Electrical conductors for electrical installations in renewable energy facilities

Abstract

The present invention relates to an electrical conductor for electrical equipment, the electrical conductor comprising: a first end segment; a second end segment; and an intermediate segment. The intermediate segment is formed by a plurality of conductor branches electrically and mechanically coupling the first end segment and the second end segment. The first end segment and the conductor branches of the plurality of conductor branches are monolithically integrated by a joint, thus forming a concave corner between the first end segment and the conductor branches of the plurality of conductor branches, and spatially separating the conductor branches of the plurality of conductor branches in two different transverse directions.

Description

[Technical field]

[0001] The present invention relates to an electrical conductor for electrical installations, for example in renewable energy facilities. The present invention further relates to a method for joining end segments of such an electrical conductor. [Background technology]

[0002] Renewable energy facilities play a crucial role in the transition to environmentally sustainable energy production, a transition that is being urgently sought around the world due to the dire prospects of climate change.

[0003] Renewable energy facilities typically rely on energy sources provided directly by the natural environment and may be subject to strong vibrations and extreme weather conditions. One example is a solar power plant, which is exposed to external weather conditions, potentially including extreme heat and cold, all year round. Another example is a wind turbine, which involves extreme forces.

[0004] One complicating factor is the presence of high currents and / or voltages within renewable facilities that must simultaneously contend with weather and vibrations.

[0005] Weather, vibration and power conditions in general tend to place increased demands on the equipment and components to be used within a renewable energy facility.

[0006] Thus, there is a need for inexpensive equipment and components that can tolerate the conditions of renewable energy facilities. Summary of the Invention [Problem to be solved by the invention]

[0007] The inventors have identified the above-mentioned problems and issues associated with renewable facility components and have subsequently made the invention described below that can improve such components.

[0008] One aspect of the invention is an electrical conductor for electrical equipment comprising: a first end segment; a second end segment; an intermediate segment formed by a plurality of conductor branches electrically and mechanically coupling the first end segment and the second end segment; A conductor comprising: the first end segment and a conductor branch of the plurality of conductor branches are monolithically integrated by a coupling, thereby forming an internal corner between the first end segment and a conductor branch of the plurality of conductor branches, and spatially separating the conductor branches of the plurality of conductor branches in two different transverse directions. Concerning electrical conductors.

[0009] In one embodiment of the invention, the electrical conductor is configured to be installed in an electrical panel in a renewable energy facility.

[0010] In one embodiment of the invention, the inside corner is formed as a concavely rounded inside corner.

[0011] As noted below, the conductor branches may "grow" from the end segments substantially perpendicular to the transverse direction of the end segments, however, to increase the structural strength of the conductor, the end segments and the conductor branches are monolithically integrated by rounded joints, thus forming concave rounded internal corners between the end segments and the conductor branches.

[0012] Electrical conductors according to the present invention may be advantageously used to promote vibration damping in electrical equipment, for example. In particular, by having an electrical conductor in which end segments are electrically and mechanically coupled by multiple conductor branches via rounded joints that monolithically integrate the conductor branches spatially separated in two different transverse directions, the electrical conductor may advantageously have the ability to improve vibration damping in either transverse direction while potentially minimizing the risk of structural damage.

[0013] Furthermore, spatial separation of the conductor branches in the two transverse directions can advantageously allow for improved heat dissipation while potentially minimizing the risk of structural damage as mentioned above.

[0014] Large currents and fluctuating weather conditions can result in wide temperature ranges in renewable energy facilities. By monolithically integrating multiple conductor branches to the first end segment with rounded connections and distributing in two transverse directions, the conductor may advantageously be better able to tolerate thermal expansion under such conditions.

[0015] The so-called skin effect is the tendency of AC current to flow primarily near the surface of a conductor. This effect can introduce additional AC resistivity into the conductor. Having multiple conductor branches can potentially increase the surface area, at least locally in the mid-segment, and thus advantageously reduce AC resistivity. At the same time, the rounded monolithic joint can advantageously facilitate the formation of multiple conductor branches in the mid-segment while minimizing conduction losses that might otherwise occur at sharp corners and / or interfaces.

[0016] Furthermore, by spatially separating the conductor branches, interference that would otherwise be generated by the arrangement of conductors is advantageously reduced. The spatial separation between the conductor branches allows visual access to components and elements located behind the conductors. Furthermore, wires or load-bearing structures can be guided through the spatial separation. Furthermore, the spatial separation may allow tools, such as a screwdriver, to be applied to components behind the electrical elements. If it is intended to guide tools or components through the spatial separation, at least some of the branches may optionally be electrically isolated by electrical insulation. The reduction of conductor interference further advantageously allows easier installation.

[0017] Moreover, the multiple conductor branches monolithically integrated with the first end segment by the rounded joints advantageously guarantee the possibility of material savings without substantially increasing the risk of structural damage due to stress concentrations at the corners. For example, material savings can be considered compared to conventional conductors having a rod or super-cuboid shape without any intermediate segments formed by multiple branches with spatial separation. By saving material, the conductors can be less expensive to manufacture and at the same time have less impact on the environment.

[0018] It should be noted that reducing the weight and amount of material for components such as electrical conductors that have requirements for vibration damping, susceptibility to structural damage, and / or current carrying capacity is extremely difficult. Simply removing material may not be feasible as it may reduce the conductor's capacity below its requirements for a given application, e.g., a particular electrical installation in a particular renewable energy facility. Thus, the potential for saving / removing material may be evaluated in combination with minimal reduction, maintenance, or even improvement of other attributes of the conductor.

[0019] An electrical conductor may be understood as an object or element that facilitates the flow of electric charge. An example of an electrical conductor is a busbar. Another example of an electrical conductor is a cable or wire arrangement. Busbars may be used, for example, to connect high voltage and / or high current devices or terminals in an electrical converter installation inside a wind turbine. Typically, the material of the electrical conductor is a metal, such as silver, copper, gold, aluminum, one or more other metals, or any combination thereof.

[0020] The electrical conductors may be installed / integrated in, for example, electrical equipment in the renewable energy facility. An example of electrical equipment is a converter, such as an AC-DC converter, a DC-AC converter, an AC-AC converter, or a DC-DC converter. Such converters are often crucial for proper and reliable conversion of electrical power from one side to another, for example between the renewable energy facility and the power grid. Other examples of electrical equipment are uninterruptible power supplies (UPS), power supplies, switch modules, and electrical equipment in general that is provided in electrical cabinets.

[0021] Examples of renewable energy facilities include renewable energy power plants, such as wind turbines, solar power plants, hydroelectric power plants, bioenergy power plants, and geothermal energy power plants. Other examples of renewable energy facilities include power storage facilities, such as battery-based power storage facilities, and power-to-x facilities, such as electrolysis facilities.

[0022] A first end segment and a second end segment of a conductor may be understood as two ends of the conductor that are distal to one another. Thus, the conductor may be used to electrically and mechanically couple otherwise uncoupled electrical terminals / connectors, for example, by coupling the first end segment to one terminal / connector and the second end segment to the other terminal / connector.

[0023] An intermediate segment may be understood as a segment that electrically and mechanically couples the first and second end segments. In some embodiments, it is contemplated that the intermediate segment does not necessarily have to be in direct contact with both end segments. For example, the intermediate segment may simply be monolithically integrated with the first end segment, while a fourth segment may be positioned between the second end segment and the intermediate segment.

[0024] It should be noted that embodiments of the present invention are not limited to having only two end segments. Some electrical conductors may function as distribution conductors that supply / distribute current and / or voltage to several electrical terminals and / or circuits. Such electrical conductors may have more than two end segments. Additionally, embodiments of the present invention may have multiple distinct intermediate segments. Thus, embodiments of the present invention may include more than just two end segments and one intermediate segment, such as a fourth segment positioned between the second end segment and the intermediate segment.

[0025] A conductor branch may be understood as an elongated protrusion for facilitating charge flow and damping vibrations (typically in combination with other conductor branches). In some embodiments, each conductor branch has the shape of a cylindrical rod (except for its connection with the first end segment, which is rounded by its connection to the end segment). In other embodiments, the conductor branches have a more irregular shape, for example similar to the branches of a tree. A conductor branch may branch into two, or even three or more diverging conductor branch arms. Such diverging conductor branch arms can be connected to other conductor branches.

[0026] The first end segment and the conductor branch may be understood as being monolithically integrated as the conductor branch and the first end segment being composed of a single unit, part or piece. For example, the conductor branch may be integrated with the first end segment without any seam or joint. There are several manufacturing methods to achieve such monolithic integration, such as casting the conductor branch and the first end segment as a single part, machining the conductor branch and the first end segment from a single piece of bulk material (e.g. milling via a CNC machine), or additively manufacturing the conductor branch and the first end segment. As an example, when casting, lost core injection molding and / or molding with side action / side pull may be utilized to manufacture complex conductor branch shapes. However, it should be noted that the present invention is not limited to these exemplary methods. Furthermore, it should be noted that the entire first end segment and the entire intermediate segment are not limited to being monolithic, but at least some of the conductor branches must be monolithically integrated with the first end segment.

[0027] According to an embodiment of the present invention, the conductor branch is monolithically integrated with the first end segment by a rounded junction, thus forming a concavely rounded inside corner between the first end segment and the conductor branch. Such a rounded junction may alternatively be referred to as a fillet. And, the conductor branch with a fillet may be referred to as a conductor branch with a fillet. Due to the concavely rounded inside corner, the width of the conductor branch (including the rounded corner) is typically greater at its junction with the first end segment than away from its junction with the first end segment.

[0028] The presence of concavely rounded internal corners between the first end segment and the conductor branches can provide some spatial separation in the transverse direction for at least some of the conductor branches, in embodiments of the invention, at least two conductor branches are spatially separated in one transverse direction and at least two branches are spatially separated in another transverse direction.

[0029] The transverse direction may be substantially transverse or substantially orthogonal to the orientation of the majority of the conductor branches, and / or it may be substantially transverse or substantially orthogonal to the longitudinal direction, and / or it may be substantially transverse or substantially orthogonal to the direction of the electrical and / or mechanical coupling between the first and second end segments.

[0030] In general, when referring to a conductor branch of the plurality of conductor branches, such reference does not necessarily mean all conductor branches of the plurality of conductor branches, but may mean only a subset of the plurality of conductor branches (e.g., at least two conductor branches).

