reshape to its original geometry as consequence of removal of an applied force.

[0079] Reshape is a consequence of elastic deformation and may be understood as the distances between the one or more conductor branches returns to the distance therebetween before a forces was applied.

[0080] In an exemplary embodiment of the invention each of said one or more conductor branches are interrupted by one or more of said airgaps in a cross-sectional view of said electrical conductor in its longitudinal direction.

[0081] In an exemplary embodiment of the invention said cross sectional view is parallel to the longitudinal axis of said electrical conductor.

[0082] In an exemplary embodiment of the invention, said electrical conductor comprises a fist deformation point and a second deformation point, wherein said electrical conductor is configured to deform in said first deformation point when exposed to a first force and wherein said electrical conductor is configured to deform in said second deformation point when exposed to a second force, wherein said first and second forces are not identical.

[0083] This is advantageous in that it has the effect, that a person may be able to deform (elastically or plastically) the electrical conductor by hand while positioning it in an electrical system. This deformation of the electrical conductor is by design determined to be at the first deformation point. Secondly, the person may be able to deform the electrical conductor (elastically or plastically) by mounting it to another component e.g. by screws or bolts. This deformation of the electrical is by design determined to be at the second deformation point. The force applied by hand is less than the force applied by e.g. a bolt. Also, the first deformation may be elastic, and the second deformation may be plastic.

[0084] In an exemplary embodiment of the invention the cross-sectional areas of said one or more conductor branches are identical.

[0085] Identical should be understood as the same i.e. 0.5 mm2, 1 mm2, 1,5 mm2etc. up to e.g. 6 mm2or above.

[0086] In an exemplary embodiment of the invention the cross-sectional areas of said one or more conductor branches are equal to or below 200mm2, preferably below 150 mm2, preferably below 100mm2, preferably below 50 mm2, preferably below 10 mm2, most preferably between 0,5 mm2and 5 mm210mm2.

[0087] The electrical conductor is advantageous in that even though each of the conductor branches is having a cross-sectional area, of 10mm2or 20mm2, the electrical conductor is still flexible. It is however evident that the thinner conductor branch the less a force is needed to deform the electrical conductor. Further, this is advantageous that different cross-sections can change the flexibility of the electrical conductor.

[0088] In an exemplary embodiment of the invention at least one of said one or more conductor branches are of a different length that other of said one or more conductor branches.

[0089] This is advantageous in that it has the effect that the electrical conductor can be made with a pre-tension i.e. bending in a predetermined angle in space. Such pretension may be built into the design of the electrical conductor and / or applied by external means such as e.g. by a spring.

[0090] In an exemplary embodiment of the invention a first part of at least one of said one or more conductor branches has a first geometry in space and a second part of said at least one of said one or more conductor branches has a second geometry in space.

[0091] A first and second geometry in space should be understood as one conductor branch may be twisted e.g. 90 degrees so that before the twist a first part from a flat horizon geometry and after the twist a second part form a flat vertical geometry.

[0092] This is advantageous in that it has the effect, that such conductor branch is flexible in one orientation in space along the first part and flexible in another orientation in space along the second part.

[0093] In an exemplary embodiment of the invention said first end segment is configured to be displaced in any direction compared to said second end segment without plastic deforming said electrical conductor material.

[0094] In an exemplary embodiment of the invention said second end segment is configured to be displaced in any direction compared to said first end segment without plastic deforming said electrical conductor material.

[0095] Such displacement may be coursed by a force applied to the first end segment when the second end is fixed e.g. to a component of an electric panel. This is advantageous in that it has the effect, that mounting of the first or second end segments to a component in an electric panel is easy, in that the electrical conductor can flex in any direction. Thereby allowing aligning with a terminal of another component i.e. tolerances do not need to be as high when mounting an electrical conductor according to the present invention compared to known electrical conductors.

[0096] In an exemplary embodiment of the invention, said one or more conductor branches of the plurality of conductor branches have an internal cooling channel.

[0097] In an exemplary embodiment of the invention at least one of said first end segment and said second end segment is monolithically joined with a connection parts.

[0098] Having a monolithic end segment with a connection part is advantageous in that no electrical losses exists in the end segment.

[0099] In an exemplary embodiment of the invention said terminals are fastener holes.

[0100] In an exemplary embodiment of the invention said terminals are connection pins.

[0101] Such terminals holes, pins or sticks are advantages in that it allows connection of the electrical conductor to other components e.g. via a bolted connection or quick connector terminal.

[0102] In an exemplary embodiment of the invention said electrical conductor comprises one first end segment and a plurality of second end segments.

[0103] This is advantageous in that it has the effect, that the electrical conductor is a splitter allowing one phase connected to a first end segment to be split into two or more connections at the second end segments. As an example of an advantageous implementation could be mentioned equalising connections between electric components and where current is conduct parallel through different electric components.

[0104] In an exemplary embodiment of the invention all of said one or more conductor branches are the same length.

[0105] In fact, in an embodiment, all the conductor branches are similar in length and geometry. Hence, one conductor branch may be a copy of another conductor branch.

[0106] In an exemplary embodiment of the invention said one or more conductor branches are having a coiled structure.

[0107] In an exemplary embodiment of the invention said one or more conductor branches are having a coiled coil structure.

[0108] In an exemplary embodiment of the invention said one or more conductor branches are having a one or more waveform structure.

[0109] In an exemplary embodiment of the invention said one or more conductor branches are having a honeycomb structure.

[0110] In an exemplary embodiment of the invention said one or more conductor branches are having twisted structure.

[0111] The twisted structure is advantage in that it creates longitudinal airgaps which allows a high degree of flexibility of the electrical conductor when applied to a force. Hence, the plurality of conductor branches are mutually twisted without physicalcontact between the individual conductor branches in the longitudinal direction of the middle segment.

[0112] In an exemplary embodiment of the invention said twisted structure comprise uniform airgaps.

[0113] In an exemplary embodiment of the invention said one or more conductor branches are individually connected to both said first end segment and said second end segment.

[0114] In an exemplary embodiment of the invention said one or more conductor branches are located in the periphery of either said first end segment and / or said second end segment.

[0115] This is advantageous in that it has the effect that flexibility of the electrical conductor is increased compared to embodiments where the conductor branches are centred in the middle of the electrical conductor. Further, it provides more space between the conductor branches for deformation.

[0116] In an exemplary embodiment of the invention said first end segment is configured to be displaced in a longitudinal direction compared to said second end segment.

[0117] This is advantageous in that it has the effect, that the electrical conductor is flexible and can be compressed or stretched along the longitudinal axis of the electrical conductor.

[0118] In an exemplary embodiment of the invention said first end segment is configured to be displaced in a transverse direction compared to said second end segment.

[0119] This is advantageous in that it has the effect, that the electrical conductor is flexible and can bend.

[0120] In an exemplary embodiment of the invention said first end segment and second end segment are configured to rotate around the centre axis of the electrical conductor.

[0121] This is advantageous in that it has the effect that the electrical conductor is flexible and can twist around its longitudinal axis.

[0122] In an exemplary embodiment of the invention either said first end segment or said second end segment is fixed to a component comprised by an electrical panel.

[0123] Moreover, the invention relates to a method of manufacturing an electrical conductor according to any of the preceding claims, wherein said method of manufacturing is an additive manufacturing process.

[0124] Moreover, the invention relates to a method for coupling a first end segment of an electrical conductor to a second end segment of said electrical conductor, the method comprising the steps of: monolithically uniting the first end segment and a conductor branch element of one or more of conductor branches via an additive manufacturing process, manufacturing said one or more conductor branches via said additive manufacturing process so as to establish airgaps between two or more conductor branch elements of said one or more conductor branches, so as to spatially separate said one or more conductor branch elements in two different directions, and electrically coupling and mechanically coupling said first end segment and said second end segment via a middle segment of the electrical conductor formed by said one or more conductor branches.

[0125] In an exemplary embodiment of the invention said airgap separates said two or more conductor branch elements in the longitudinal direction of said electrical conductor.

[0126] In an exemplary embodiment of the invention said two different directions is a first transversal direction and a second transversal direction of said electrical conductor.

[0127] In an exemplary embodiment of the invention said electrically coupling and mechanically coupling achieved by said additive manufacturing process.

[0128] In an exemplary embodiment of the invention said method include a step of applying an isolation material to said plurality of conductor branches.

[0129] In an exemplary embodiment of the invention said additive manufacturing process include a step of applying an isolation material to said plurality of conductor branches.

[0130] Moreover, the invention relates to a use of an electrical conductor according to any of the preceding paragraphs, in an electric system.

[0131] Moreover, the invention relates to use of additive manufacturing for at least partly manufacturing an electrical conductor according to any of the above paragraphs.

[0132] Moreover, the invention relates to an electric panel comprising an electrical conductor according to any of the preceding paragraphs.

[0133] In an exemplary embodiment of the invention said electric panel is comprised by a renewable power generating system

[0134] A renewable power generating system may include a wind turbine, solar system, power-to-x system such as an electrolyser, battery storage, etc.The drawings

[0135] For a more complete understanding of this disclosure, reference is now made to the following brief description, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts. The drawings illustrate embodiment of the invention and elements of different drawings can be combined within the scope of the invention:Fig la-lc illustrates the principles of an electrical conductor,Fig. 2 illustrates method steps of manufacturing an electrical conductor,Fig. 3 illustrates a twisted electrical conductor,Fig. 4 illustrates an electrical conductor with a web like structure,Fig. 5 illustrates an electrical conductor having a plurality of middle segments,Fig. 6 illustrates an electrical conductor with a spiral like middle segment,Fig. 7 illustrates an electrical conductor with a wave like middle segment,Fig. 8 illustrates an electrical conductor with a middle segments comprising multiple wave like structures,Fig. 9 illustrates an electrical conductor with a squared-spiral like middle segment,Fig. 10 illustrates an electrical conductor with a middle segment having layers of conductor branches,Fig. 11 illustrates an electrical conductor with conductor branches in a curved plate like structure, andFig. 12 illustrates an electrical conductor with conductor branches in bended rod like structure.Detailed description

[0136] The present invention is described in view of exemplary embodiments only intended to illustrate the principles and implementation of the present invention. The skilled person will be able to provide several embodiments within the scope of the claims.

[0137] Fig. la-c illustrate an electrical conductor 1 according to an embodiment of the invention. Particularly, Fig. la illustrates an angled view, Fig. lb illustrates a twisted view and Fig. 1c illustrates a transition between an end segment and a middle segment 4 of the electrical conductor 1. Note, that in relation to Fig. la-c axes indicating a lengthwise (longitudinal) direction 9 between the first and second ends 2,3, a first transversal direction 8a, and a second transversal direction 8b is illustrated. Further, note that if the electrical conductor is tilted the axis 8a, 8b, and 9 are tilted accordingly.

[0138] The electrical conductor 1 comprises a first end segment 2 and a second end segment 3, the second end segment being 3 distal to the first end segment 2 and spaced apart from each other by a middle segment 4. Each of these two ends may for example be galvanically coupled to respective terminals of an electrical installation. Hence, the ends, 2, 3 may comprise connection parts 15 e.g. comprising fastener holes 18 such as illustrated e.g. in fig. 3, 4 and 5.

[0139] Typically, these holes 18 are terminals 13 (as illustrated in fig. 7 and 8a), but could also be used for securing the conductor to mechanical support e.g. of a panel. When such holes 18 are terminals 13 they would be used to connect the busbar inside an electrical panel to other busbars or components. Inside such enclosure the terminals and busbars should be able to comply with requirements to high voltages i.e. voltages above 24V such as 110V, 230V, 400V, 690V just to mentions a few voltage levels of an electric installation in which the electrical conductor of the present invention would be suitable. The voltage (and thereby current) may be AC or DC and the electrical conductor may be used in HVDC applications i.e. with voltage levels up to several hundreds kilo voltage or more.