[0031] In an embodiment of the invention, the plurality of conductor branches are monolithically integrated through the first end segment and through the second end segment.

[0032] In an embodiment of the invention, the second end segment and a conductor branch of the plurality of conductor branches are monolithically integrated by a rounded connection, thus forming a concavely rounded internal corner between the second end segment and a conductor branch of the plurality of conductor branches, and spatially separating the conductor branches of the plurality of conductor branches in the two different transverse directions.

[0033] The rounded connection between the second end segment and a conductor branch of the plurality of conductor branches may have similar properties and characteristics as the rounded connection between the first end segment and a conductor branch of the plurality of conductor branches. In addition to having a rounded connection between the first end segment and a conductor branch of the plurality of conductor branches, having a rounded connection between the second end segment and a conductor branch of the plurality of conductor branches may further improve the conductor, for example, for reasons similar to the way that having a rounded connection between the first end segment and a conductor branch of the plurality of conductor branches may improve the conductor.

[0034] In an embodiment of the invention, the plurality of conductor branches form a web structure between the first end segment and the second end segment.

[0035] In an embodiment of the invention, the first end segment and the second end segment are at least partially formed as a web structure.

[0036] This is advantageous in that weight is reduced and heat dissipation is enhanced. To ensure sufficient structural strength in the terminal, the portion of the end segment that contains the terminal is typically manufactured in a solid form. This portion may be limited to a small portion surrounding the terminal, for example surrounding a hole through the end segment.

[0037] In an embodiment of the invention, the multiple conductor branches are twisted together with no physical contact between the individual conductor branches along the length of the intermediate segment.

[0038] While the conductor branches are both electrically and mechanically coupled at the end segments, along the length of the mid-segment, in this embodiment there is no electrical or mechanical coupling between the individual conductor sections, in other words, the conductor branches are not twisted or coupled (either electrically or mechanically).

[0039] The intertwisted conductor design can benefit from one or more of the following advantages: reduced AC losses in the high frequency windings, increased efficiency, reduced skin effect, minimal eddy current losses, lower operating temperatures, reduced footprint and substantial weight savings in the end product.

[0040] A stranded conductor design is advantageous in that such a design allows for tolerances to be obtained both longitudinally, side by side, and in the axis.

[0041] In an embodiment of the invention, the electrical conductor includes a cooling structure extending longitudinally from the middle section.

[0042] The cooling structure may extend from the conductor in a direction substantially perpendicular to the longitudinal direction of the intermediate section. The cooling structure may be designed as a web or the like having a high heat dissipation capacity. The cooling structure may include air guide fins that force a portion of the air flow through the cooling structure.

[0043] In an embodiment of the invention, the electrical conductor includes a plurality of cooling structures spaced apart a distance that facilitates assembly of a ferrite core between two cooling structures.

[0044] Isolating the ferrite core with a cooling structure is advantageous in that it has the effect of holding the ferrite core in place whilst still allowing the electrical conductors to dissipate heat through the cooling structure.

[0045] In an embodiment of the invention, the cooling structure extends farther from the electrical conductor than the ferrite core.

[0046] Having the cooling structure extend from the conductor longer than the ferrite core is advantageous in that the cooling structure is in contact with the airflow used for cooling, and therefore it is still possible to cool the conductor even though it is encapsulated within the ferrite core.

[0047] In an embodiment of the invention, one or more of the plurality of conductor branches has an internal cooling channel.

[0048] The internal cooling channel may further be fluidly coupled to the external environment through the cooling channel that opens into the first end segment and / or the cooling channel that opens into the second end segment.

[0049] The internal cooling channels can advantageously facilitate and improve the cooling of the electrical conductors, in particular the conductor branches. Moreover, the cooling channels may advantageously allow for further reduction in material.

[0050] The internal cooling channels may facilitate air and / or liquid cooling, and in either case may be coupled to a flow generating means, such as a pump or fan, to generate fluid flow within the channels.

[0051] Additionally, the internal cooling channels may facilitate transport of cooling fluid between components, such as components of electrical equipment. For example, fluid may need to be transported from a fluid pump to a processor requiring cooling fluid, and integrating the cooling channels within the conductor branches may advantageously obviate the need for separate fluid conduits within the electrical equipment to transport the fluid therefrom.

[0052] The cooling channels also advantageously allow for less material to be used to manufacture the electrical conductors.

[0053] In some embodiments, only one conductor branch has a cooling channel, in some embodiments, multiple conductor branches have a cooling channel, and in some embodiments, all conductor branches have a cooling channel.

[0054] Generally, the inlets and outlets of the internal cooling channels can be located anywhere in any of the end segments, and even within the conductor branches. The inlets and outlets may optionally include electrical insulation to provide galvanic isolation between the bulk of the conductor and the cooling pipes attached to it.

[0055] In an embodiment of the invention, two of the plurality of conductor branches are mechanically and electrically coupled by a transverse branch out portion.

[0056] In an embodiment of the invention, the intermediate segment is a first intermediate segment and the conductor further includes a second intermediate segment formed by a second plurality of conductor branches that similarly electrically and mechanically couple the first end segment and the second end segment.

[0057] In one embodiment of the invention, the second end segment and a conductor branch of the second plurality of conductor branches are monolithically integrated by a rounded connection, thus forming a concavely rounded inside corner between the second end segment and a conductor branch of the second plurality of conductor branches and spatially separating the conductor branches of the second plurality of conductor branches in the different transverse directions.

[0058] In an embodiment of the invention, the conductor is monolithic.

[0059] In an embodiment of the invention, said electrical conductor is at least partially manufactured by an additive manufacturing process.

[0060] Additive manufacturing is well suited for producing complex shapes and is therefore advantageously utilized for producing the intermediate segment formed by the multiple conductor branches.

[0061] In an embodiment of the invention, the electrical conductor comprises two or more central body segments, with the conductor portions connected to the same central body segment having different geometries.

[0062] In one embodiment of the invention, the electrical conductor includes two central body segments joined by an inductor portion.

[0063] In one embodiment of the invention, a ferrite core is coupled through the inductor portion.

[0064] The different conductor geometries of the conductors coupled to the central body segment are advantageous in that they allow for different types of coupling of the conductor to additional electrical systems. Furthermore, it allows for designing a section of the conductor for a specific purpose, such as an inductor through which the ferrite core can extend. In this way, it may be possible to limit the need for multiple ferrite cores to one ferrite core.

[0065] In an embodiment of the invention, a branch diameter of one of the plurality of conductor branches is less than 3 cm, such as less than 2.5 cm, such as less than 2 cm, such as less than 1.5 cm.

[0066] Such exemplary branch diameters can advantageously provide the necessary mechanical and electrical properties that are sought after, which is advantageous.

[0067] The bifurcation diameter is measured at the smallest diameter of the bifurcation.

[0068] In an embodiment of the invention, one conductor branch of the plurality of conductor branches has a rounded junction and is shaped with one or more concavely rounded internal corners having a corner radius of at least 0.2 branch diameters of the conductor branch, such as at least 0.3 branch diameters, for example at least 0.5 branch diameters, such as at least 0.8 branch diameters, for example at least 1.2 branch diameters.

[0069] In an embodiment of the present invention, one conductor branch of two adjacent conductor branches of the plurality of conductor branches has a rounded connection and is shaped with one or more concavely rounded inside corners having a corner radius of at least 0.05 adjacent separation distance of the two adjacent conductor branches, such as at least 0.1 adjacent separation distance, for example at least 0.2 adjacent separation distance, such as at least 0.3 adjacent separation distance, for example at least 0.4 adjacent separation distance.

[0070] Having one or more rounded corners with a radius (i.e., branch diameter) of at least a certain size in relation to the adjacent separation distance ensures the ability of these corners to withstand vibration while minimizing the risk of damage due to stress concentrations.

[0071] However, it should be noted that the present invention is not limited to circular, elliptical, parabolic, hyperbolic, or any other shaped corners, but at least some embodiments have corners with rounded joints, where the conductor material is spatially arranged such that the outer surface of a given rounded joint lies outside the arc of a circle with a particular radius.

[0072] In an embodiment of the invention, the electrical conductor has a resonant vibration frequency associated with relative motion between the first and second end segments.

[0073] Said resonant vibration frequency is at most 300 Hz, such as at most 150 Hz, for example at most 70 Hz, such as at most 30 Hz, for example at most 20 Hz.

[0074] Said resonant vibration frequency is at least 300 Hz, such as at least 500 Hz, such as at least 1 kHz, such as at least 5 kHz.

[0075] In an embodiment of the invention, the electrical conductor comprises an inner bulk structure and an outer surface structure, the inner bulk structure and the outer surface structure having different material compositions.

[0076] In an embodiment of the invention, either the first end segment or the second end segment includes at least one fastening hole for electrically and mechanically coupling the electrical conductor to an electrical terminal.

[0077] For example, the electrical terminal of an electrical equipment. The fastening hole can also be called the terminal of a conductor.

[0078] In one embodiment of the invention, the electrical conductor includes a first portion having a first outer diameter and a second portion having a second outer diameter, the first diameter being greater than the second diameter.

[0079] The first and second parts are the stranded parts. The outer diameter is the outer diameter of the entire stranded conductor, i.e. the outer diameter that can be measured by vernier calipers. This has the advantage that if the winding part has a small diameter, it leads to the requirement that a smaller window in the core has the part / leg around which the winding part is wound. Thus, a more compact core is obtained with reduced size, weight and cost.

[0080] One aspect of the invention is a method of 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: monolithically integrating the first end segment and a conductor branch of the plurality of conductor branches via a coupling portion to form an internal corner between the first end segment and a conductor branch of the plurality of conductor branches and to spatially separate the conductor branch of the plurality of conductor branches in two different directions; electrically and mechanically coupling the first end segment and the second end segment through an intermediate segment of the conductor formed by the plurality of conductor branches; The present invention relates to a method comprising the steps of:

[0081] A method for joining a first end segment and a second end segment of an electrical conductor according to the present invention can potentially provide any of the advantages of the electrical conductor according to the present invention.

[0082] In an embodiment of the invention, the electrical equipment is included in a renewable energy facility.

[0083] In an embodiment of the invention, the coupling is a rounded coupling that forms a concavely rounded internal corner between the first end segment and the conductor branch of the plurality of conductor branches.

[0084] In an embodiment of the present invention, the electrical conductor is a electrical conductor according to any of the embodiments of the present disclosure.

[0085] In an embodiment of the invention, the method includes establishing a digital representation of the electrical conductor.

[0086] In an embodiment of the invention, the method includes performing a digital geometry optimization of the digital representation of the electrical conductor to at least partially form the plurality of conductor branches.

[0087] In an embodiment of the invention, the method includes additively manufacturing the electrical conductor based on the digital representation of the electrical conductor.

[0088] Additive manufacturing advantageously allows for simplified production of complex geometries, such as the electrical conductors of the present invention. In particular, geometric features of the electrical conductors, such as conductor branches, may be directly additively manufactured while establishing spatial separation of the conductor branches in two different transverse directions.

[0089] Moreover, additive manufacturing can advantageously reduce the number of steps required for manufacturing. However, it should be noted that embodiments of the present invention are not limited to a particular number of manufacturing steps.

[0090] In an embodiment of the invention, the step of additively manufacturing the electrical conductor comprises selective laser melting.

[0091] Selective lasers are alternatively referred to or involve direct metal laser melting and powder bed fusion bonding.

[0092] In an embodiment of the invention, the step of additively manufacturing the electrical conductor comprises wire-arc additive manufacturing.

[0093] Wire-arc additive manufacturing may be highly suitable for relatively inexpensively producing electrical conductors according to the present invention.

[0094] In embodiments of the invention having different structures of different materials, these different structures may or may not be additively manufactured, in some embodiments, one structure of the conductor is additively manufactured while another structure is produced by a different process.

[0095] One aspect of the present invention relates to an electrical installation for a renewable energy facility, including an electrical conductor according to any of the embodiments of the present disclosure.

[0096] The electrical equipment may be, for example, a converter, an uninterruptible power supply, or a power supply and switch module.

[0097] An electrical installation having an electrical conductor according to the present invention can take advantage of the advantages of the electrical conductor.

[0098] One aspect of the present invention relates to a renewable energy facility that includes electrical equipment that includes an electrical conductor according to any of the embodiments of the present disclosure.

[0099] The renewable energy facility may be, for example, any of a wind turbine, a solar power plant, a hydroelectric power plant, a bioenergy power plant, a geothermal energy power plant, a power storage facility, and a power-to-x facility.

[0100] A renewable energy facility having an electrical conductor according to the present invention can promote the benefits of electrical conductors.

[0101] One aspect of the invention relates to the use of additive manufacturing for at least partially manufacturing electrical conductors for electrical equipment of a renewable energy facility.

[0102] Using additive manufacturing to produce electrical conductors for renewable energy facilities is advantageous as it may allow the conductors to be adapted to the conditions of the renewable energy facility.

[0103] In an embodiment of the present invention, the electrical conductor is a electrical conductor according to any of the embodiments of the present disclosure.

[0104] One aspect of the invention is a longitudinally elongated electrical conductor comprising: An inner bulk structure; an outer surface structure; Including, the inner bulk structure and the outer surface structure have different material compositions, and the conductance of the outer surface structure is greater than the conductance of the inner bulk structure; Concerning electrical conductors.

[0105] Various embodiments of the present invention are described below with reference to the drawings in which: [Brief description of the drawings]

[0106] [Figure 1a] 1a-c illustrate an electrical conductor according to one embodiment of the present invention. [Figure 1b] FIG. 1b illustrates an electrical conductor according to one embodiment of the present invention. [Figure 1c] FIG. 1c illustrates an electrical conductor according to one embodiment of the present invention. [Diagram 2] FIG. 2 illustrates a side view of one embodiment of the present invention and a method for quantifying various measurements. [Diagram 3] FIG. 3 illustrates method steps according to one embodiment of the present invention. [Figure 4a] FIG. 4a illustrates a side view and different cross-sectional views of one embodiment of the present invention. [Figure 4b]FIG. 4b illustrates a side view and different cross-sectional views of one embodiment of the present invention. [Figure 4c] FIG. 4c illustrates a side view and different cross-sectional views of one embodiment of the present invention. [Figure 4d] FIG. 4d illustrates a side view and different cross-sectional views of one embodiment of the present invention. [Figure 5a] FIG. 5a illustrates an embodiment with cooling channels according to the present invention. [Figure 5b] FIG. 5b illustrates an embodiment with cooling channels according to the present invention. [Figure 6a] FIG. 6a illustrates one embodiment with an inner bulk structure and an outer surface structure according to the present invention. [Figure 6b] FIG. 6b illustrates an embodiment with an inner bulk structure and an outer surface structure according to the present invention. [Figure 6c] FIG. 6c illustrates an embodiment with an inner bulk structure and an outer surface structure according to the present invention. [Figure 7a] FIG. 7a illustrates an alternative embodiment of the present invention. [Figure 7b] FIG. 7b illustrates an alternative embodiment of the present invention. [Figure 8] FIG. 8 illustrates another embodiment of the present invention. [Figure 9] FIG. 9 illustrates an electrical conductor with a cooling structure according to one embodiment of the present invention. [Figure 10] FIG. 10 illustrates a cooling structure and electrical conductor with a ferrite core according to one embodiment of the present invention. [Figure 11] FIG. 11 illustrates a stranded conductor according to one embodiment of the present invention. [Figure 12] FIG. 12 illustrates a web conductor design according to one embodiment of the present invention. [Figure 13] FIG. 13 illustrates a twisted design conductor with an inductor portion according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0107] 1a-c illustrate an electrical conductor according to one embodiment of the present invention. In particular, Fig. 1a illustrates a perspective view of electrical conductor 1, Fig. 1b illustrates a front view of electrical conductor 1, and Fig. 1c illustrates a side view of electrical conductor 1c.

[0108] Each of Figures 1a-c further shows axes indicating a longitudinal direction 9, a first transverse direction 8a and a second transverse direction 8b.

[0109] The electrical conductor includes a first end segment 2 and a second end segment 3, the second end segment 3 being distal to the first end segment 2. The two ends may be galvanically coupled, for example, to respective terminals of electrical equipment in the renewable energy facility, such that the electrical conductor can facilitate the transfer of current and / or voltage.

[0110] The first and second end segments 2, 3 are electrically and mechanically coupled by an intermediate segment 4. The intermediate segment 4 is formed by a number of conductor branches 5a-5d. This particular embodiment includes a total of six conductor branches 5a-5d distributed in a 2x3 two-dimensional array. Two of the conductor branches are barely visible in FIG. 1a because they are hidden behind the other conductor branches 5b, 5c.

[0111] Each of the conductor branches 5a-5d is monolithically integrated with at least the first end segment 2. This means that the conductor branches as well as the end segments are constructed by varying the dimensions of the layers in order to construct the desired structure of the conductor branches, end segments and the transitions between them, respectively. The first and intermediate segments 2, 4 are monolithically integrated since they are manufactured from a single bulk piece of material that is machined to provide the conductor 1. Here, the bulk piece of material is to be understood as the material from which the conductor 1 is made.

[0112] The manufacturing of the electrical conductor 1 may be performed by an additive manufacturing process. Such a manufacturing process may be based on one of the additive manufacturing processes such as, but not limited to, 3D printing, layer-by-layer printing, wire-arc additive manufacturing, fused deposition modeling, directed 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 is not important as long as the material from which the electrical conductor is built is an electrically conductive material.

[0113] In Figures 1b and 1c, the conductor branch 5 is constructed from the end segment 2. The dashed lines serve to illustrate the perimeter of the end segment 2. In Figure 2, the dashed lines between the end segments 2, 3 and the conductor branch 5 could be omitted to illustrate that the conductor 1 is monolithically integrated. However, they are included in Figure 2 as well for purposes of illustrating the corner radius 12. In Figure 4a, the lines have been omitted to illustrate that the conductor is monolithically integrated.

[0114] Each of the conductor branches 5a-5d illustrated in Figures la-lc may be monolithically integrated with the first end segment via a rounded connection, each of which forms a concavely rounded inside corner 6 between the first end segment and the conductor branch.

[0115] In this particular embodiment, the rounded junction and resulting concavely rounded inside corner 6 is different from the junction between the second end segment 3 and the conductor branches 5a-5d, which does not form a concavely rounded inside corner between the second end segment 3 and the conductor branches 5a-5d (see Figures 1b and 1c).

[0116] In another particular embodiment, the conductor branches 5a-5d are connected to both end segments 2, 3 without any concavely rounded inside corners 6 (see FIG. 2).

[0117] Thus, the conductor branches 5a-5d may be connected to both end segments 2, 3 via a concavely rounded inside corner 6, to one of the end segments 2, 3 via a concavely rounded inside corner 6, or without a concavely rounded corner 6.

[0118] The concavely rounded inside corner 6 is established by successively increasing or decreasing the size of one or more layers from one of the end segments 2, 3, thereby progressing progressively from the construction of the end segment to the construction of the conductor branch.

[0119] A non-concave rounded joint between the end segment and the conductor branch may be established by building multiple layers with the same geometric shape, such as a square, thus proceeding from building the end segment to building the conductor branch "instantly" from the last layer of the end segment to the first layer of the conductor branch.

[0120] It should be noted that the junctions between the end segments and the conductor branches are, in principle, always substantially orthogonal when looking at the junctions at the "layer level" (orthogonal enough to add one layer to another). However, when referring to a junction in the context of this invention, reference is made to three or more successive layers, i.e., multiple layers that together form the shape of the junction / transition between the end segments and the conductor branches.

[0121] Thus, the end segments, the conductor branches 5a-5d and the transitions between the end segments and the conductor branches may have any given geometric shape that can be produced by additive manufacturing.

[0122] The geometry of the rounded junctions further spatially separates the conductor branches 5a-5d from one another. In particular, the conductor branches 5a-5d are not spatially separated only in a single transverse direction. Instead, the conductor branches 5a-5d are separated in a first transverse direction 8a by a first spatial separation 7a and at the same time in a second transverse direction 8b by a second spatial separation 7b. Such a separation may likewise be established when designing the conductors, and thus such a separation may likewise be obtained by means of orthogonal transitions between the end sections and the conductor branches.