[0140] Mentioning these voltages, it should be mentioned, that in principle there are no lower limits as to the voltage and current i.e. such version of the electrical conductor may be used in 24V or 48V systems conducting currents below 2A just to mention one example. Hence, the electrical conductor of the present invention may be manufactures as a wire harness as an alternative to traces of an printed circuit board or wire harness used for mounting in an electric panel.

[0141] In terms of current, an electrical conductor according to the present invention may conduct several hundreds of amps (16, 32, 64, and so on up to 100, 200 and so on up to e.g. 900A) up to a couple of thousand amps (1000A-3000A). Such electric installation may e.g. be in an energy facility, such that the electrical conductor can facility transfer of current and / or voltage in such panel / energy facility. The energy facility may e.g. be a renewable energy facility.

[0142] The first and second end segments 2,3 are electrically and mechanically coupled by a middle segment 4. The middle segment 4 is formed by a plurality of conductor branches 5a-5d. The particular embodiment illustrated in Fig. la-c comprises a total of six conductor branches 5a-5f, distributed in a 2x3 two-dimensional array. Note that two of the conductor branches are hardly visible in Fig. la, and 1c, since they are hidden behind other conductor branches 5b, 5c.

[0143] Put in another way, in an embodiment, the invention relates to an electrical conductor 1 comprising: a first end 2 and a second end 3 spaced apart by a middle segment 4, said middle segment 4 comprising one or more conductor branches 5, wherein said one or more conductor branches 5 are made of electric conductive material, and wherein at least one of said one or more conductor branches 5 is longer than the shortest distance 10 between said first and second end 2, 3, and wherein said electrical conductor 1 is configured to change geometry by a deformation of said one or more conductor branches 5.

[0144] In fig. la the individual conductor branches 5 are equal to the shortest distance 10 between the end segments 2, 3. In fig. lb the individual conductor branches 5 are longer than the shortest distance 10 between the end segments 2, 3.

[0145] The middle segment 4 of fig. la comprise parallel conductor branches 5 which are spaced by transverse airgaps 6a in direction of axis 8a, 8b in a relaxed position (no force is applied, “no force” should be understood as no other than gravitational force). This allows for a certain axial flexibility (see arrow X at fig. la) i.e. the electrical conductor may be able to deform slightly (rotate) when an axial / rotational force is applied to one or both ends. However, this design does not allow any particular flexibility / deformation when a force is applied perpendicular to the longitudinal axis 9 (see arrow Y at fig la). As long as such force is applied (and leading to a stress in the material below its yield point) the conductor may deform elastically and when the force is removed, the conductor may return to its relaced position. If the force lead to a stress above material yield point, the deformation is plastic i.e. one or more of the conductor branch may bend or break and to an extend where it will not return to its originally relaxed position when the force is removed.

[0146] It should be noted that the conductor branches 5c is divided in what is referred to as conductor branch elements 5c-l, 5c-2 and 5c-n and the conductor branches 5d is divided in what is referred to as conductor branch elements 5d- 1 , 5d-2 and 5d-n. The number of branch elements 5x-n of a conductor branch 5 may be different from three as one part referred to as a branch element 5x-n may be different in shape and length than another branch element. Hence, together conductor branch elements may be denoted 5x-n, where “x” denotes the branch and “n” denotes the element of the branch. It should be noted, that in some of the embodiment of the present invention one conductor branch may only comprise one conductor branch element.

[0147] Fig. lb illustrates a conductor 1 similar to the one of fig. la. However, the conductor 1 of fig. lb is twisted in its relaxed position. Hence, both the conductor 1 of fig. la and fig. lb are illustrated in relaxed position.

[0148] It is noted that between two branch elements, namely branch element 5c-2 and 5d-2, an airgap 6b now exists in the longitudinal direction 9 of the conductor 1. This airgap 6b is leading to the twisted design or the twisted design creates the airgap 6b. This airgap 6b adds flexibility to the conductor 1 at least in all directions which are perpendicular to the longitudinal direction 9. Hence, the conductor 1 of fig. lb is ableto deform equally no matter from which of the directions 8a, 8b a force is applied. In fact the conductor deform equally if the force is applied in any of the 360 degrees around the longitudinal direction 9 (indicated by arrows X of fig. lb).

[0149] In fact, the airgaps 6b allows a certain deformation in the longitudinal direct 9 i.e. the length between the two end segments 2, 3 may be sorter or longer due to the airgaps 6b.

[0150] Preferably each of the conductor branches 5a-5f are monolithically united with at least the first end segment 2. This means that an end segment is built together with a conductor branch. In an embodiment of the invention built together should be understood as built together by changing layer dimensions so as to build the desired structure of the conductor branch, the end segment respectively and the transition therebetween. The transition between an end segment and middle segment may be built as a smooth transition by changing e.g. diameter of each layer a bit compared to previous layer. The other extreme is to build a perpendicular transition where the first, second and so on layers of the conductor branch are of the same diameter (length and width if not circular). By building may be understood as manufactured by one way of additive manufacturing as described below.

[0151] In the embodiment illustrated in fig. la, lb, the first and middle segments 2,4 and the second and middle segments 3,4 are monolithically united, since they are manufacturing from a single bulk piece of material, which was machined to provide the electrical conductor 1. Here bulk piece of material should be understood as the material of which the electrical conductor 1 is made.

[0152] The manufacturing of the electrical conductor 1 may be done by an additive manufacturing process. Such manufacturing process may be based on, but not limited to, one of the following additive manufacturing processes: 3D printing, layer by layer printing, Wire Arc Additive Manufacturing, Fused Deposition Modeling, Direct Energy Deposition, Direct Metal Deposition, Sintering based processes, laser based processes, etc. It should be mentioned that the actual additive manufacturing process used to print or build the electrical conductor for most types / geometry may not beimportant as long as the material of which the electrical conductor is build is an electrical conductive material.

[0153] The stipulated line surrounding the conductor branches of fig. 1c serves to illustrate the perimeter of the conductor branch connected to the end segment 2 when the transition therebetween is made a plurality of layers with changing diameter.

[0154] Note that it is possible to manufacture an electric conductor as illustrated in fig. la, where the transition is a clear cut from the last layer of the end segment 2 to the first layer of the conductor branches 5. Such clear cut should be understood as during the layer-by-layer manufacturing, when the upper layer (layer towards the middle segment) is built, the next layer to be built is the first layer of all conductor branches. The diameter of this first layer is the diameter of the conductor branch or at least of a part (comprising at least 10 layers) of the conductor branch. The electric conductor may be manufacture be additive manufacturing.

[0155] The conductor branches 5a-5e illustrated in fig. la-c may in an embodiment be monolithically united with the first end segment via rounded connections (see fig. 1c). Each of these rounded connections shapes a concavely rounded interior corner between one or both of the first end segment 2,3 and a conductor branch 5. Alternative other connection shapes may be used such as the mentioned perpendicular or a combination thereof between the conductor branches.

[0156] A mix of different connection shapes may be used if a higher current is desired through one conductor branch than another. Accordingly, rounded transitions tend to be preferred over perpendicular transitions and therefore current through the end segments may be controlled by design of the connection shapes.

[0157] In a particular embodiment, rounded connections may be selected and the resulting concavely rounded interior comers differ from the connection between the second end segment 3 and the conductor branches 5a-5e, which do not shape concavely rounded interior comers between the second end segment 3 and the conductor branches 5a-5d (see e.g. Fig. lb).

[0158] Hence conductor branches 5a-5e may be connected to both end segments 2, 3 via concavely rounded interior corners, to one of the end segments 2, 3 via concavely rounded interior corners or without concavely rounded corners.

[0159] The concavely rounded interior corners may be established by successively increased or decreasing the size of one or more layers from one of the end segments 2, 3. Thereby gradually going from building an end segment to building a conductor branch. This may change as the conductor branches are built in that the diameter hereof may also change between the two end segments.

[0160] The non-concavely rounded connections between an end segment and a conductor branch may be established by building a plurality of layers with the same geometry such as a square. Thereby “instantly” from the last layer of the end segment to the first layer of the conductor branch going from building an end segment to building a conductor branch.

[0161] It should be noted that the connections between end segment and conductor branch in principle always is substantially perpendicular when looking at the connection on a “layer level” (as perpendicular as one layer can be added to another layer). However, when referring to a connection in the content of this invention a reference is made to two or more successive layers i.e. a plurality of layers together forming the shape of the connection / transition between end segment and conductor branch.

[0162] Accordingly, the end segment, conductor branches 5a-5e and transition between end segment and conductor branch may have any given geometry possible to manufacture by additive manufacturing.

[0163] By nature, the geometry of rounded connections further spatially separate the conductor branches 5a-5e from each other. But also other types of connection shapes spatially separate the conductor branches from each other in the transversal and / or in the longitudinal direction. Such separation may be established when designing the electrical conductor and therefore such separation is also possible to obtain withperpendicular or other transition shapes (including a mix of transition spaces) between end section and conductor branch.

[0164] The middle segment 4 is formed by conductor branches 5a-5e, the embodiment thus provides electrical and mechanical coupling of the two end segments 2,3 via the conductor branches 5a-5e.

[0165] It should be noted that even though the conductor branches 5a-5e in fig. la and lb are illustrated as more or less uniform conductors, the design / geometry may take any machinable / printable shape. Such shape may be optimized according to conducting current (skin effect), cooling including air guidance, etc. Specifically to these points hollow conductor branches may be built.

[0166] The particular electrical conductor 1 of fig. la, lb and 1c may be made of copper, but could also be made of other electrically conductive materials such as aluminum, titanium, etc.

[0167] In an embodiment, a particular branch 5 may have a uniform diameter (measured in a transversal direction) along the lengthwise direction. The diameter of the plurality of conductor branches 5 may be between identical with a cross sectional area of e.g. 0.5mm2, 1mm2, 1,5mm2etc. up to e.g. 6mm2or above such as up to 10mm2. In fact, the cross sectional area may be defined by the minimum and maximum size possible to manufacture by the additive manufacturing process.2

[0168] In an embodiment, a particular branch 5 may have a non-uniform diameter (measured in a transversal direction) along the lengthwise direction, a well-defined branch diameter may nevertheless be determined at a transversal plane at which that branch has its smallest diameter.

[0169] A neighbor spacing of two neighboring conductor branches 5 may be quantified. As for the branch diameter, a non-uniform diameter of conductor branches may result in a non-uniform distance between two conductor branches 5. Nevertheless, a well-defined neighbor spacing (such as an airgap 6a between two conductorbranches) may be determined by measuring in the transversal plane in which the largest spatial separation between two given conductor branches is present.

[0170] In an embodiment where the transition between end segment and middle segment includes concavely rounded interior corners, these corners may as example be quantified as follows. The rounded connection between the first end segment and a conductor branch forms the interior corner, which may be characterized by a corner radius. A first line may be drawn in the lengthwise direction as a tangent line to the point at which the branch diameter is measured (i.e., where the branch has its smallest diameter in the transversal direction). A second line may be drawn in the transversal direction where the middle segment and the first end segment are united. This second line may for example be a tangent line to the lengthwise air gap / spatial separation between the first end segment 2 and the second end segment 3. A circle (or a part of a circle) having the first line and the second line as tangent lines may then be drawn. The radius of the largest possible circle for which the part of the circle between the two intersection points with the first line and second line lies entirely within the interior corner is then the corner radius. As an example, the corner radius may equal to 1.0 branch diameter. The ratio of neighbor spacing of two neighboring conductor branches 5 to a branch diameter of one of these conductor branches may be 2.0.