[0123] It should be noted that each individual conductor branch is not necessarily spatially separated from the remaining conductor branches in both transverse directions 8a, 8b. For example, in the embodiment illustrated in Figures 1a and 1c, focusing on the conductor branch labeled "5c", this conductor branch is spatially separated in the first transverse direction 8a from the conductor branches labeled "5a" and "5b", but is not spatially separated in the first transverse direction 8a from the conductor branch labeled "5d". Instead, the conductor branch labeled "5c" is spatially separated in the second transverse direction 8b from the conductor branch labeled "5d", but is not spatially separated in the second transverse direction 8b from the conductor branches labeled "5a" and "5b".

[0124] The intermediate segment 4 is formed by the conductor branches 5a-5d, thus the embodiment provides an electrical and mechanical coupling of the two end segments 2, 3 via the conductor branches 5a-5d.

[0125] It should be noted that although the conductor branches 5a-5d in Figures 1a-1c are illustrated as more or less uniform conductors, the design / geometry can be any machinable / printable shape, which may be optimized depending on the current carrying (skin effect), cooling including air guiding, etc.

[0126] The particular electrical conductor 1 of Figures 1a-c may be made of copper, although it is contemplated that it could be made of other conductive materials such as aluminum, titanium, etc.

[0127] FIG. 2 illustrates a side view of an electrical conductor according to one embodiment and a method of quantifying various measurements according to the present invention.

[0128] In this particular view, three conductor branches 5a-5c are visible. Additionally, the embodiment may have additional branches that are not visible from this particular view because the three visible conductor branches 5a-5c obscure the view. In other words, from this particular viewing angle, additional conductor branches may be located behind the visible conductor branches 5a-5c.

[0129] The figure illustrates how the branch diameter 10 of a conductor branch 5a can be quantified. In particular, even if a particular branch 5a has a highly non-uniform diameter (measured transversely) along its length, it is still possible to determine a well-defined branch diameter 10. That is, the branch diameter 10 may be determined in a transverse plane in which the branch has its smallest diameter. In this particular figure, this plane corresponds to the approximate center (in the length direction) of the conductor branch 5a. If the diameter of the conductor branch 5a was measured away from this center, it would be expected that a larger diameter would be measured. This center is therefore where the branch diameter 10 is measured.

[0130] The figure further illustrates how the adjacent separation distance 11 of two adjacent conductor branches 5a, 5b can be quantified. In terms of branch diameter, the distance between the two conductor branches 5a, 5b can be non-uniform as a result of the non-uniform diameter of the conductor branches. Nevertheless, a well-defined adjacent separation distance 11 can be determined by measuring in a transverse plane where there is a maximum spatial separation between two given conductor branches. In this particular figure, the maximum spatial separation is approximately in the middle (in the length direction) of the adjacent conductor branches 5a, 5b. If the distance between these two conductor branches were measured in a transverse plane away from this middle, a smaller distance would be measured. Thus, the middle is where the adjacent separation distance 11 is measured.

[0131] In this particular embodiment, adjacent separation distance 11 and branch diameter 10 are measured in the same transverse plane, however, in other embodiments, due to the geometry of the conductor branches, adjacent separation distance and branch diameter are measured in different transverse planes (at different locations along the length).

[0132] The figure further illustrates how the corner radius 12 of the concavely rounded inside corner 6 can be quantified. The rounded junction between the first end segment 2 and the conductor branch 5b forms an inside corner 6, which can be characterized by its corner radius 12. The exemplary figure shows how the corner radius of this inside corner can be determined in the plane of the figure. The corner radius can vary between different planes. A first line 18a is drawn longitudinally in the plane of the figure as a tangent to the point where the branch diameter is measured (i.e. the branch has its smallest diameter in the transverse direction). A second line 18b is drawn transversely in the plane of the figure where the intermediate segment 4 and the first end segment 2 are integrated. This line 18b can be, for example, a tangent to the longitudinal gap / spatial separation between the first end segment 2 and the second end segment 3. (The longitudinal spatial separation is a result of having an intermediate segment 4 formed by the conductor branches 5a-5c). A circle (or a portion of a circle) may then be drawn with the first line 18a and the second line 18b as tangents. The radius of the largest possible circle such that the portion of the circle between the two intersection points 24 with the first line 18a and the second line 18b falls completely inside the inside corner 6 is then the corner radius 12.

[0133] 2, the corner radius 12 is equal to 1.0 branch diameter 10. The ratio of the adjacent separation distance 11 of two adjacent conductor branches 5a, 5b to the branch diameter 10 of one of these conductor branches 5a, 5b is 2.0.

[0134] 3 illustrates method steps for machining a conductor according to one embodiment of the present invention. The particular method involves coupling two segments of the conductor, a first end segment and a second end segment, with a conductor branch.

[0135] It should be noted that this may include printing steps of both end segments and the conductor branch, so the method starts with printing one end segment, then the transition to the conductor, then the conductor, then the transition to the second end segment, and finally the second end segment.

[0136] Alternatively, the end segments may be separate elements connected via a middle section, which may be printed and attached to the end segments during their manufacture, such as by being printed on the end segments, or the middle section may be joined to the end segments using means such as welding, printing, soldering, etc.

[0137] It should be noted that the end segments may include terminals for connecting the completed electrical conductor to other electrical portions / conductors of an electrical system.

[0138] In step S1 of this particular method, a first end segment and an intermediate segment in the form of a conductor branch of the plurality of conductor branches are monolithically integrated via a separate transition portion that may include a rounded joint to form a concavely rounded inside corner between the first end segment and the conductor branch of the plurality of conductor branches and to spatially separate the conductor branches of the plurality of conductor branches.

[0139] The step of monolithically integrating the first end segment and the conductor branch can be implemented using a variety of methods, such as additive manufacturing, such as 3D printing, casting, and simply removing material from a bulk metal slab via machining to form the conductor branch integrated with the first end segment.

[0140] In step S2 of the method, the first end segment and the second end segment are electrically and mechanically coupled via an intermediate segment of an electrical conductor formed by multiple conductor branches.

[0141] The intermediate segment may in principle have any design / geometry. It may be formed by a solid conductor branch or may have an internal cavity to reduce the amount of material required to manufacture the conductor. It may be formed by one web or may be formed as a hybrid or web between conductor branches.

[0142] The internal cavities can be used as cooling channels and / or additional surfaces for conducting high frequency currents. Thus, the end and middle segments may be designed for the particular panel / electrical system in which it is used, for the particular type of current to be conducted, to have desired or dual functionality, etc.

[0143] One such functionality, besides those mentioned above, may be that of structural support. Thus, if necessary, a conductor may be designed to help carry the weight of an electrical component coupled to it. Thus, its dimensions may be larger than it would need to be to carry the required current. Similarly, its geometry may be designed for a combined purpose of mechanical support and electrical conductance.

[0144] It should be mentioned that the conductor 1 can be produced with more than one resolution. In case of additive manufacturing, the resolution is defined by the thickness of the layers that build up the conductor. A first resolution, finer, i.e. with a thinner layer size, than the second resolution may be used when producing an interface between the conductor and the part to which it is connected. Such an interface may be part of a terminal that contacts another part. Alternatively, the resolution may be determined by the material deposition rate, the material flow rate, etc., depending on the type of additive manufacturing used.

[0145] To avoid electrical losses in the connection between two conductors, it is important that the two parts have flat surfaces. The more precisely these interfaces are manufactured, the better / less post-manufacturing processing will be required to ensure a sufficiently flat surface. With this being said, it should be pointed out that the end segments of two conductors may be joined by means of mating teeth, slider locks, tongues and grooves, etc. This may allow easier assembly of conductors such as busbars in electrical systems.

[0146] The second resolution, for example made with a thicker layer, is coarser and leads to a larger surface area. At least for medium and high frequency currents, this may lead to a higher current conductance without increasing the material / dimension needs of the conductor. In fact, the intermediate segment may be intentionally made with a corrugated surface in order to increase the current passing through the outer surface of the conductor (currents passing through medium and high frequencies), for example due to more efficient cooling due to the turbulence of the cooling air flow created by the corrugated surface. It should be pointed out that, if the conductor includes an internal space, the inner surface of the conductor creating such an internal space may be corrugated for the same purpose as well. The corrugated surface has the effect of introducing turbulence into the flow of the cooling fluid, such as air. The increased velocity of the cooling fluid may lead to a higher cooling effect.

[0147] As an example, the depth into a conductor used to conduct current at medium and high frequencies is approximately 1.5 mm in a specific embodiment. In this specific example, the conductor is made of copper, which has a resistivity of approximately 1.68 μΩcm and a relative permeability of approximately 1 at a frequency of 2 kHz. Thus, the conductor for this particular embodiment may be hollow, with a conductor thickness of twice 1.5 mm. In practice, such a conductor may be manufactured with a thickness of 4-5 mm, leaving room for cooling inside or reduction in conductor material and therefore weight.

[0148] Since skin effect is known to appear even at, for example, 50Hz, references to mid-frequency with respect to surface effect are to frequencies beginning around 500Hz, where skin effect can be taken into account in the design of the conductor. The mid-frequency range may be 500Hz to 10kHz, and above 10kHz can be referred to as high frequencies where skin effect is a fact (the higher the frequency, the closer the current will be conducted to the surface).

[0149] Additionally, it should be mentioned that the outer surface may also be designed with fins or corrugated to increase heat dissipation from the electrical conductors.

[0150] The electrical conductor resulting from the method may be used as an electrical conductor in an electrical installation. The electrical installation may be an electrical panel that may be part of a renewable energy facility such as a wind turbine. However, manufacturing the electrical conductor and thus achieving the electrical and mechanical coupling between the first and second end segments is typically performed before installing the electrical conductor in the electrical installation and before installing the electrical installation in the renewable energy facility. Thus, according to an exemplary embodiment of the invention, the electrical and mechanical coupling is performed prior to the installation / integration of the electrical conductor. Nevertheless, the method according to the invention is not necessarily limited to a particular sequence of steps. Furthermore, various methods according to the invention may include additional steps, such as performing digital geometric optimization, additively manufacturing the electrical conductor and conducting an electric current.

[0151] In short, a designer designs a digital representation of a conductor according to electrical, mechanical, structural requirements etc. in a 3D CAD software, e.g. Solidworks. A file (digital representation) from such a 3D development tool is exported to e.g. a 3D printer, where the conductor is printed according to the CAD file.

[0152] Figures 4a-d illustrate a side view and different cross-sections of an electrical conductor according to one embodiment of the invention: Figure 4a illustrates a side view of an electrical conductor 1 according to one embodiment of the invention with three transverse planes 15a-15c displayed as horizontal lines; Figures 4b-4d illustrate cross-sections of the electrical conductor 1 in each of these three transverse planes 15a-15c, where Figure 4b illustrates the cross-section in the top transverse plane 15c, Figure 4c illustrates the cross-section in the middle transverse plane 15b, and Figure 4d illustrates the cross-section in the bottom transverse plane 15a.

[0153] The illustrated conductor 1 has four conductor branches 5a-5d, of which only two conductor branches 5a-5b are visible in Fig. 4a. Each of the four conductor branches 5a-5d is a branched branch, with a branch stem 13a-13d branching into two diverging branch lines 14a-14h.

[0154] A given conductor branch 5a is monolithically integrated with the first end segment 2 in the form of a single connection, which in this embodiment is rounded, from which a branch stem 13a of the conductor branch 5a projects. Away from the first end segment 2, along its extension in the length direction, the conductor branch 5a eventually branches into two branch lines 14a, 14b. This is clearly illustrated in Fig. 4c-4d, where the branch stem 13a of the conductor branch 5a in one transverse plane 15a is split into two branch lines 14a, 14b in another transverse plane 15b. As a result, in this particular embodiment, a given conductor branch 5a has only one rounded connection with the first end segment 2, while it has multiple connections with the second end segment 3. Similarly, in this particular embodiment, the second end segment 3 and each of the branch lines 14a-14h are monolithically integrated by rounded connections, thus forming concave rounded inside corners between the second end segment 3 and the branch lines 14a-14h.

[0155] 4a-4d further illustrate how the cross-sectional area of ​​the conductor can be reduced in the middle segment 4. This becomes extremely evident by comparing FIG. 4b with either FIG. 4c or FIG. 4d. FIG. 4b has the largest cross-sectional area. Moreover, the cross-sectional area actually varies across the middle segment 4. Here, this is evident in that the cross-sectional area in FIG. 4c is smaller than the cross-sectional area in FIG. 4d. In general, the gradual varying cross-sectional area across each portion of the middle segment can advantageously ensure robustness of the conductor while minimizing the material required to manufacture the conductor 1.

[0156] Moreover, Figures 4a-4d illustrate how the perimeter can vary in the transverse planes 15a-15c at different longitudinal positions. The perimeter of a given segment 2-4 can be simply measured as the sum of all the perimeters of the areas in a given transverse plane. In this embodiment, the perimeter of the second end segment 3 is thus the perimeter of the cross section illustrated in Figure 4b. And the perimeter of the intermediate segment 4 is the sum of the perimeters of all the individual branched branches 14a-14h in Figure 4c or the perimeters of all the individual branched stems 13a-13d in Figure 4d. If many different perimeters are possible for the intermediate segment (as is the case here), preferably the smallest perimeter may be used.

[0157] In the illustrated embodiment, the ratio of perimeter to cross-sectional area is greater in the intermediate segment 4 than in either of the first and second end segments 2,3.

[0158] Generally, the cross-sectional area, perimeter and their ratio are measures of how much material is removed from the middle segment (compared to a busbar having a more uniform design).

[0159] It should be noted that the conductors illustrated in Figures 2-4, for example, include uniform conductor branches 5. However, in variant embodiments, the conductor branches 5 of one conductor 1 may all have different geometries, such that only two or none of the branch diameters are the same, and only two or none of the adjacent separation distances 11 are the same. It should also be noted that the intermediate segments, or alternatively the conductor branches, may be manufactured as a uniform web-like structure with a uniform perimeter across the conductor branches of the web-like structure. An example of a web-like structure may be a honeycomb structure.

[0160] 5a-b illustrate embodiments of an electrical conductor 1 with cooling channels 16 according to the present invention. Each of the two embodiments is illustrated via a cross-section in a plane spanning the longitudinal and transverse axes.

[0161] In Fig. 5a, both the first end segment 2 and the second end segment 3 have channel openings 17, which allow a cooling fluid, such as water or air, to flow through the cooling channels 16. The cooling channels themselves pass through one of the conductor branches 5b of the electrical conductor 1. This conductor branch is then cooled very efficiently. With regard to cooling, it should also be noted that the separation distances between two adjacent conductor branches are also used to cool the electrical conductor, for example by providing an air flow through these separation distances.

[0162] Although the conductor branch 5b with the cooling channel 16 may facilitate most of the current power transfer of the conductor 1, the other branches 5a, 5c advantageously provide mechanical support so that the conductor does not deform during use under conditions involving stress and / or vibration.

[0163] Such structural support and cooling considerations may lead to the design of electrical conductors having conductor branches with different geometries. In fact, electrical conductors may be manufactured with structural support branches that are electrically insulated and have only the function of structural support and no function of electrical conductance support. Such stems or branches may simultaneously serve as heat dissipation parts while functioning as structural support.

[0164] The conductor branches 5a, 5c without internal cooling channels may have a relative surface area that ensures that these branches are sufficiently cooled without internal cooling channels, or alternatively, the thermal conductivity of the conductor may ensure that the cooling provided by the cooling channels passing through a subset of the conductor branches is sufficient to cool all parts of the conductor.

[0165] In FIG. 5b, similar to FIG. 5a, both the first end segment 2 and the second end segment 3 have channel openings 17. However, the path of the cooling channel 16 is different in FIG. 5b. It does not only pass through a single conductor branch, but through multiple conductor branches 5a-5c. As a result, a single cooling channel 16 is advantageously capable of providing cooling for multiple conductor branches. Moreover, advantageously, cooling may be distributed evenly throughout the conductor, e.g., more evenly among the first end segment 2 and the second end segment. The even cooling distribution between the end segments 2, 3 may be advantageously enhanced since the cooling channel may alternately enter and exit the end segments 2, 3.

[0166] It should be mentioned that a cooling system, not illustrated, may be connected in the end segment to the channel openings 17. This connection may for example include a threaded portion, which may also be monolithically integrated with the end segment, i.e., manufactured as part of or integral with the end segment, being a recess for a nut or other attachment.

[0167] In other embodiments, a single cooling channel crosses the intermediate segment an even number of times via conductor branches, thus allowing both channel openings of the cooling channel to be located in the same one of the first and second end segments. This can ensure easier coupling of the fluid coupling to the channel openings 17, for example when two channel openings are placed immediately next to each other on the same segment. This is particularly relevant when using a cooling liquid such as water (compared to air, for example). Even more relevant when using liquid cooling is to have an internal cooling channel insulation layer that galvanically insulates the interior of the cooling channel from the bulk of the conductor.

[0168] 5b, air guiding fins 25 for guiding a portion of the air flow 26 in the cooling channels 16 are illustrated in dashed lines. The air guiding fins 25 are established by additive manufacturing as a remaining part of the conductor 1 and may be designed to guide exactly the required portion of the air flow 26 in the cooling channels 16.

[0169] It should be noted that embodiments of the present invention are not limited to cooling via one or more internal cooling channels. Other possible cooling sources are attachment of a heat sink (e.g., one or more heat sinks monolithically integrated with one or more segments of electrical conductor, see FIG. 9 and the description below), heat dissipation via attachment of end segments to electrical terminals, and cooling via external air flow.

[0170] It is further noted that embodiments may include multiple cooling channels, and that a cooling channel may branch into multiple diverging cooling sub-channels. For example, a single cooling channel in a first end segment may branch into multiple cooling sub-channels that pass through different respective conductor branches and rejoin together into a single cooling channel within one of the end segments.

[0171] Additionally, in some embodiments of the invention, one or more of the internal cooling channels each include an insulating layer that provides galvanic isolation. Any insulating material may be used that provides a barrier between the current carrying portions of the electrical conductors and any liquid within the internal cooling channels.

[0172] Figures 6a-c illustrate an embodiment with an inner bulk structure 19 and an outer surface structure 20 according to the present invention. Figure 6a illustrates a cross-sectional side view of an electrical conductor 1 according to one embodiment of the present invention, displaying a transverse plane 15 as a horizontal line. Figure 6b illustrates a cross-sectional view of the electrical conductor 1 in this transverse plane, particularly highlighting the individual conductor branches 5a-5f of the embodiment. And Figure 6c illustrates a perspective view of a portion of the electrical conductor (e.g., a portion of a conductor branch).

[0173] The materials of the inner bulk structure 19 and the outer surface structure 20 are different. In this particular embodiment, the outer surface structure comprises primarily copper, while the inner bulk structure comprises primarily aluminum. Thus, the surface of the conductor 1, where the AC current is primarily conducted due to the skin effect, has a relatively high conductance while significantly reducing the amount of copper required compared to a conductor of a similar material that comprises primarily copper throughout the bulk of the conductor.

[0174] It should be noted that the inner bulk structure 19 itself has two end segments and an intermediate segment formed by a number of conductor branches joining the end segments, where the conductor branches are monolithically integrated by rounded joints, thus forming concavely rounded corners and spatially separating the conductor branches in different transverse directions. And further, the outer surface structure 20 itself has two end segments and an intermediate segment formed by a number of conductor branches joining the end segments, where the conductor branches are monolithically integrated by rounded joints, thus forming concavely rounded corners and spatially separating the conductor branches in different transverse directions. In other embodiments, only one of the two structures 19, 20 may have such properties.

[0175] FIG. 6c illustrates a perspective view of a portion of a conductor, such as a portion of a conductor branch. In principle, the portion illustrated can be used alone. That is, the portion illustrated in FIG. 6c can in principle be used as a conductor by itself, without necessarily being monolithically integrated with an end segment. Such a conductor without multiple branches may nevertheless have one or more of the advantages of the present disclosure. In particular, because the materials of the inner bulk structure 19 and the outer surface structure 20 are different, a relatively high AC conductance is achieved while additionally having the advantages of the material of the inner bulk structure, such as price, weight, manufacturing and vibration properties, and structural properties (e.g. elasticity / rigidity, plasticity, etc.).