[0171] In an embodiment, the electrical conductor comprises a plurality of conductor branches of which two or at least three are mutually spaced in both a transversal and in a longitudinal direction. Looking along the length of two conductor branches, they may be space e.g. in one of the transversal directions (8a and 8b fig. 1c) and / or in the longitudinal direction (9 fig. 1c). Such two conductor branches may be space with a third conductor branch in one or two of the directions (transversal 8a, 8b and longitudinal 9) in which the two conductor branches are not spaced.

[0172] Such airy design may result in that no matter from which orientation the electrical conductor is seen more than one conductor can be seen. More specific, such design comprise openings / airgaps between two conductor branches no matter from which orientation the conductor branch is seen. Hence, no matter from which orientation a person is looking at the electrical conductor it is possible to see throughthe conductor. Further, such design may alternatively result in at least one opening / outlet for a flow of air through the electrical conductor from any orientation (at least from any angle around the longitudinal axis of the conductor) i.e. air can enter or leave the electrical conductor from any angle, at least from any angle around the longitudinal axis of the electrical conductor. This is contrary to e.g. braided conductors through which an air flow is not allowed to pass through at least through the width (transversal direction) of the braided conductor. It could be argued that through the height (longitudinal) of a braided conductor air flow is allowed, however such air flow will not have a cooling effect on all conductor branches it passes as would be the case with a conductor of the above-described design of the present invention. In fact, directing a flow of air to a braided busbar would result in that the airflow is not going through the conductor but instead around the conductor because the individual conductor branches are braided (touching each other) forming a closed middle segment through which an airflow cannot pass through.

[0173] An example of the above design is introducing line of sight through the electrical conductor. Line of sight may be understood as being able to see through the electrical conductor in fact it may be possible to have line of sight through the electrical conductor from any angle around the longitudinal axis of the electrical conductor. Such design has an advantage of providing airflow inlet through the electrical conductor from any such angle.

[0174] An example of the above design allows to see one conductor branch through an airgap between two other conductor branches. This may be true for any orientation i.e. in any angle around the longitudinal axis of the conductor. This allow a flow of air to impact all three conductor branches.

[0175] An example of the above design does not allow to see through the electrical conductor from any angle around the longitudinal axis of the electrical conductor. Hence it is possible to see into the interior of the electrical conductor but not all the way through the electrical conductor. This allows for a guidance of a flow of air to cool the electrical conductor inside or through the electrical conductor.

[0176] An example of the above design includes a plurality of airgaps on two or more sides / surfaces of the contour of the electrical conductor where it is possible to, simultaneously, see through a plurality of airgaps positioned opposite the contour of the electrical conductor and thereby through the electrical conductor.

[0177] The above design inherent a plurality of the advantages described in this document. A common advantage of the above design is a reduction of material, improved or controlled flexibility and improved or controlled cooling including individual cooling of each individual conductor branch preferably from any angle of the longitudinal axis of the conductor branch e.g. via a flow of air or other coolants.

[0178] When referring to an angle above, the angle may be perpendicular to the longitudinal axis of the electrical conductor or to a conductor branch.

[0179] In an embodiment, the middle segment 4 comprise a plurality of parallel conductor branches 5. The part of the conductor branches 5 that are parallel are only or at least 2cm. The parallel parts of two (or more) conductor branches may be parallel at the same or overlapping distances from the first or second end segments. Alternatively, such parallel parts may not overlap and thus extend at different distances from the first or second end. A non-limiting example may be a first conductor branch having a part starting 3cm from the first end segment and ending 8cm from the first end segment. A second conductor branch may have a part starting 9cm from the first end segment and ending 10cm from the first end segment. Even though the parts of the first and second conductor branches do not overlap along the longitudinal axis of the electrical conductor, they may be considered parallel.

[0180] Note that a plurality of parts of one conductor branch may be parallel to a plurality of parts of other conductor branches and / or to a plurality of parts of one particular conductor branches along the length of these conductor branches. Hence two conductor branches may be parallel a plurality of times between the two end segments. Further, one conductor branch may be parallel to the longitudinal axis of the middle segment / electrical conductor branch a plurality of times between the two end segments.

[0181] A parallel part of one or more conductor branch may extent for at least 10% of the length of the conductor branch / middle segment.

[0182] The part of the conductor branches that are parallel may be defined by the surface of two or more conductor branches including tangents to curved surfaces of one or more conductor branches. Alternative or in addition, the parallel part of two or more conductor branches may be the center axis of the conductor branches. Note that more than two conductor branches may be parallel according to the above definition such as between 3 and 100 (or any natural number therebetween) conductor branches.

[0183] Further, a conductor branches may be defined as parallel to a longitudinal axis of the electrical conductor, this axis may be defined as the shortest / direct path between a center of the first end segment and a center of the second end segment. Hence one or more conductor branch may be parallel to the longitudinal axis or part of the longitudinal axis of the electrical conductor.

[0184] The above design with parallel conductor branches may inherent a plurality of the advantages described in this document. A common advantage of the above described parallel design is a reduction of material, improved or controlled flexibility and improved or controlled cooling including individual cooling of each individual conductor branch preferably from any angle of the longitudinal axis of the conductor branch e.g. via a flow of air or other coolants. In addition, the partly parallel / nonparallel conductor branch design may allow various electrical conductor layout including curved, twisted, bended, etc. layout of the electrical conductor between two terminals to when the first and second end segments are to be connected.

[0185] It should be mentioned that conductor branches in embodiments may also extend between two end segments without being parallel, being parallel for a distance below 2cm, being parallel to each other and non-parallel to further conductor branches, etc.

[0186] Fig. 2 illustrates method steps for machining an electrical conductor according to an embodiment of the invention. The particular method relates to coupling two segments of an electrical conductor, namely a first end segment and asecond end segment with conductor branches, but may be used for producing any kind of electrical conductors of the present invention.

[0187] It should be mentioned that this may include printing both end segments and the conductor branches in one process. Hence, the method may start by printing one end segment, then the transition to the conductors, then the conductors, then the transition to the second end segment and finally the second end segment.

[0188] Alternatively, the end segments may be separate elements that is connected via the middle section. The middle section may be printed and during the manufacturing of the middle section it may be attached to the end segments such as printed onto the end sections. The middle section may be joints to the end sections by means of welding, printing, soldering, etc.

[0189] It should be noted that the end segments may comprise terminals for connecting the finalized electrical conductor to other electric parts / conductors of an electric system. Such terminals may be produced like the rest of the conductor.

[0190] In a step SI of this particular method, the first end segment and middle segment in the form of conductor branches of a plurality of conductor branches are monolithically united via individual transitions that may or may not include rounded connections to shape concavely rounded interior comers between the first end segment and conductor branches of the plurality of conductor branches and to spatially separate conductor branches of said plurality of conductor branches.

[0191] The step of monolithically uniting the first end segment and conductor branches may be implemented using various methods, for example methods, such as additive manufacturing such as 3D printing, casting, and simply removing of material, via machining, from a bulk metal slab to form conductor branches united with a first end segment.

[0192] In a step S2 of the method, the first end segment and the second end segment are electrically coupled and mechanically coupled via a middle segment of the electrical conductor formed by the plurality of conductor branches.

[0193] Middle segment may in principles have any design / geometry providing flexibility thereto allowing the electrical conductor to deform. It may be formed by conductor branches being solid or have internal cavities to reduce the amount of material that is needed to manufacture the electrical conductor. It may be formed by a web or as a hybrid between conductor branches or web just to mention a few possible designs.

[0194] Internal cavities may be used as cooling channels and / or additional surface for conducting high frequency current. Accordingly, the end segments and middle segments may be designed for the particular panel / electric system in which it is used, for a particular type of current to conduct, for having a desired or dual functionality, etc.

[0195] One such functionality, beside the above-mentioned may be as a structural support. Hence, if needed the electrical conductor may be designed to assist in carrying the weight of electric components connected thereto. Hence, its dimensions may be larger than what needed by it for carrying the required current. Similarly, its geometry may be designed of the combined purpose of mechanical support and electric conductance. This is especially true if such support is flexible / deformable in that it may both assist in supporting and at the same time assist in absorbing vibrations.

[0196] It should be mentioned that the electrical conductor 1 may be manufactured in two or more resolutions. The thicker layer the faster manufacturing. The layer thickness depends on the material and printing apparatus and may vary from a few millimetres to 20um, using some combinations the layer thickness is between 50um and 150um. In case of additive manufacturing resolution may be defined by thickness of the layers of which the electrical conductor is build (another word for machined and processed). A first resolution that is finer i.e. having thinner layer size than a second resolution may be used when manufacturing the interface between the electrical conductor and the part to which it is connected. Such interface may be the part of the terminal that is in contact with the other part. Alternatively, resolution may be determined by material deposition rate, material flow rate, etc. depending on the type of additive manufacturing used.

[0197] To avoid electric losses in connections between two electrical conductors it is important that the two parts are having planer surfaces. The finer these interfaces are manufactured the better / the less post manufacturing processing is needed to ensure sufficient planer surfaces. With this said, it should be noted that end segments of two electrical conductors may be joints by means of engaging tooths, slider lock, tongue and groove, etc. This may lead to an easier assembly of electrical conductors such as busbars in an electric system.

[0198] The second resolution manufactured e.g. with thicker layers would be more rough leading to more surface area. At least for middle and high frequency currents this may lead to conductance of more current without increasing the need for material / dimensions of the conductor. In fact, the middle segment may be manufactures intentionally with a corrugated surface to increase the current carrying outer surface of the electrical conductor (current carrying with medium and high frequencies) because of more efficient cooling due to the turbulence of e.g. cooling air flow created due to the corrugated surface. It should be noted, that if the conductor includes an interior space, the inner surface of the conductors creating such interior space may also be corrugated for the same purpose. A corrugated surface has the effect, that it introduces turbulence in the flow of cooling fluid such as air. Increased speed of cooling fluid may lead to higher cooling effect.

[0199] As an example, the depth into the conductor which is used for conducting current at medium and high frequencies may in a specific embodiment be approximate 1.5mm. In this specific example, the conductor is made of copper with a resistivity of approximate 1.68pQ cm, a relative permeability of approximate 1 at a frequency of 2kHz. Thus, a conductor for this particular embodiment may be hollow having conductor thickness of 2 times 1.5mm. In practice such conductor may be manufactured with a thickness 4-5mm leaving room for a cooling in the interior or simple reduction of conductor material and thereby weight.

[0200] Knowing that skin effect also appears at e.g. 50Hz, a reference to a medium frequency with respect to skin effect is a reference to frequency starting around 500Hz where the design of the conductor may account for the skin effect. The mediumfrequency range may be between 500Hz and 10kHz, above 10kHz may be referred to as high frequency where skin effect is a fact (the higher frequency, the closer to the surface the current will be conducted).

[0201] Further, it should be mentioned that the outer surface may also be corrugated or designed with fins for increasing heat dissipation from the electrical conductor.

[0202] The electrical conductor resulting from the method may be used as an electrical conductor of an electrical installation. The electrical installation may be an electric panel which may be part of a renewable energy facility such as a wind turbine, solar system, grid, substation, etc. The electrical installation or system in which the electrical conductor is used may by an electric vehicle, battery system, power to x facility, ship or other minor or larger electric systems. Further, an electrical conductor resulting from the method can be used inside an electric panel, i.e. in a cabinet / enclosure, or outside such panel, it can be used to connect separated panels, etc.

[0203] A variant of an electrical conductor according to the present invention is connected to a traditional cable or busbar. In such embodiment, a traditional busbar e.g. in the back of an electric panel or a traditional cable e.g. between two electric panels may be connected to an electrical conductor of the invention. In this way a traditional cable or busbar may be connected to a component via a conductor according to the invention. Thereby, an easy connection is facilitated due to the flexibility of the electrical conductor of the invention.

[0204] However, note that manufacturing the electrical conductor, and thus accomplishing the electrical and mechanical coupling between the first end segment and the second end segment, is typically performed prior to installing the electrical conductor in the electrical installation, and prior to installing the electrical installation in the renewable energy facility. Thus, according to typical embodiments of the invention, the electrical and mechanical coupling is performed prior to installation / integration of the electrical conductor. Nevertheless, methods according to the invention are not necessarily restricted to a particular sequence of steps. Further,various methods according to the invention may comprise additional steps, such as performing digital geometry optimization, additively manufacturing the electrical conductor, and conducting current.

[0205] Summing up, a designer is designing a digital representation of the conductor according to electrical, mechanical, structural, etc. requirements in e.g. a 3D CAD software such as Solidworks. Files (digital representation) from such 3D developing tool is exported to e.g. a 3D printer, where the conductor is printed according to the CAD files. Once printed, an additional step may be to apply i.e. a heat treatment to the finalized conductor. A heat treatment may e.g. be 4 hours at 400C and upwards depending on the material. An advantage of heat treatment is that the particles of the manufactured conductor is mutual positioning or merging leading to higher conductivity both thermal and electrical. This is at least true for Aheadd® CPI 20 / 63 aluminum powders and other aluminum-iron-zirconium powder solutions. Such powders may be used in laser powder bed fusion machineries. Using this type of powder and heat treatment may lead to higher thermal stability, thermal conductivity, corrosion performance and surface finishing as well as higher electrical conductivity.

[0206] Moreover, in an embodiment of the invention the perimeter length may vary in transversal planes at different positions in the lengthwise direction of the electrical conductor (and of the individual conductor branches). The perimeter length of a given segment may simply be measured as the sum of all lengths of perimeters of areas in a given transversal plane. Hence, the perimeter length of the second end segment 3 may thus be the length of the perimeter of a cross-section perpendicular to the longitudinal direction of the electrical conductor.

[0207] The perimeter length of the middle segment 4 may be the sum of lengths of perimeters of all individual conductor branches. As one conductor branch may split from a stem to two or more twigs, the perimeter at one part of the middle segment 4 may be different from (twig part) another part (stem part). Hence, the sum of lengths of perimeters of the middle segment may be the sum of all individual twigs or of all the individual stems. In case of multiple different possible perimeter lengths for themiddle segment, the smallest perimeter length may preferably be used in calculation of current conduction capability of the electrical conductor.

[0208] In an embodiment, the electrical conductor may comprise one or more cooling channels, where the cooling channel may be placed in the middle section inside one or more conductor branches.

[0209] In the following figures various examples of electrical conductors all within the scope of the present invention are illustrated.

[0210] The electrical conductor 1 of the embodiment of the invention illustrated in fig. 3 comprises two end segments 2, 3 each terminated in a connection part 15 with a fastener hole 18. The fastener holes 18 are used to connect the electrical conductor to fastener holes or terminals of other electric parts. In other embodiment, the end segments 2, 3 may be equipped with bars / connector pins for fastening the electrical conductor in associated terminals of neighboring components. No matter how the end segments 2, 3 are terminated the preferred intention is for the electrical conductor to be able conduct current received from the neighboring component or to conduct current to such neighboring component.

[0211] The electrical conductor illustrated in fig. 3 also comprises a middle section 4. In this particular embodiment the conductor branches 5 of the electrical conductor 1 is optimized e.g. to allow a flow of a cooling fluid such as air to pass by all conductor branches of its middle section 4.

[0212] In this particular embodiment, the plurality of conductor branches 5 are divided in sets of conductor branches 5 more specifically in three sets (the number of sets is a design choice). In other embodiments the electrical conductor 1 may comprise additional sets such as 5, 7, 9 or even more set of these conductor branches. As illustrated, the conductor branches 5 in each of the sets are twisted. The number of conductor branches in one set may as in this embodiment be 3 or any other suitable number determined based on geometry or conducting capacity.

[0213] The conductor branches of the individual sets of conductor branches are twisted. The sets of twisted conductor branches are also twisted. The twisted design is created with airgaps 6b at least between a first conductor branch and a second conductor branch. More specifically, airgaps 6b are created between a particular branch element of one branch and a particular branch element of a second branch.

[0214] All individual conductor branches 5 are connected to the end segments 2, 3. This may be done via rounded corners or perpendicular connections between the conductor branch 5 and the end segment 2, 3. The illustrated design may have the advantage that it facilitates a linear current path which may lead to a reduced resistance.

[0215] It should be noted that the three sets of twisted conductor branches 5 are also mutually twisted i.e. continuously changing so an inner side and an outer side change position. Letting all conductor branches be part of the outer surface / periphery of the electrical conductor, at least at one part (one branch element) hereof is directly cooled by surrounding air.

[0216] The illustrated conductor 1 is manufactured from additive manufacturing and thereby it is possible to ensure a distance between each of the individual conductor branches 5. This design illustrated in fig. 3 is inspired by the so-called Liz wire to achieve the advantages of this wire design. Since it can be manufactured e.g. by 3D printing it can be shaped in any form utilizing free space between conductor branches also referred to as airgap e.g. in an electric panel.

[0217] A twisted conductor design as the one illustrated e.g. in fig. 3 and 5 is advantageous in that it has the effect, that it adds flexibility to the electric system. Hence, the accuracy of the fastener holes / terminals 18 of the electrical conductor and additional electric components to which it is to be connected may be allowed to be less accurate. This is because by pulling or pushing the conductor branches, the terminal / fastener holes 18 may move and thereby fit to the other component to which it is to be mounted. Further, tension or forces acting on the additional electric component may be reduced in that the twisted design allows for obtaining tolerances both in thelongitudinal direction, transversal, and axial. This is true both in terms of forces introduced by vibrations but also static forces e.g. occurring by forcing an electrical conductor to a position where it is possible to mount to an additional electric component.

[0218] Both for this and other embodiment of the invention presented in this document it should be mentioned that if electric insulation is required for the electrical conductor 1, the electrical conductor 1 may be dipped into a bath of liquid like insulating material. In this way all outer surfaces of both the middle segment and end segments may be electrically insulated when the insulating material congeal. Insulating material may alternatively be spray -painted or printed in a non-conducting material to one or more conductor branches of an electric conductor.

[0219] The conductor branches of the conductor 1 illustrated in fig. 4 is manufactures as a web like structure 31. Hence, there are no individual conductor branch as such, but a web or structure of a plurality of conductor branches in which the current can be conducted through the conductor 1. Such web or bionic designed structure may be referred to as a plurality of conductor branches meeting and branching off a plurality of times in multiple directions relative to the longitudinal direction 9 of the electrical conductor 1.

[0220] Each of the “holes” in the web or honeycomb-like structure may be considered an airgap 6. As illustrated (also e.g. in fig. 3) the plurality of airgaps 6 are uniform. The particular airgaps 6 illustrated in fig. 3 extend in the longitudinal direction having a distance between two intersession points 11, this distance may be referred to as the airgap 6b. Similarly, such airgap 6 may extend in the transversal direction having a distance between two intersession points 11, this distance may be referred to as the airgap 6a.

[0221] In such design the current would prefer the most direct path provided by conductor branches between connection parts 15 i.e. the branches together forming the shortest path therebetween. The conductor branches which are branching off and thereby creating (a potential increasingly) longer path between two connection parts15 may in addition to conducting current also used as a bearing structural part of the electrical conductor 1 so as to maintain its geometry or as a cooling fin / cooling area.

[0222] The design illustrated on fig. 4 has the advantage that it has a large surface compared to a standard known conductor. This large surface is especially advantageous in medium to high frequency applications. Further, with respect to cooling a web-like structure is advantageous in that air can pass through the conductor and cool the large areas efficiently.

[0223] The obvious fact, that less material is used is advantageous in that material costs are reduced but also weight. A reduction in weight e.g. lead to a reduction in fastening (such as brackets) needed to fix the conductor 1 to ensure safe operation also in environment where the conductor / panel in which it is mounted is exposed to vibrations. Also, the lower weight the cheaper transport expensed is expected.

[0224] It should be mentioned that end sections 2, 3 comprising terminals or connection parts 15 of a web like structured electrical conductor 1 may also be at least partly manufactured in a web like design. Thus, the transition between longitudinal direction of the middle segment and the end segments is more or less erased.

[0225] However, the part of the end segments 2, 3 should comprise a solid part, at least if nuts and bolt are used to connect the conductor 1 to an additional electric component. The end segments may be completely of a web like design e.g. if connection to additional electric components are made by twist and turn or other quick lock principles.

[0226] The terminal parts 15 of the end segments 2, 3 in the embodiment illustrated in fig. 4 comprises a solid abutment plate (see the first end segment 2) against which an additional electric component can be connected. On the other side of the end segment (indicated at the second end segment 3) around the hole for the connecting bolt, the end segment comprises a solid part which extend through the end segment to ensure sufficient strength when using nuts and bolts to fasten the conductor 1 to an additional electric component.

[0227] As illustrated the connection parts 15 of the electrical conductors 1 illustrated in fig. 3 and 4 are monolithically manufactured with the end segments 2, 3 and the middle segment 4. Thus, compared to traditional cable and busbars including braided conductors, there are no mechanical connection of parts of the electrical conductor of the present invention and thus, no electrical losses which is advantageous. Further, the manufacturing process of attaching the terminal end of the braided conductor is avoided when that the electrical conductor according to the present invention is made monolithically between connection parts 15 / end segments 2, 3

[0228] The embodiment illustrated in fig. 5 could be said to be a combination of several different electrical conductor designs of the present invention. The electrical conductor 1 illustrated on fig. 5 is of a twisted type. It has three central body segments 19a, 19b, 19c. A first 19a is separating one larger twisted part extending between 19a and 19b into six twisted parts (extending between 19a and end segment 2) individually having a smaller diameter than the larger twisted part of the electrical conductor between 19a and 19b. The central body segments 19b and 19c are connecting the part between 19a and 19b and a part extending between 19b and end segment 3 with an inductor part 20 extending between 19b and 19c. The six twisted conductor parts each terminates in a first end segment 2. These six first end segments 2 are connected to an additional electric component 21 via a nut and bolt 22 connection. The second end segment 3 is also connected to an additional electric component 21 via a nut and bolt 22 connection.

[0229] As illustrated the electrical conductor 1 comprises an inductor part 20 with five windings. Through each of these windings one core 23 such as a ferrite core extend. Hence, by the illustrated conductor 1 design, four ferrite cores around the conductor 1 are avoided without compromising the noise reduction.

[0230] All of the central body segments 19 and the inductor part 20 is built of conductor branches 5 having airgaps 6 therebetween.

[0231] The embodiment illustrated in fig. 5 is one example of an electrical conductor having different dimensions i.e. a thick part connected to the second end segment 3and to a thinner inductor part 20 which again is connected to a thick part. This way of designing the electrical conductor is advantageous in that it has the effect, that the thinner part (inductor part 20 on fig. 5) of the electrical conductor may be coiled around a core. The core may be a ferrite core as illustrated, but may also be e.g. a core of a transformer or the electrical conductor may be coiled to form a reactor.

[0232] By manufacturing the electrical conductor 1 with a thinner part and using this thinner part to coil (instead of coiling the thicker part) is leading to a reduction of the size of the ferrite core, transformer core, reactor or the like. This is because the window in e.g. the ferrite core need to by larger if the thicker part is coiled and need to go through the coil compared to a coiled part of the thinner part. The core may be smaller, more compact and thereby weight is reduced, hence, cost of and footprint in the electric system are saved.