[0176] Figures 7a-b illustrate variant embodiments of the invention. In particular, Figure 7a illustrates an embodiment with several intermediate segments 4a, 4b, each of which is formed by multiple conductor branches 5, and Figure 7b illustrates an embodiment in which the conductors 1 are angled.

[0177] In Fig. 7a, the electrical conductor 1 includes a first end segment 2 that is directly coupled to a first intermediate segment 4a. Similarly, the electrical conductor includes a second end segment 3 that is directly coupled to a second intermediate segment 4b. Each of these two intermediate segments 4a, 4b is then directly coupled to a central body segment 21. Thus, the first end segment 2 and the second end segment 3 are electrically coupled and mechanically coupled via the first intermediate segment 4a, the central body segment 21 and the second intermediate segment 4b.

[0178] In particular, several intermediate segments formed by multiple conductor branches can facilitate and potentially further improve upon any of the advantages that a single intermediate segment would otherwise provide. Furthermore, several intermediate segments can enable additional designs of the conductor. For example, certain constraints (e.g., spatial constraints) may limit the spatial extent allowed for a single intermediate segment. Thus, having several intermediate segments may allow conductors with advantageous properties to be implemented in situations and configurations where they would not otherwise be available.

[0179] In FIG. 7b, the conductor 7b includes a first end segment 2 and a second end segment 3 joined by an intermediate segment 4. In this particular embodiment, the first end segment is angled. The multiple conductor branches 5 and the direction in which they join the end segments determine the length of the conductor 1. The bend / angle of the first end segment 2 allows the conductor 1 to deviate from this length. This in itself can allow alternative structural designs of the conductor 1 and improve the possibility of coupling the conductor 1 inside an electrical installation. In some embodiments, both end segments 2, 3 include one and / or more bends / angles. In some embodiments, the intermediate segment includes a bend / angle while electrically and mechanically coupling the first and second end segments in the length direction.

[0180] 8 illustrates another embodiment of the present invention. Compared to the other embodiments illustrated in this disclosure, the conductor branches of the electrical conductor of this particular embodiment have an overall rounded design.

[0181] For other embodiments, the intermediate segment 4 is formed by multiple conductor branches 5. In the illustration, the front conductor branch 5 blocks the view of the other conductor branches. Many of the conductor branches 5 are connected to each other, for example, via a conductor branch that branches into two diverging conductor branches that are themselves integrated with the other conductor branch, or via a transverse branch out portion 22 that joins two conductor branches that are otherwise spatially separated.

[0182] Furthermore, each of the first and second end segments 2, 3 includes a fastening hole 23 (also called a terminal), which allows fastening of the end segments 2, 3 of the electrical conductor to different terminals in an electrical installation.

[0183] The embodiment of the invention illustrated in Figure 9 is an electrical conductor 1 having a cooling structure 27 attached. The electrical conductor 1 may be manufactured according to the additive manufacturing process described above or may be a standard conductor such as a solid copper conductor. The conductor 1 may include a first end segment 2 including a fastening hole 23 and a second end segment 3 configured to be coupled to another conductor, or may simply extend further so that other electrical components may be coupled to the illustrated conductor 1.

[0184] When used in the mid-to-high frequency domain, it may be advantageous to, for example, 3D print the conductors in that only the outer parts of the conductors are available for current conduction due to the skin effect mentioned above.

[0185] The cooling structure 27 may be attached to the standard conductor by additive manufacturing or may be monolithically integrated with the conductor during manufacture.

[0186] The cooling structure 27 and the conductors 1, when produced by additive manufacturing, can make use of free space, for example, in an electrical panel. The cooling structure 27 may therefore be designed / produced in such a way that it can "aid" an air flow, for example established by a ventilation device of the electrical panel.

[0187] The illustrated cooling structure 27 is illustrated as a cooling web that can guide air flow inside the conductor 1 where cooling channels (not shown) may be created during manufacturing. The end segment 3 may be connected to another conductor 1 and the cooling channels may be continuous from the illustrated conductor 1 to the next conductor.

[0188] The electrical conductor 1 illustrated in Figure 10 is similar to that illustrated in Figure 9. Visible are the two end segments 2, 3 and a cooling structure. Additional electrical components such as a flexible bus bar 28 are connected to the first end section 2 by nuts and bolts 29.

[0189] A number of ferrite cores 30 are illustrated between the cooling structures 27, which include a first portion connectable to a second portion, thereby surrounding an intermediate portion of the electrical conductor 1. In this manner, electrical noise from the conductor 1 can be reduced or eliminated.

[0190] It is pointed out that the cooling structure 27 extends longer than the ferrite core 30, i.e. the cooling structure 27 is in direct contact with the possible cold air flow, so that heat dissipation from the conductor 1 is still possible even when it is enveloped by the ferrite core.

[0191] Additionally, the distance between the cooling structures 27 may be determined by the thickness of the ferrite core 30 to aid in positioning the ferrite core 30 at a desired location on the conductor 1. This is true during transportation and during operation in a vibrating environment.

[0192] The embodiment of the invention illustrated in Fig. 11 is again a conductor 1. This embodiment again includes two end segments 2, 3 and a middle section 4 with one fastening hole 23 each. In this particular embodiment, the conductor is optimized according to the outer surface of the conductor. This can be easily seen due to the multiple conductor branches 5 connecting the two end segments 2, 3.

[0193] In this particular embodiment, the multiple conductor branches 5 are divided into three sets. In other embodiments, the conductor may include additional sets such as 5, 7, 9, and even more twisted sets. In these three sets, the conductor branches are twisted, and the three sets of twisted conductor branches 5 are twisted as well. All the individual conductor branches are connected to the end segments 2, 3. This can be done through rounded corners or through orthogonal connections between the conductor branches 5 and the end segments 2, 3. The illustrated design may have the advantage of promoting linear current paths, which may lead to reduced resistance. This design is inspired by Litz wire to achieve the advantages of this wire type.

[0194] The illustrated conductor 1 is manufactured by additive manufacturing and thus makes it possible to ensure a distance between each individual conductor branch 5. This type of conductor is inspired by the advantages of so-called Litz wires, which can be manufactured, for example, by 3D printing and can therefore be shaped to any shape, for example taking advantage of the free space in an electrical panel.

[0195] A twisted conductor design such as that illustrated in Figures 11 and 13 is advantageous in that it is effective and adds versatility to the electrical system. Thus, less precision can be tolerated for the holes / terminals of the conductor and the additional electrical component to which it is to be connected, since by pulling or pushing the terminals / holes can move and thus fit the other component. Furthermore, tensions or forces acting on the electrical component can be reduced in that the twisted design allows for tolerances to be obtained in the longitudinal direction, both on the side and in the axis. This is true both in terms of the forces introduced by vibrations and in terms of the static forces that arise from forcing the conductor to a position where it can be assembled to an additional electrical component, for example.

[0196] It should be mentioned that for both this and other embodiments of the invention presented herein, if electrical insulation is required for conductor 1, conductor 1 may be immersed in a bath of liquid-like insulating material. In this manner, all exterior surfaces of both the middle and end segments can be electrically insulated.

[0197] The conductor branches of the conductor 1 illustrated in Figure 12 are fabricated as web-like structures 31. Thus, there are no such web-like or structured conductor branches within which current can be conducted through the conductor 1.

[0198] Such a design has the advantage of having a large surface area compared to standard known conductors, which is particularly advantageous in medium to high frequency applications, and, with respect to cooling, the web-like structure is advantageous in that air can pass through the conductor to efficiently cool a large area.

[0199] The obvious fact that less material is used is an advantage in that it reduces not only material costs but also weight. The weight reduction translates into fewer brackets being required to secure the conductor 1, ensuring safe operation in environments where the assembled conductor / panel is subject to vibration. Similarly, the lower weight is expected to result in lower shipping costs.

[0200] The illustrated compact conductor is advantageous not only for its compact design, but also because it can be designed as needed: thus, if another conductor needs to pass through the illustrated conductor, the illustrated conductor may be designed and subsequently manufactured with free space through which the other conductor can pass.

[0201] It should be mentioned that the end sections 2, 3 containing the terminals 23 of the conductor 1 of web-like structure may likewise be manufactured at least partially in a web-like design, so that the transition between the longitudinal direction of the intermediate segment and the end segments is more or less eliminated.

[0202] However, at least a portion of the end segments 2, 3 must contain solid portions if nuts and bolts are used to connect the conductor 1 to the additional electrical component. The end segments may be of a completely web-like design, for example if the connection to the additional electrical component is made by twist-and-turn or by other quick-locking principles.

[0203] The terminal portions of the end segments 2, 3 in the embodiment illustrated in Figure 12 include a solid abutment plate (see the first end segment) against which an additional electrical component can be connected. On the other side of the end segment (see the second end segment), around the hole for the connecting bolt, the end segment includes a solid portion extending therethrough to ensure sufficient strength when using nuts and bolts to fasten the conductor 1 to the additional electrical component.

[0204] It can be said that the embodiment illustrated in FIG. 13 is a combination of some of the embodiments illustrated / described above. The conductor 1 illustrated in FIG. 13 is of the twisted type illustrated in FIG. 11. It has three central body segments 21, one of which separates the larger twisted conductor portion into six twisted conductor portions that have a smaller diameter than the larger twisted conductor individually. The other two central body segments connect the first and second larger twisted conductor portions to the inductor portion 32. The six twisted conductor portions each terminate in a first end segment 2. These six first end segments 2 are connected to additional electrical components 28 via nut and bolt 29 connections. The second end segment 3 is similarly connected to additional electrical components 28 via nut and bolt 29 connections.

[0205] As illustrated, conductor 1 includes an inductor portion 32 with five windings. One ferrite core 30 extends through each of these windings, providing substantially the same noise reduction as the embodiment illustrated in Figure 10. Thus, the illustrated conductor 1 design avoids four ferrite cores without compromising noise reduction.

[0206] The embodiment illustrated in Figure 13 is an example of a conductor with different dimensions, with a thicker section connected to a second end segment 3 and to a thinner inductor section 32, which is again connected to a thicker section. This method of designing the conductor is advantageous in that it works and allows the thinner section of the conductor (inductor section 32 on Figure 13) to be wound around a core. The core may be a ferrite core as illustrated, but may also be, for example, a transformer core, or the conductor may be wound to form a reactor.