[0233] Reducing the diameter of cause comes with the disadvantage that the thinner part is becoming warmer than the thicker part in that the same current are running through the two parts. However, the electrical conductor may be designed so that it is just before the coiled part starts, the diameter is reduced and just after the coiled part ends, the diameter is reshaped back to the thicker diameter again. In such design heat may be dissipated from the coiled / inductor part (thinner part) towards and into the thicker part. Further, the coiled part is small so this part having higher resistance than the remaining part of the conductor is which will reduce the heat generations. Further, the design illustrated where it may be possible to circulate air through the twisted conductor branches, may facilitate better cooling.

[0234] Compared to the embodiments illustrated in fig. 3, 4 and 5, the embodiments illustrated in figures 6-12 presents a few variants of middle segment designs according to the invention. These embodiments are characterized by having parts or areas, mainly of the middle segment 4, which are providing the flexibility to the conductor. Hence, where the embodiments illustrate in figures 3-6 are having a more or less uniform design along the entire conductor, the design of the embodiments illustrated in figures 6-12 only facilitates the flexibility at a reduced part of the length of the conductor.

[0235] As illustrated, in the designs og figures 6-12, the end segments 2, 3 and the flexible middle segment 4 are not as separable / distinct as e.g .in figure 3. Hence, one end of the middle segment 4 may comprise or be referred to as a first end segment 2. The second end segment 3 may be considered as part of the rod denoted 3, 4 or the part of the middle segment 4 opposite to the first end segment transitioning to the rod3, 4. One way to define an end segment is where terminals 13 are provided in the conductor. Accordingly, in some of the embodiments of fig. 6-12, the rod is defined as second end segment 3 and in other the rod is defined as part of the middle segment4.

[0236] Only having a part of the middle segment or of the length of the conductor providing the flexibility is advantageous in that the length from this part to the terminals e.g. at the end of a rod can be used to vary the degree of flexibility according to the principles of the lever.

[0237] It should be noted that one conductor may have several middle segments facilitating flexibility along the length of the conductor. The design of such areas may not need to be the same and in fact, they may facilitate controlled flexibility in different directions relative to the direction of current through the conductor. Further it should be note that the flexible part of the middle segment may also be implemented along the entire length of the conductor as illustrated in fig. lb.

[0238] The designs on fig. 6, 8, 9 and 10 allows substantially equal deformation independent on from where a force perpendicular to the illustrated arm / second end 3 is applied. The middle segment of figures 7, 11 and 12 allows a larger deformation “up and down” than “sideways” (sideways and up / down may in embodiments refer to the direction of axis 8a, 8b of the fig. 1).

[0239] The electrical conductor 1 in fig. 6a-6c has a combination of a spiral structured middle segment 4 located towards the first end segment 2 and a rod-like second end segment 3. The middle segment comprises a plurality of conductor branches 5a, 5b, . . ., 5n (commonly denoted 5) separated by a plurality of free spaces / airgaps 6b. The middle segment 4 is in each end attached to a plate i.e. to twoperpendicular plates. These plates mark the end of the middle segment 4 and the beginning of the first and second end segments 2, 3. Hence, the middle segment 4 is attached to / continues into the end segments 2, 3 and a transitions therebetween, as described with respect to fig. 1, is established.

[0240] The second end segment 3 is in this design embodied as a rod like structure i.e. an example that illustrates that the two end segments 2, 3 does not need to be identical (no terminals are illustrated). The rod like structure can either be designed with multiple conductor branches 5 or as one solid rod (as illustrated).

[0241] The conductor illustrated in fig. 6a and 6b are illustrated in a resting position where no force is acting on them. Most of the conductors of the figures are also illustrated in resting position. The conductor illustrated in fig. 6c is illustrated when a force is acting in a downward direction.

[0242] The electrical conductor 1 illustrated at fig. 6a-6c has the advantage that the spiral structured middle segment 4 enables a high degree of flexibility (deformation) towards the second end segment 2. The free space / airgaps 6b between conductor branches 5 in the spiral structured middle part 4 enables the flexibility for the rod / second end segment 3. The flexibility of the rod formed second end segment 3 is advantageous in that it provides flexibility in any direction because of the circular form of the spiral structured middle segment 4.

[0243] The free space / airgap 6b between the conductor branches 5 in the spiral structured middle segment also adds the possibility to let a coolant fluid pass through in order to cool the conductor 1.

[0244] The electrical conductor 1 illustrated on fig. 6b and 6c is an example of the flexibility provided by the deformation of the conductor branches 5 and / or the mutual displacement in space of the conductor branches allowed by the airgaps 6b. Note only the longitudinal airgaps 6b are illustrated.

[0245] The conductor 1 illustrated in fig. 6b is sufficiently rigid to not change shape solely based on the gravitational force acting on it (at least it can be neglected). In fig.6c a downward acting force of e.g. ION is applied to the tip of the second end segment 3. As illustrated in fig. 6c, this lead to a change in geometry of the middle segment 4 and thus of the electrical conductor 1 as such. The change is illustrated as the distance denoted D and is in this example 11.5mm. Of course, this distance is depending on the material and cross sectional area of the conductor branches 5.

[0246] The electrical conductor 1 illustrated in fig. 7 has a wave-like structured middle segment 4 which in one end terminates in a first end segment 2 and in another end is attached to a second end segment 3. The second end segment 3 is in this embodiment a rod (no fastening means / connection parts 15 are illustrated). The transition part between the middle segment 4 and the second end segment 3 may be designed as described above.

[0247] The middle segment 4 is made of only one conductor branch 5a. This conductor branch 5a is designed with a plurality of parallel conductor branch elements 5a-l, 5a-2, . . ., 5a-n. The elements are space from each other with airgaps 6b. Hence, only one conductor branch 5 is in this embodiment used to establish a flexible electrical conductor 1.

[0248] As mentioned, the electrical conductor 1 illustrated in fig. 6a-6c is flexible in 360degrees. In principle, the electrical conductor 1 illustrated in fig. 7 is also flexible in 360degrees, however the flexibility is higher in an up / down direction that in sideways direction. The degree of flexibility may be controlled e.g. by the number of conductor branch elements / airgaps (number of waves), thickness of the branch element and area of the individual waves, airgap size (distance between two branch elements in the longitudinal direction but also in the transversal direction), etc.

[0249] The conductor branch 5a forming conductor branch elements 5a-n making the wave-like structure is perpendicular to the rod of the second end segment. It should be mentioned that the rod could be angled or rotated.

[0250] The distance between the conductor branch (airgap size) in the wave-like structure allows the use of various coolant fluids to cool the electrical conductor.

[0251] Another embodiment of the invention is shown in fig. 8a and 8b. In this embodiment the electrical conductor 1 has a rod-end like illustrated in fig. 7. The middle segment 4 is connected with two plates spaced apert forming part of the first and second end segments 2, 3 as described above. It should be mentioned, that these plates may also be referred to as being part of the middle segment without breaking away from the scope of the present invention.

[0252] The middle segment 4 in the embodiment illustrated in fig. 8 and 8a comprises more than on electrical conductor 5, more specifically three electrical conductor elements 5a, 5b, 5c. These electrical conductors 5a, 5b, 5c have a wave-like structure. This wave-like structure may be designed according to the same principles as the one illustrated in fig. 7. Variants hereof may be implemented and thus v-tum / u-turns / waveforms do not need to be identical in size nor in form.

[0253] As illustrated in fig. 8b the individual conductor branches 5a-5c are vertically spaced apart by airgaps. In principles, the space therebetween could also be referred to as an airgap. The individual conductor branch elements 5a-l to 5c-n are horizontally spaced by airgaps 6b.

[0254] The design illustrated in fig. 8a, 8b is advantages both in the flexibility and the space between conductor branches allowing cooling / flow of a coolant.

[0255] The design illustrated in fig. 8a, 8b could be said to be similar to the one illustrated in fig. 7 where the design in fig. 8a, 8b include a plurality of conductor branches 5a-5c whereas the design of fig. 7 only include one conductor branch 5.

[0256] The design illustrated in fig. 9 also only comprise one conductor branch 5a comprising a plurality of conductor branch elements 5a-l - 5a-n between which longitudinal (horizontal) airgaps 6b and transversal (vertical) airgaps 6a exists.

[0257] The first end segment 2 is formed by / in / as one of the conductor branch elements 5a-x. The second end segment 3 may also be formed as one of the conductor branch elements 5a-x (the inner most part of the conductor branch forming the middle segment 4).

[0258] A rod may be monolithically manufactured in one with the second end segment 3. Thus, this rod (comprising a fastener hole 18) may be considered as part of the electrical conductor 1. This, together with other embodiment including a rod, is an example of an electrical conductor 1 which extend beyond one of the first and second end segments 2,3. In fig. 10 below, this rod is considered part of the second end segment 3 i.e. this is more a question of definition than a feature of the electrical conductor.

[0259] The embodiment of the invention illustrated in fig. 9a and 9b has a middle segment 4 established by one conductor branch 5a formed as a squared spiral. This conductor branch 5a comprises a plurality of conductor branch elements 5a-l to 5a-n separated by airgaps 6. It should be mentioned that other forms could also have been used and having the same advantageous as the squared spiral.

[0260] The first end segment 2 is connected to or forming part of the middle segment 4. Similarly, the second end segment 3 is connected to or forming part of the middle segment 4. Note that the second end segment 3 is in this embodiment located in the middle of the middle segment 4. Further note that a rod is connected to the second end segment 3 and thus could be considered to be part of the second end segment 3.

[0261] Hence, in the various embodiments of the invention, the end segments 2, 3 may be considered as staring where the middle segment 4 end also if these are integrated. They may be considered as stopping at its terminal holes 18 (or other means of connection) also if these terminal holes 18 are at the other end of a rod as illustrated in fig. 9a, 9b. In this embodiment, the second end segment may said to extend from the middle of the middle segment 4 to the end of the rod after the terminal hole 18.

[0262] In the embodiment illustrated in fig. 9a, 9b it is noted, that the conductor element branches has a through hole through which the rod extents. Fig. 9a illustrates an airgap 6 between the conductor branch element and the rod. This airgap together with the airgaps 6a, 6b between the individual conductor branch elements of the squared spiral facilitates the flexibility of the rod.

[0263] In embodiment such as those illustrated in fig. 7-9, the conductor branch elements may meet when the geometry of the electrical conductor change. Hence, the size of one specific airgap i.e. the distance between two specific conductor branch elements may decrease until contact is obtained between the two conductor branch elements. Until then other airgaps may only decrease slightly. After such contact is obtained, the size of another airgap may start to decrease faster than remaining airgaps. In this way the more airgaps that is included in a design, the higher degree of flexibility of the electrical conductor.

[0264] As one can imagen, when an airgap decreases until contact as described above, another airgap (or another part of the same airgap) may increase in size i.e. the distance between two conductor branch elements may increase. Which airgaps / part of airgaps that increases and decreases is defined by the direction of the force applied and thereby in which direction in space the electrical conductor is moving.

[0265] Even though two or more branches or branch element are in contact or close to be in contact, there will be created no electric arc in that the potential on the branches / branch elements is the same

[0266] Hence, the plurality of airgaps of an electrical conductor of the present invention may change unequal (not uniformly) when a force is applied. The same is true for the deformation of the conductor branches / conductor branch elements.

[0267] Fig. 10a illustrated yet another embodiment of the invention which is very similar to the body segments 19 if the embodiment illustrated at fig. 6. From the closeup view of fig. 10b it is however noted that a plurality of conductor branch elements all denoted 5x-n is defining the outer peripheral of the middle segment 4. Further, even though it is hard to see, there is also a set of conductor branch elements defining the inner peripheral of the middle segment 4. Thus, the middle segment 4 comprises at least two axial layers of conductor branch elements. Axial layer should be understood as a set of conductor branches or conductor branch elements that is forming a circular middle segment 4.

[0268] As mentioned above, the space / airgaps 6b between the squared spiral conductor branches increases the flexibility of the rod of the electrical conductor branch 1. And the circular spiral form gives a flexibility in any direction for the end of the rod.

[0269] The embodiment illustrated in fig. 11 and 12 are further examples of a vast variety of electric conductors 1 within the scope of the invention. In the embodiment of fig. 11, conductor branches 5a-5c are formed as blades spaced by airgaps 6. Depending on where the airgaps are measured, they are either longitudinal 6b or transversal 6a. In this embodiment airgaps 6b are found both between elements of the same conductor branch and between (elements of) two conductor branches. Three blades are illustrated but according to requirements to flexibility etc. this number can be changed as can the width and thickness.

[0270] In fig. 12 a plurality of conductor branches 5a-5n are illustrated. Airgaps are found between elements of two different conductor branches.

[0271] Note that both the rod and the part of connected to the conductor branches of the middle segment may be denoted 3. This is to indicate that the rod may be seen as part of the second end segment 3 or as a separate part. Also, it should be mentioned, that no rod is required hence the electrical conductor 1 of the figures may end in the first and second end structures 2, 3.

[0272] Note that the electric conductor 1 may comprise one first conductor branch 5 that may branch off to a plurality of second conductor branches 5, each of these second conductor branches may further branch off to a plurality of third conductor branches 5 and so on through the middle segment of the electric conductor 1. In this way, following the direction of the current flow through the electric conductor 1 from a first end to a second end, current is allowed to flow in the first conductor branch, then allowed to divide into a flow in the second conductor branches and again allowed to divide into a flow in the third conductor branches and so on into additional nthconductor branches.

[0273] In an embodiment, if current is flowing from a first end segment to a second end segment, the first conductor branch may have a first cross-sectional area, the second conductor branches may have a second cross-sectional area which is smaller than the first cross-section area. Following, the third conductor branches may have a cross-sectional area smaller than the second cross-sectional area. Accordingly, the cross-sectional area of the conductor branches may be varied in size in the longitudinal direction of the middle segment.

[0274] As described above, the conductor branches of the electric conductor may branch off into a plurality of additional (nth) conductors. In the same way, the conductor branches may also converge from a higher number of conductor branches into a lower number of conductor branches.

[0275] It should be mentioned that a cross-sectional area of the middle segment at one distance from a first end segment may be the same as a cross-sectional area of the middle segment at a second distance from the first end segment while the number of conductor branches at the first distance is different from the number of conductor branches at the second distance.

[0276] Further, it should be mentioned that the cross-sectional area of the middle segment at the first and second distances from a first end segment may be different while the number of conductor branches may be the same. Of course, the cross- sectional area and the number of conductor branches may also be the same at the first and second distances from the first end segment.

[0277] The branching off may be in one plane. This plane may be of a tangent to the surface of an electrical conductor having a curved design. Further note that such branching off may either be at the within the fixed uniformity of the conductor and / or it may be from one conductor to another e.g. via a joint / fixing of two conductors.

[0278] It should be mentioned that embodiment of the electrical conductor may also include designs where the conductor branches branch off from the first end segment to a plurality of conductor branches and converge again into the second end segment without branching off between the first and second end segments.

[0279] According to the invention, the electrical conductor 1 may have any “printable” form / design. Above is described various such forms / designs, but the invention is not limited to these illustrated designs.

[0280] Hence, a non-illustrated design which is still within the scope of the present invention is a T-shaped electrical conductor 1. Such T-shaped conductor may extend between a point A and a point B between with a middle point M therebetween. The electrical conductor also comprises a part extending from the middle point M to a point C (and in theory a plurality of other points in space). It should be mentioned that the middle point M should just be between the points A and B thus the shape may also be close to an L-shape.

[0281] A middle segment may be provided in the line segment between A and M, B and M or between M and C or any combination thereof. Hence, such conductor may be designed to maintain its form between points A and B while a middle segment with conductor branch elements / conductor branches is positioned between points M and C. Thereby the line segment between point M and C is elastically deformable by applying a force to point C below the yield point.

[0282] Another non-illustrated embodiment within the scope of the present invention is an electrical conductor only comprising the middle segment. In such embodiment fastener holes / terminals may be comprised by the end of the middle segment i.e. by one or more conductor branches. In such embodiment, the end segments could be said to be the end of one or more of the conductor branches. More specifically, the end segment in such embodiment may be the part of the electrical conductor that is designed to connect and be fastened to another electrical component.

[0283] Another embodiment of the electrical conductor 1 within the scope of the invention has a conductor branch of which a first part has a first geometry in space and a second part has a second geometry in space. One non-limiting example of a conductor branch having first and second geometry in space is a conductor branch 5 that may be twisted e.g. 90 degrees so that before the twist a first part from a flat horizon geometry and after the twist the a second part form a flat vertical geometry.This is advantageous in that such conductor branch is flexible in one orientation in space along the first part and flexible in another orientation in space along the second part.

[0284] Another non-illustrated embodiment within the scope of the present invention is an electrical conductor that is designed to exploit any free space in the electric / mechanical layout of an electric system / panel. The conductor branches 5 of an electrical conductor 1 may branch off in one or more sub-conductor branches. In this way the electrical conductor 1 by approach a component branch off and go both ways around the component and meet again. Similarly, one or more conductor branches may form a loop around a core or through which another conductor branch / electric conductor may pass. I this way an inductor may be designed in any way allowed by the space available in the electric system.

[0285] Another non-illustrated embodiment within the scope of the present invention is an electric wire harness. Such wire harness may be an alternative to known wire harnesses made of traditional massive or threaded conductors or to printed circuit board traces. With such wire harness a plurality of electric components may be mutually connected with an electrical conductor of the invention manufactured according to the method of the invention. This is especially true if the method include connecting two conductor branches with a non-conducting material, allowing applying insulating material, etc.

[0286] Another non-illustrated embodiment within the scope of the present invention is an electrical conductor with the function of a connection part between two components such as two traditional massive busbars. As an alternative to known braided busbars, a conductor 1 may be produced by additive manufacturing with a design according to the present invention that is designed to a specific connection in terms of vibrations absorbance, footprint, etc. Hence, between electric panels traditional cables or busbars are used and when these are to be connected to components in the panels or branches off, this may be done by an electric conductor according to the present invention.

[0287] Another non-illustrated embodiment within the scope of the present invention is an electrical conductor with two or more deformation points. A deformation point may be a part of the conductor such as a middle point i.e. where deformation by design is determined. Alternatively, a deformation point may be a recess (or other weakening or strengthening designs) in a rod part of the electrical conductor where deformation (typically plastic) would happen if a force is applied. The force needed to deform at such recess may be predetermined and associate with the size of the recess. Further part of the electrical conductor may be strengthened to ensure that deformation of electrical conductor does not happen at the strengthened part. Further, e.g. around terminal holes 18, the electrical conductor may be strengthened to deform plastically to a predetermined level facilitating a desired electrical connection to another conductor or component. The force applied when mounting the electrical conductor e.g. via bolts may be determined by a torque wrench and referred to as a clamping force. An example of a conductor having more than one deformation point is illustrated in fig. 5.

[0288] As illustrated e.g. from a comparison of fig. 3 and 7 or 8, the extent of the middle segment 4 relative to the length of the electrical conductor 1 may vary. The middle segment 4 in these figures is found between the end segments 2, 3.

[0289] In fig. 4 the length of the end segments 2, 3 is substantially the same i.e. the distance from where the middle segment 4 is connected to the end segment 2, 3 and to the fastener holes 18 are more or less the same.

[0290] However, in the electrical conductor illustrated in fig. 8 the second end segment 3 to which the middle segment 4 is connected is much longer than the first end segment 2. As illustrated the second end segment continues in one conductor branch to the hole 23 and thereby the length of the second end segment 3 is several times longer than the length of the first end segment 2.

[0291] In this way, the middle segment may be positioned in the electrical conductor according to where it is desired to have the flexibility. Either towards one of the end segments or towards the middle of the electrical conductor.

[0292] As can also be understood from the above, the freedom of design and manufacturing of the middle segment 4 to obtain a desired flexibility is extremely large. With desired flexibility should be understood a directional flexibility of the electrical conductor. Again, with reference to fig. 7 and 8 the flexibility in these illustrated embodiments are designed to be “up and down”. However, if the illustrated middle segments were turned 90 degrees, the flexibility of the electrical conductors were then sideways.

[0293] Accordingly, the freedom of design implies that flexibility of the electrical conductor can be designed and via an additive manufacturing manufactured in any angle around the longitudinal axis of the electrical conductor by “turning the middle segment”.

[0294] Further, by design of the middle segment, the force needed to deform and thereby flex the electrical conductor can be determined. The middle segment of the electrical conductor illustrated in fig. 8 would most likely deform solely by the gravitational force acting on the long second end segment 3. In contrary, the middle segment of the electrical conductor illustrated in fig 3 would need a force to be applied to deform.

[0295] It is evident that the thinner conductor branch 5, the less force is needed to deform the electrical conductor 1 i.e. there is a relationship between stiffness of the conductor and conductor cross section. Further, there is a relationship between material and orientation which also influences the size of the force required to provide a stress sufficient to deform the electrical conductor. In fact, the mentioned (and other not mentioned) parameters may all influence a deformation force (force required to provide stress leading to deformation). This is true for both the electrical conductor as such and for the individual conductor branches and it is true both for the elastic and plastic deformation.

[0296] A flexible / deformable conductor is especially advantageous when the conductor is connected to sensitive electronic components in that force / vibrations is not conducted via the conductor to the sensitive electronic component.

[0297] A rigid conductor is especially advantageous when the electrical conductor 1 is used as a structural component of e.g. an electric system or panel or when to connect to other rigid parts of an electric system or panel.

[0298] The force needed to deform the middle segments of course depend on several factors including the dimensions of the conductor branches / conductor branch element, the length of the end segments, the material used, orientation of conductor branches, etc. An electrical conductor according to the present invention, is applicable to a large range of applications from very small (wirehamess like conductors) requiring a small force of maybe ION or lower to deform a particular part of an electrical conductor to very big applications, requiring a force of maybe 10A7N or higher to deform.

[0299] According to the present invention, deformation of the electrical conductor should be understood as alternation of form or shape of one or more conductor branches (and thereby conductor branch elements or parts hereof) comprised by the middle segment.

[0300] Such deformation lead to a change in geometry of the electrical conductor in space. An example of a change of geometry is a rotation of one end segment relative to the other, an increase or decrease of the relative distances between electrical branches and / or electrical conductor, a bend of the electrical conductor, etc.

[0301] As mentioned above one or more conductor branches 5 are mutually separated by one or more air spaces / free-spaces. Such air space may separate one or more conductor branches in a direction perpendicular to the longitudinal direction of said electrical conductor. Separating one conductor branch by an air space is possible if such conductor branch is shaped e.g. in a spiral, harmonica-like form, twisted, etc.

[0302] The separation of the conductor branches may be in a direction perpendicular to the longitudinal direction of said electrical conductor. Some conductor branches may be separated from several other conductor branches by a plurality of airgaps in different directions and some may only be separated from other branches in one direction.