[0207] Manufacturing conductors with thinner sections and winding them instead of winding thicker sections leads to a reduction in the size of ferrite cores, transformer cores, reactors, etc. This is because a larger window in, for example, a ferrite core needs to be created and run through the coil when a thicker section is wound compared to a thinner section wound section, and the core can be smaller and more compact, which reduces weight and thus saves cost and footprint of the electrical system.

[0208] The reduction in diameter of course comes with the drawback that the thinner section will be hotter than the thicker section since the same current is running through the two sections. However, the conductor may be designed (as illustrated in FIG. 13) such that the diameter is reduced just before the beginning of the winding section and reshaped to return to the thicker diameter again just after the winding section is finished. In such a design, heat may be dissipated from the winding / inductor section (thinner section) towards and into the thicker section. Furthermore, the winding section is smaller and therefore has a higher resistance than the rest of the conductor, which reduces heat generation. Furthermore, the illustrated design, which may be able to circulate air through the twisted conductor branches, may facilitate better cooling.

[0209] Various embodiments of the present invention are described below.

[0210] In an embodiment of the invention, the plurality of conductor branches electrically and mechanically couple the first end segment and the second end segment along a length of the conductor, where the different transverse directions are substantially perpendicular to the length.

[0211] Thus, the conductor branches may determine / define a length direction and in turn the transverse direction may be determined based on this length direction.

[0212] In an embodiment of the invention, the two different transverse directions are a first transverse direction and a second transverse direction, wherein the first transverse direction and the second transverse direction are both substantially perpendicular to the longitudinal direction, and the first transverse direction and the second transverse direction are substantially perpendicular to the longitudinal direction.

[0213] In an embodiment of the invention, conductor branches of the plurality of conductor branches are distributed in both of the two different transverse directions.

[0214] In other words, all of the conductor branches are not simply distributed in linear (transverse) rows of columns, but are distributed in both transverse directions in a transverse plane spanning two different transverse directions.

[0215] Such a distribution can advantageously ensure a reduced risk of structural damage during exposure to vibrations in both transverse directions.

[0216] In an embodiment of the invention, conductor branches of the plurality of conductor branches are distributed differently in the two different transverse directions along the length direction.

[0217] For example, in different parallel transverse planes having different positions along the length of a span across two different transverse directions, the distribution of conductor branches may be different along these different planes.

[0218] Such varying distributions may also be characterized as organic or bionic branching structures.

[0219] Such a structure may advantageously reduce the risk of damage to the structure during exposure to vibration in both transverse directions.

[0220] More specifically, conductor branches that are differentially distributed along the length may be understood as conductor branches having different positions, different numbers of conductors (e.g. due to branching branches), different cross-sectional sizes, different shapes, or any combination thereof.

[0221] In an embodiment of the present invention, the concavely rounded internal corners of two adjacent ones of the conductor branches are located between the two adjacent conductor branches.

[0222] In an embodiment of the invention, the concavely rounded corner located between the two adjacent conductor branches forms an arch structure between the two adjacent conductor branches.

[0223] For example, having concavely rounded inside corners between adjacent conductor branches forming an arched structure can advantageously reduce stress concentrations in this region.

[0224] In an embodiment of the invention, the internal cooling channel fluidly couples the first end segment and the second end segment.

[0225] In an embodiment of the invention, the internal cooling channel passes successively through some of the plurality of conductor branches.

[0226] By passing the cooling channels successively through several conductor branches, each of these conductor branches can advantageously be cooled without the need to introduce new fluid couplings to the electrical conductors.

[0227] In an embodiment of the invention, the internal cooling channel includes an insulating layer that provides galvanic isolation.

[0228] When using liquid cooling, such as water cooling, an insulating layer is useful: it can galvanically insulate the inner housing of the cooling channel from the rest of the conductor, and therefore it can limit the passage of voltage / current from the bulk of the conductor into the liquid passing through the cooling channel.

[0229] In an embodiment of the invention, one conductor branch of the plurality of conductor branches is a bifurcated branch, where a branch stem branches into at least two diverging branch arms.

[0230] In an embodiment of the invention, the transverse branch offshoot is spatially separated from the first end segment and the second end segment in the longitudinal direction.

[0231] Having one or more branched and / or transverse branched offshoots can advantageously improve the promotion of vibration damping while reducing the required amount of material needed to dampen vibrations. Additionally, such features can advantageously reduce shear, bending and torsional deformations.

[0232] In an embodiment of the invention, the electrical conductor comprises one or more internal spatial voids.

[0233] The air gap within the conductor can reduce the amount of material required, which can advantageously simultaneously or alternatively reduce the skin effect since the back electromotive force can be reduced.

[0234] In an embodiment of the invention, the first intermediate segment and the second intermediate segment are mechanically and electrically coupled by a central body segment.

[0235] The central body segment may optionally include fixing points or fastening holes that allow the electrical conductor to be electrically and / or mechanically coupled to other components. This may, for example, advantageously allow the weight of the electrical conductor to be partially or primarily supported through points other than its connection to the electrical terminal. Additionally, the central body segment may facilitate attachment of measurement instruments such as current probes.

[0236] In an embodiment of the invention, the first end segment has a first end cross-sectional area, the second end segment has a second end cross-sectional area, and the middle segment has an intermediate cross-sectional area, where the intermediate cross-sectional area is smaller than both the first cross-sectional area and the second cross-sectional area.

[0237] In an embodiment of the invention, the ratio of said intermediate cross-sectional area to either said first cross-sectional area or said second cross-sectional area is less than 1, such as less than 0.8, such as less than 0.6, such as less than 0.4, such as less than 0.3.

[0238] The concept of relative cross-sectional area is one way to quantify the special topologies and geometries provided by embodiments of the present invention. In general, a relative reduction in intermediate cross-sectional area is advantageously accompanied by a reduction in the volume and therefore mass of the conductors.

[0239] In an embodiment of the invention, a branch diameter of one of said plurality of conductor branches is at least 0.1 cm, such as at least 0.2 cm, such as at least 0.3 cm, such as at least 0.5 cm, such as at least 0.8 cm.

[0240] In an embodiment of the invention, the plurality of conductor branches includes at least four conductor branches, such as at least six conductor branches, such as at least eight conductor branches, such as at least ten conductor branches.

[0241] Such an exemplary number of conductor branches can advantageously provide the necessary mechanical and electrical properties required, which is advantageous.

[0242] In embodiments involving branched branches and / or transverse branch offshoots, the number of branches may be quantified as the number of connections between the first end segment and the multiple conductor branches.

[0243] In an embodiment of the invention, two adjacent conductor branches of the plurality of conductor branches are spatially separated in one of the different transverse directions by an adjacent separation distance of at least 0.3 cm, such as at least 0.5 cm, for example at least 0.7 cm, such as at least 1 cm, for example at least 1.5 cm.

[0244] Non-uniform thickness of the branches, for example due to rounded joints, can result in variations in the distance between the conductor branches along different points along their length. The distance between adjacent conductor branches can be quantified by taking measurements at their maximum spatial separation in the transverse direction.

[0245] Two adjacent conductor branches may, for example, be understood as any two conductor branches that are spatially separated by a distance that is smaller than any other spatial separation between one of these two adjacent conductor branches and any of the remaining conductor branches.

[0246] In an embodiment of the invention, a ratio between an adjacent separation distance of two adjacent conductor branches of the plurality of conductor branches and a branch diameter of one of the two adjacent conductor branches is at least 0.5, such as at least 1, for example at least 1.5.

[0247] Such exemplary spatial separation can advantageously improve heat dissipation or material savings, which is advantageous.

[0248] In an embodiment of the invention, the first end segment has a first end perimeter, the second end segment has a second end perimeter, and the intermediate segment has an intermediate perimeter; wherein the ratio of the intermediate perimeter to the intermediate cross-sectional area is relatively greater than either the ratio of the first end perimeter to the first end cross-sectional area and the ratio of the second end perimeter to the second end cross-sectional area by a factor of at least 1.5, such as at least 2, such as at least 2.5, such as at least 3, such as at least 4, such as at least 5.

[0249] The relative ratio of the intermediate perimeter to the intermediate cross-sectional area may be one way of quantifying the spatial geometry of an embodiment of the present invention. In general, a greater ratio of perimeter to cross-sectional area in the intermediate section is a measure indicative of a reduction in material.

[0250] In an embodiment of the invention, the total weight of said conductors is less than 200 kilograms, such as less than 150 kilograms, such as less than 120 kilograms, such as less than 100 kilograms, such as less than 80 kilograms.

[0251] In an embodiment of the invention, the total weight of said conductors is at least 1 kg, such as at least 2 kg, such as at least 5 kg, such as at least 10 kg, such as at least 30 kg, such as at least 100 kg.

[0252] Utilizing the principles of the present invention is highly advantageous for heavy conductors, since here more material can be saved and heat dissipation can be more difficult. Furthermore, heavy conductors according to conventional principles can potentially impede access to a substantial amount of other equipment, which can potentially be solved by the spatial separation between conductor branches according to the present invention.

[0253] In an embodiment of the invention, the periphery of each of the conductor branches of the plurality of conductor branches has a substantially circular shape in a plane spanning the different transverse directions.

[0254] The circular shape of the conductor branches can advantageously ensure that these conductor branches do not have any structural weaknesses in a particular transverse direction.

[0255] In an embodiment of the present invention, a stress concentration factor at a rounded junction of one of the plurality of conductor branches is less than 5, such as less than 4, such as less than 3, such as less than 2, such as less than 1.5.

[0256] The stress concentration factor quantifies the stress concentration.

[0257] The stress concentration factor Kt may be defined as the ratio of the maximum stress Smax to the nominal stress Snom: Kt=Smax / Snom.

[0258] For an infinitely sharp corner, the stress concentration factor is theoretically infinite. By having a rounded junction that shapes the rounded inside corner, the stress concentration factor can be correspondingly reduced, so that the stress concentration factor at the rounded junction of the conductor branch is, for example, less than 5.

[0259] In some embodiments, some rounded junctions of some conductor branches have a stress concentration factor less than 5, such as less than 4, such as less than 3, such as less than 2, such as less than 1.5.

[0260] In an embodiment of the invention, the relative movement between the first end segment and the second end segment is coupled to any of the different transverse directions.