[0303] Spacing the conductor branches is advantageous in that e.g. an air flow, or other media used for cooling, is able to pass through the airgaps and thus between conductor branches. Hence the free spaces / airgaps are establishing one or more cooling paths between conductor branches leading to an increased cooling efficiency of the electrical conductor of the present invention compared to known electrical conductors. The higher cooling efficiency i.e. the lower temperature of the conductor, the more current the electrical conductor is allowed to conducted.

[0304] In fact tests has indicated that a reduction of material used to produce an electrical conductor according to the present invention can be reduced by 80% to 95% and maybe even more in specific designs and with appropriate cooling.

[0305] The separation is advantageous in that it enables the electrical conductor to deform i.e. twist, bend and being compressed and / or stretched leading to easier mounting, vibration absorption and a reduction in transfer of tension from one component connected to the electrical conductor to another component connected to the electrical conductor. As an example hereof could be mentioned that the airgap define a distance between one or more conductor branches and the distance is configured to decrease or increased as consequence of an applied force. This is advantageous in that it has the effect, that when a force is applied the distance between two conductor branches can change (increase or decrease) thereby allowing the electrical conductor to deform.

[0306] The distance between conductor branches / branch elements i.e. the size of the airgaps 6b may vary between a few tenths of a millimeter and up to a few centimetres depending e.g. on size of current needed to be conducted, weight of the conductor, etc. In larger scale electrical systems, the airgaps may be between 30cm and 50cm.

[0307] In an embodiment, the invention relates to a high voltage conductor having a first and a second end 2, 3 connected to each other with a middle segment 4 comprising a plurality of conductor branches 5. The two ends 2, 3 may each have connection parts15 via which the high voltage conductor is connectable to other electric components. The high voltage conductor is manufactured by additive manufacturing.

[0308] High voltage is voltages between 48V and 700V, such as 1000V or 1500V, preferably between 48V and lOkV, most preferably between 48V and lOOOkV. High voltage may be either AC or DC such as HVDC (High voltage DC).

[0309] In an embodiment, the invention relates to a method of bending an electrical conductor having a first and a second end 2, 3 connected to each other with a middle segment 4 comprising a plurality of conductor branches 5. The two ends 2, 3 may each have connection parts 15 via which the high voltage conductor is connectable to other electric components. The force used to bend the electrical conductor is providing a stress in the material of which the electrical conductor is made which is above the yield point of the material and this force is applied by hand. By hand should be understood as applied by a work person who e.g. is mounting the electrical conductor in an electrical panel or a work person packing and shipping the electrical conductor. This electrical conductor may be manufactured by additive manufacturing.

[0310] In an embodiment, the invention relates to an electrical conductor comprising: a first end segment (2) and a second end segment (3) spaced apart by a middle segment (4), wherein said middle segment (4) comprising a plurality of conductor branches (5a, . . ., 5n), wherein said plurality of conductor branches (5a, . . ., 5n) are made of electric conductive material, wherein at least part of at least two of said plurality of conductor branches (5a, . . ., 5n) are spaced apart by an airgap (6). The middle segment may space the first and second end segments (2, 3) in a longitudinal direction of said electrical conductor (1). The airgap may be in a longitudinal direction (9) of said electrical conductor (1).

[0311] In an embodiment, the invention relates to an electrical conductor (1) comprising: a first end segment (2) and a second end segment (3) spaced apart by a middle segment (4), wherein said middle segment (4) comprising one conductor branch (5), wherein said conductor branch (5) is made of electric conductive material, and wherein at least two parts of said conductor branch (5) are spaced apart by anairgap (6). The middle segment may space the first and second end segments (2, 3) in a longitudinal direction of said electrical conductor (1). The airgap may be in a longitudinal direction (9) of said electrical conductor (1). The conductor branch (5) may comprise a plurality of conductor branch elements (5x-n) and it may be two of these conductor branch elements that are spaced apart by the airgap (6)

[0312] In a specific embodiment, the invention further include an electrical conductor (1) for an electrical installation, the electrical conductor comprising: a first end segment (2); a second end segment (3); and a middle segment (4) formed by a plurality of conductor branches (5a-5n) which electrically couples and mechanically couples the first end segment (2) and the second end segment (3), wherein the first end segment (2) and conductor branches of the plurality of conductor branches (5a-5d) are monolithically united by connections thus shaping interior corners (6) between the first end segment (2) and conductor branches (5) of the plurality of conductor branches (5) and spatially separating conductor branches (5) of the plurality of conductor branches (5) in two different transversal directions (8a, 8b).

[0313] In the specific embodiment, the plurality of conductor branches (5) are mutually twisted without physical contact between the individual conductor branches in the longitudinal direction of the middle segment (4).

[0314] In the specific embodiment, the electric conductor (1) comprises a cooling structure extending from the longitudinal direction of the middle section (4).

[0315] In the specific embodiment, the electric conductor (1) comprises a plurality of cooling structures spaced apart with a distance facilitating the mounting of a ferrite core between two cooling structures.

[0316] In the specific embodiment, the cooling structures extends further away from the electric conductor (1) than the ferrite core.

[0317] In the specific embodiment, two conductor branches of the plurality of conductor branches are mechanically coupled and electrically coupled by a transversal branch outgrowth.

[0318] In the specific embodiment, the middle segment is a first middle segment, wherein the electrical conductor further comprises a second middle segment formed by a second plurality of conductor branches which also electrically couples and mechanically couples the first end segment and the second end segment,

[0319] In the specific embodiment, the second end segment and conductor branches of the second plurality of conductor branches are monolithically united by rounded connections thus shaping concavely rounded interior corners between the second end segment and conductor branches of the second plurality of conductor branches and spatially separating conductor branches of said second plurality of conductor branches in the different transversal directions.

[0320] In the specific embodiment, the electrical conductor is at least partly manufactured by an additive manufacturing process.

[0321] In the specific embodiment, electric conductor (1) comprises two or more central body segments, wherein the geometry of the conductor parts connected to the same central body segment are different.

[0322] In the specific embodiment, electric conductor (1) comprises two central body segments connected with an inductor part.

[0323] In the specific embodiment, a ferrite core is connected through the inductor part.

[0324] In the specific embodiment, a branch diameter of a conductor branch of said plurality of conductor branches is less than 3 cm, for example less than 2.5 cm, for example less than 2 cm, such as less than 1.5 cm.

[0325] In the specific embodiment, a conductor branch of the plurality of conductor branches has a rounded connection shaping one or more concavely rounded interior corners having a corner radius of at least 0.2 branch diameters of that conductor branch, for example at least 0.3 branch diameters, for example at least 0.5 branch diameters, for example at least 0.8 branch diameters, such as at least 1.2 branch diameters.

[0326] In the specific embodiment, a conductor branch of two neighbouring conductor branches of the plurality of conductor branches has a rounded connection shaping one or more concavely rounded interior comers having a corner radius of at least 0.05 neighbour spacings of said two neighbouring conductor branches, for example at least 0.1 neighbour spacings, for example at least 0.2 neighbour spacings, for example at least 0.3 neighbour spacings, such as at least 0.4 neighbour spacings.

[0327] In the specific embodiment, electrical conductor has a resonance vibration frequency associated with relative motion between said first end segment and said second end segment, wherein the resonance vibration frequency is at most 300 Hz, for example at most 150 Hz, for example at most 70 Hz, for example at most 30 Hz, for example at most 20 Hz or is at least 300 Hz, for example at least 500 Hz, for example at least 1 kHz, such as at least 5 kHz.

[0328] In the specific embodiment, electrical conductor comprises an inner bulk structure, and an outer surface structure, wherein the inner bulk structure and the outer surface structure have different material compositions.

[0329] In the specific embodiment, electric conductor (1) comprises a first part having a first outer diameter and a second part, having a second outer diameter, wherein said first diameter is larger than said second diameter.

[0330] In a specific embodiment, the invention include a method for coupling a first end segment of an electrical conductor to a second end segment of the electrical conductor within an electrical installation, the method comprising the steps of monolithically uniting the first end segment and conductor branches of a plurality of conductor branches via connections to shape interior corners between the first end segment and conductor branches of the plurality of conductor branches and to spatially separate conductor branches of the plurality of conductor branches in two different directions, and electrically coupling and mechanically coupling the first end segment and the second end segment via a middle segment of the electrical conductor formed by the plurality of conductor branches.

[0331] In the method of the specific embodiment, the electric installation is comprised by a renewable energy facility.

[0332] In the method of the specific embodiment, the method comprises a step of establishing a digital representation of said electrical conductor.

[0333] In the method of the specific embodiment, the method comprises a step of performing digital geometry optimization of the digital representation of the electrical conductor to at least partially form said plurality of conductor branches.

[0334] In the method of the specific embodiment, the method comprises a step of additively manufacturing the electrical conductor based on the digital representation of the electrical conductor.

[0335] In the method of the specific embodiment, step of additively manufacturing the electrical conductor comprises selective laser melting.

[0336] In the method of the specific embodiment, the step of additively manufacturing said electrical conductor comprises wire arc additive manufacturing.

[0337] From the above it is clear that the invention relates to a flexible electrical conductor such as a busbar. Especially the busbar of the present invention is relevant when used in an electric panel and most conductors in a renewable energy generating plant such as a wind turbine. This is because of its flexible nature (airgaps inherent in the design of the electrical conductor) which is caused by the ability of the conductor branch / conductor branch elements of the electrical conductor to deform and thereby change chape of the electrical conductor. Because the electrical conductor is designed with conductor branch(es) / conductor branch elements spaced apart by airgaps the electrical conductor is able to carry a high current while at the same time being able to change geometry (change form in space).

[0338] The electrical conductor is able to carry a high current in that it comprises a plurality of conductor branches / conductor branch elements. Because it is designed with airgaps between these branches, the weight of the electrical conductor is reduced compared to known electrical conductor designs carrying the same current. Further,because of the ability to deform and the airgaps, the electrical conductor according to the present invention is able to absorb vibrations and enhanced cooling is also achieved.

[0339] Finally, the reason why it is possible to equip an electrical conductor with such properties is that it is designed by a computer program either automatic based on relevant input or manually designed and that the result of this design is possible to produce / manufacture by an additive manufacturing process.

[0340] The invention has been exemplified above with the purpose of illustration rather than limitation with reference to specific examples of methods and designs. Details such as a specific method and structures have been provided in order to understand embodiments of the invention. Note that detailed descriptions of well- known systems, devices, circuits, and methods have been omitted so as to not obscure the description of the invention with unnecessary details.List1. Electrical conductor2. First end segment3. Second end segment4. Middle section5. Conductor branch x. Conductor branch1.Conductor branch element6. Airgap7. Not used8. Transversal directions9. Longitudinal direction10. Shortest distance between first end segment and second end segment.11. Intersection point12. Web-like structure13. Terminals14. Not used15. Connection part16. Not used17. Not used18. Fastener hole19. Central body segment20. Inductor part21. Additional electric component22. Bolt23. Core

Claims

Patent claims1. An electrical conductor (1) comprising: a first end segment (2) and a second end segment (3) spaced apart by a middle segment (4) in a longitudinal direction of said electrical conductor (1), wherein said middle segment (4) comprising a plurality of conductor branch elements (5x-n), wherein said plurality of conductor branch elements ( 5x-n) are made of electric conductive material, wherein at least part of at least two of said plurality of conductor branch elements (5x- n) are spaced apart by an airgap (6) in a longitudinal direction (9) of said electrical conductor (1).

2. An electrical conductor (1) according to claim 1, wherein said plurality of conductor branch elements (5x-n) are formed by one conductor branch (5).

3. An electrical conductor (1) according to claim 1, wherein said plurality of conductor branch elements (5x-n) are formed by two or more conductor branches (5).

4. An electrical conductor (1) according to any of the preceding claims, wherein said electrical conductor (1) is monolithic.

5. An electrical conductor (1) according to any of the preceding claims, wherein said electrical conductor (1) is at least partly manufactured by an additive manufacturing process.

6. An electrical conductor (1) according to any of the preceding claims, wherein said airgap (6) is defined by a distance, wherein said distance is the shortest distance between a conductor branch element of a first conductor branch and a conductor branch element of a second conductor branch in the longitudinal direction (9) of said electrical conductor (1).

7. An electrical conductor (1) according to any of the preceding claims, wherein said airgap (6) is defined by a distance, wherein said distance is the shortest distance between two conductor branch elements of one conductor branch in the longitudinal direction (9) of said electrical conductor (1).

8. An electrical conductor (1) according to any of the preceding claims, wherein said airgap (6) is below 1cm, preferably below 0,5cm, most preferably below 0.25cm.

9. An electrical conductor (1) according to any of the preceding claims, wherein said airgap (6) is below 20cm, preferably below 15cm, most preferably below 10cm.

10. An electrical conductor (1) according to any of the preceding claims, wherein said airgap is between 0,01cm and 40cm.

11. An electrical conductor (1) according to any of the preceding claims, wherein said airgap (6) is configured to change geometry as consequence of a force applied to said electrical conductor (1).

12. An electrical conductor (1) according to claim 11, wherein said airgap (6) geometry is configured to change by deformation of said at least two of said plurality of conductor branch elements (5x-n).

13. An electrical conductor (1) according to any of the preceding claims, wherein a plurality of airgaps (6) is established between said plurality of conductor branch elements (5x-n) in the longitudinal direction (9) of said electrical conductor (1).

14. An electrical conductor (1) according to any of the preceding claims, wherein said plurality of conductor branch elements (5x-n) is configured to deform so as to change geometry of one subset of said plurality of airgaps (6) differently from a second subset of said plurality of airgaps (6).

15. An electrical conductor (1) according claim 3-14, wherein said airgap (6) is extending between said at least two conductor branches (5) and separates said at least two conductor branches (5) in the longitudinal direction (9) of said conductor branch (5) between said first end segment (2) and said second end segment (3).

16. An electrical conductor (1) according to any of the preceding claims, wherein at least two of said plurality conductor branch elements (5x-n) meet in an intersection point (11) and wherein at least two conductor branch elements (5x-n) branches off from said intersection point (11).

17. An electrical conductor (1) according to any of the preceding claims 1-15, wherein at least one of said plurality conductor branch elements (5x-n) branches off from an intersection point (11) into at least two conductor branch elements (5x-n).

18. An electrical conductor (1) according to any of the preceding claims, wherein said plurality of conductor branch elements (5x-n) forming a plurality of airgaps (6) are implemented as a web-like structure (12).

19. An electrical conductor (1) according to any of the preceding claims, wherein said plurality of conductor branch elements (5x-n) forming a plurality of airgaps (6) are implemented as a bionic structure.

20. An electrical conductor (1) according to any of the preceding claims, wherein said airgap (6) is an axial airgap (6).

21. An electrical conductor (1) according to any of the preceding claims, wherein said airgap (6) separate said at least two conductor branch elements (5x-n) in a transversal direction of said electrical conductor (1).

22. An electrical conductor (1) according to any of the preceding claims, wherein at least one of said first end segment (2) and said second end segment (3) is terminating in a connection part (15).

23. An electrical conductor (1) according to claim 22, wherein said connection part (15) is a fastener hole (18).

24. An electrical conductor (1) according to any of the preceding claims, wherein at least one of said plurality of conductor branch elements (5x-n) is longer than the shortest distance (10) between said first and second end segments (2, 3),and wherein said electrical conductor (1) is configured to change geometry by a deformation of said one or more conductor branch elements (5x-n).

25. An electrical conductor (1) according to any of the preceding claims, and wherein said plurality of conductor branch elements (5x-n) are implemented as one or more conductor branches (5) and wherein one of said one or more conductor branches (5) is longer than the shortest distance (10) between said first and second end segments (2, 3), and wherein said electrical conductor (1) is configured to change geometry by a deformation of said one or more conductor branches (5).

26. An electrical conductor (1) according to claim 24 or 25, wherein said deformation is an elastic deformation.

27. An electrical conductor (1) according to claim 26, wherein said electrical conductor (1) is configured to elastically deform when a force is applied to said electrical conductor (1), wherein said force generates a stress within the electrical conductor which is less than the yield point of the material of the electrical conductor (1).

28. An electrical conductor (1) according to claim 27, wherein said force is below 400N29. An electrical conductor (1) according to claim 24 or 25, wherein said deformation is a plastic deformation.

30. An electrical conductor (1) according to claim 29, wherein said electrical conductor (1) is configured to plastically deform when a force is applied to said electrical conductor (1), wherein said force results in stresses above the yield point of the material of the electrical conductor (1).

31. An electrical conductor (1) according to any of the previous claims 25-30, wherein at least one of said one or more conductor branches (5) is designed with a geometry comprising a plurality of airgaps, wherein said plurality of airgaps decrease non- uniformly as consequence of a force applied to said at least one of said one or more conductor branches (5).

32. An electrical conductor (1) according to any of the previous claims 25-31, wherein said electrical conductor (1) is configured to reshape to its original geometry as consequence of removal of an applied force.

33. An electrical conductor (1) according to any of previous claims 25-32, wherein each of said one or more conductor branches (5) are interrupted by one or more of said airgaps (6) in a cross-sectional view (7) of said electrical conductor (1) in its longitudinal direction (9).

34. An electrical conductor (1) according to claim 33, wherein said cross sectional view (7) is parallel to the longitudinal axis of said electrical conductor (1).

35. An electrical conductor (1) according to any of the preceding claims, wherein said electrical conductor (1) comprises a fist deformation point and a second deformation point, wherein said electrical conductor (1) is configured to deform in said first deformation point when exposed to a first force and wherein said electrical conductor is configured to deform in said second deformation point when exposed to a second force, wherein said first and second forces are not identical.

36. An electrical conductor (1) according to any of the previous claims 25-35, wherein the cross-sectional areas of said one or more conductor branches (5) are identical.

37. An electrical conductor (1) according to any of the previous claims 25-36, wherein the cross-sectional areas of said one or more conductor branches (5) are equal to or below 200mm2, preferably below 150 mm2, preferably below 100mm2, preferably below 50 mm2, preferably below 10 mm2, most preferably between 0,5 mm2and 5 mm2.

38. An electrical conductor (1) according to any of the previous claims 25-37, wherein at least one of said one or more conductor branches (5) are of a different length that other of said one or more conductor branches (5).

39. An electrical conductor (1) according to any of the previous claims 25-38, wherein a first part (5a-l, 5b-l, . . .) of at least one of said one or more conductor branches (5)has a first geometry in space and a second part (5a-2, 5b-2, . . .) of said at least one of said one or more conductor branches (5) has a second geometry in space.

40. An electrical conductor (1) according to any of the previous claims 25-39, wherein said first end segment (2) is configured to be displaced in any direction compared to said second end segment (3) without plastic deforming said electrical conductor (1) material.

41. An electrical conductor (1) according to any of the previous claims 25-40, wherein said second end segment (3) is configured to be displaced in any direction compared to said first end segment (2) without plastic deforming said electrical conductor (1) material.

42. An electrical conductor (1) according to any of the preceding claims, wherein said one or more conductor branches of the plurality of conductor branches have an internal cooling channel.

43. An electrical conductor (1) according to any of the previous claims, wherein at least one of said first end segment (2) and said second end segment (3) is monolithically joined with a connection parts (15).

44. An electrical conductor (1) according to any of the previous claims, wherein said terminals (8) are fastener holes (18).

45. An electrical conductor (1) according to any of the previous claims 43-44, wherein said terminals are connecting pins.

46. An electrical conductor (1) according to any of the previous claims, wherein said electrical conductor (1) comprises one first end segment (2) and a plurality of second end segments.

47. An electrical conductor (1) according to any of the preceding claims, wherein all of said one or more conductor branches (5) are the same length.

48. An electrical conductor (1) according to any of the previous claims 25-47, wherein said one or more conductor branches (5) are having a coiled structure.

49. An electrical conductor (1) according to any of the previous claims 25-48, wherein said one or more conductor branches (5) are having a coiled coil structure.

50. An electrical conductor (1) according to any of the previous claims 25-49, wherein said one or more conductor branches (5) are having a one or more waveform structure.

51. An electrical conductor (1) according to any of the previous claims 25-50, wherein said one or more conductor branches (5) are having a honeycomb structure.

52. An electrical conductor (1) according to any of the previous claims 25-51, wherein said one or more conductor branches (5) are having twisted structure.

53. An electrical conductor (1) according to any of the preceding claims, wherein said twisted structure comprise uniform airgaps (6)54. An electrical conductor (1) according to any of the previous claims 25-53, wherein said one or more conductor branches (5) are individually connected to both said first end segment (2) and said second end segment (3).

55. An electrical conductor (1) according to any of the previous claims 25-54, wherein said one or more conductor branches (5) are located in the periphery of either said first end segment (2) and / or said second end segment (3).

56. An electrical conductor (1) according to any of the previous claims, wherein said first end segment (2) is configured to be displaced in a longitudinal direction compared to said second end segment (3).

57. An electrical conductor (1) according to any of the previous claims, wherein said first end (2) is configured to be displaced in a transverse direction compared to said second end (3).

58. An electrical conductor (1) according to any of the previous claims, wherein said first end segment (2) and second end segment (3) are configured to rotate around the centre axis of the electrical conductor (1).

59. An electrical conductor (1) according to any of the previous claims, wherein either said first end segment (2) or said second end segment (3) is fixed to a component comprised by an electrical panel.

60. A method of manufacturing an electrical conductor (1) according to any of the preceding claims, wherein said method of manufacturing is an additive manufacturing process.

61. A method for coupling a first end segment (2) of an electrical conductor (1) to a second end segment (3) of said electrical conductor, the method comprising the steps of: monolithically uniting the first end segment (2) and a conductor branch element (5x-n) of one or more of conductor branches (5) via an additive manufacturing process, manufacturing said one or more conductor branches (5) via said additive manufacturing process so as to establish airgaps (6) between two or more conductor branch elements (5x-n) of said one or more conductor branches (5), so as to spatially separate said one or more conductor branch elements in two different directions, and electrically coupling and mechanically coupling said first end segment and said second end segment via a middle segment (4) of the electrical conductor formed by said one or more conductor branches (5).

62. A method according to claim 61, wherein said airgap (6) separates said two or more conductor branch elements (5x-n) in the longitudinal direction (9) of said electrical conductor (1).

63. A method according to any of claims 61 and 62, wherein said two different directions is a first transversal direction (8a) and a second transversal direction (8b) of said electrical conductor (1).

64. A method according to any of claims 61 - 63, wherein said electrically coupling and mechanically coupling achieved by said additive manufacturing process.

65. A method according to any of claims 61 - 64, wherein said method include a step of applying an isolation material to said plurality of conductor branches (5).

66. A method according to any of claims 61 - 65, wherein said additive manufacturing process include a step of applying an isolation material to said plurality of conductor branches (5).

67. Use of an electrical conductor (1) according to any of the preceding claims 1-59, in an electric system.

68. Use of additive manufacturing for at least partly manufacturing an electrical conductor (1) according to any of claims 1-59.

69. An electric panel comprising an electrical conductor (1) according to any of the preceding claims 1-59.

70. An electric panel according to claim 69, wherein said electric panel is comprised by a renewable power generating system.

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