[0261] In an embodiment of the invention, the relative movement between the first end segment and the second end segment is coupled to the length direction.

[0262] In an embodiment of the invention, the resonant vibration frequency is coupled with a vibration damping, wherein the resonant vibration frequency damping is at least 0.001, such as at least 0.01, such as at least 0.03, such as at least 0.05.

[0263] Having a particular resonant vibration frequency can ensure certain damping characteristics for the conductor, which can be advantageous. In particular, vibrations at frequencies higher than the resonant frequency are typically highly damped. Furthermore, ensuring that the resonant vibration frequency has a particular minimum vibration damping can be advantageous to ensure robustness against vibrations in the tower.

[0264] Wind turbine blade rotors typically have a rotation period of a few seconds. However, wind turbine gearboxes may have gear ratios of 100:1 or even larger, which extends the relevant frequency regime. Having a resonant vibration frequency below this relevant frequency regime can therefore ensure vibration damping. Alternatively, the resonant vibration frequency can be designed to be far above the relevant frequency regime, so that destructive resonant vibrations do not occur at all.

[0265] Resonant vibration damping may also be understood by considering the electrical conductor as a driven damped simple harmonic oscillator, and may alternatively be referred to as the damping ratio.

[0266] In an embodiment of the invention, the electrical conductor has a current carrying capacity of at least 0.1 kiloamps, such as at least 0.3 kiloamps, such as at least 1.0 kiloamps, such as at least 3 kiloamps.

[0267] Having current carrying capability can ensure that the conductor is capable of its required task. In particular, embodiments of the present invention can advantageously allow for the use of less material or reduced cross-sectional area while still having a large current carrying capability.

[0268] Optionally, the upper limit of the current carrying capacity is at most 100 kiloamps, such as at most 80 kiloamps, such as at most 50 kiloamps.

[0269] In an embodiment of the invention, the conductance of the outer support structure is greater than the conductance of the inner bulk structure.

[0270] In an embodiment of the invention, the mass density of the outer support structure is greater than the mass density of the inner bulk structure.

[0271] Having conductor structures with different material compositions can advantageously allow for reductions in cost and weight of the conductors, which is advantageous.

[0272] For example, the outer surface structure may be formed of a material with high conductance, such as copper, while the inner bulk structure is formed of a material with a relatively low mass density, such as aluminum or tin. Because AC currents may flow primarily at the surface due to surface effects, the inner portion can advantageously be replaced with a lightweight material to reduce weight and cost without significantly reducing AC conductance while maintaining structural strength.

[0273] In an embodiment of the invention, the total surface area of ​​said intermediate segment is primarily defined by said outer surface structure.

[0274] In an embodiment of the invention, the different material compositions are different metal compositions, such as different metals.

[0275] Alternatively, the different material compositions may be different polymers / resins.

[0276] In an embodiment of the invention, the material of said outer surface structure is copper, silver or gold.

[0277] In an embodiment of the present invention, the material of the inner bulk structure is aluminum or tin.

[0278] In an embodiment of the present invention, the conductor is a bus bar.

[0279] In an embodiment of the present invention, each conductor branch of the plurality of conductor branches is solid.

[0280] In an exemplary embodiment of the invention, a conductor branch of the plurality of conductor branches is solid as opposed to being formed of stranded wire and as opposed to being formed of a foil / layer / sheet / plate / laminated conductor.

[0281] In an embodiment of the invention, the conductor is a non-insulated conductor.

[0282] In an embodiment of the invention, at least one material of said electrical conductor is at least one metal.

[0283] In an embodiment of the invention, the at least one metal comprises any of copper, tin, aluminum, iron, silver, titanium and gold.

[0284] It is further noted that the conductors may be based on one or more alloys, such as brass or steel, as well as based on conductive polymers, e.g., printable polymers, such as carbon-filled resin-based materials.

[0285] In an embodiment of the invention, two conductors are joined using mating teeth, slider locks, tongue and grooves, etc. This can facilitate the assembly of conductors such as busbars in an electrical system, particularly corner joints of busbars. Such joints can be stronger.

[0286] In the following, various embodiments of methods for coupling a first end segment of an electrical conductor to a second end segment of said electrical conductor within an electrical device are described.

[0287] In an embodiment of the invention, the electrical conductor is based on the digital representation of the electrical conductor.

[0288] In an embodiment of the present invention, the digital geometry optimization comprises a topology optimization.

[0289] In an embodiment of the present invention, the digital geometry optimization comprises a shape optimization.

[0290] In an embodiment of the invention, the digital geometry optimization comprises a generative design process.

[0291] Digital geometry optimization can be used to improve electrical conductors in general, and in particular to conserve material while advantageously taking into account the structural and vibrational properties of the conductors.

[0292] In an embodiment of the invention, the digital geometry optimization is based on one or more optimization criteria.

[0293] In an embodiment of the invention, the one or more optimization criteria include a size constraint of the conductor.

[0294] Size constraints may advantageously ensure that conductors fit into the physical locations where they are intended to fit.

[0295] In an embodiment of the invention, the one or more optimization criteria comprises a surface area of ​​the conductor.

[0296] An optimization criterion relating to surface area may for example advantageously concern maximizing the surface area of ​​the electrical conductors, in particular the surface area of ​​the conductor branches, in order to improve air cooling.

[0297] In an embodiment of the invention, the one or more optimization criteria comprises a volume of the electrical conductor.

[0298] A volume-related optimization criterion may for example advantageously concern the minimization of the area of ​​said electrical conductors, in particular the maximization of the surface area of ​​the conductor branches, in order to improve air cooling.

[0299] In an embodiment of the invention, the one or more optimization criteria comprises the ratio of the surface area to the volume of the electrical conductor.

[0300] Maximizing the ratio between surface area and volume advantageously ensures minimal use of materials while ensuring sufficient cooling.

[0301] In an embodiment of the invention, the one or more optimization criteria include a resonant vibration frequency coupled to relative movement between the first end segment and the second end segment.

[0302] By including a resonant vibration frequency, it can be ensured that this resonant vibration frequency is advantageously well positioned (in frequency space).

[0303] In an embodiment of the invention, the one or more optimization criteria includes vibration damping coupled with the resonant vibration frequency.

[0304] The vibration damping may be, for example, a minimum vibration damping associated with a resonant vibration frequency, which may advantageously reduce the risk of destructive resonant vibrations of the electrical conductor.

[0305] In an embodiment of the invention, the one or more optimization criteria comprises the current carrying capability of the electrical conductor.

[0306] The current carrying capacity may be, for example, the minimum power, e.g., minimum AC power, that an electrical conductor can conduct from a first end segment to a second end segment without danger. Such minimum power may further be via the ratio of a minimum cross-sectional area of ​​the electrical conductor to (AC) power, e.g., 300 square millimeters per megawatt. For example, if an electrical conductor must carry 2 megawatts, the electrical conductor must have a minimum cross-sectional area of ​​at least 600 square millimeters.

[0307] In an embodiment of the invention, the one or more optimization criteria include a minimum thickness of a conductor branch among the plurality of conductor branches.

[0308] Including a minimum thickness can advantageously ensure easier manufacture (e.g., via additive manufacturing) and / or minimum robustness of the electrical conductor.

[0309] In an embodiment of the present invention, the minimum thickness is between 0.1 mm and 1 cm, for example between 0.2 mm and 0.6 cm.

[0310] Having the resonant vibration frequency as a constraint may advantageously allow for undesirable resonant vibration frequencies of the electrical conductor to be avoided, which is advantageous, and may also advantageously allow for defining the approximate frequency at which vibration damping occurs, since damping typically occurs at frequencies higher than the resonant vibration frequency.

[0311] The resonant vibrational frequency may be, for example, either longitudinal or transverse.

[0312] In an embodiment of the invention, the method includes conducting an electrical current between the first end segment and the second end segment.

[0313] In an embodiment of the invention, the step of conducting an electric current between the first end segment and the second end segment is the step of conducting an alternating current between the first end segment and the second end segment.

[0314] In an embodiment of the invention, the step of conducting an electric current between the first end segment and the second end segment is the step of conducting a direct current between the first end segment and the second end segment.

[0315] In an embodiment of the invention, the step of conducting an electric current includes the step of transporting AC power, and a ratio of the minimum cross-sectional area of ​​the conductor to the AC power is at most 350 square millimeters per megawatt, such as at most 300 square millimeters per megawatt, such as at most 250 square millimeters per megawatt, for example at most 200 square millimeters per megawatt.

[0316] The geometries provided by embodiments of the present invention may potentially allow for advantageously reducing the minimum cross-sectional area of ​​a conductor in relation to the current being conducted, which may be understood as the smallest of all cross-sectional areas in a plane perpendicular to the length direction.

[0317] One aspect of the invention relates to the use of digital geometry optimization to at least partially form a digital representation of at least an electrical conductor, the physical conductor of an electrical installation of a renewable energy facility being based on said digital representation of said conductor.

[0318] The use of digital geometric optimization such as topology optimization, shape optimization or generative design processes to shape / design the conductors of a renewable energy facility is advantageous as it may allow the conductors to be tailored to the conditions of the renewable energy facility.

[0319] The physical conductor may be based on the digital representation through the manufacture of a physical conductor based on a design derived from the digital representation.

[0320] In an embodiment of the invention, the physical electrical conductor is an electrical conductor according to any of the embodiments of the present disclosure.

[0321] In the following, various embodiments of the electrical conductor according to the invention having different material compositions are described.

[0322] In an embodiment of the invention, the different material compositions are different metal compositions, such as different metals.

[0323] In an embodiment of the invention, the mass density of the outer support structure is greater than the material density of the inner bulk structure.

[0324] In an embodiment of the invention, the material of said outer surface structure is copper, silver or gold.

[0325] In an embodiment of the present invention, the material of the inner bulk structure is aluminum or tin.

[0326] Having a conductor with an outer surface structure that has a greater conductance than the inner bulk structure is advantageous because it potentially reduces excess material in the outer surface structure while maintaining structural support for the inner bulk structure. Such a conductor may, for example, have a cylindrical shape with the axis of the cylinder running longitudinally and the outer surface structure corresponding to a hollow cylinder shape around the inner bulk structure.

[0327] From the above, it should now be apparent that the present invention is directed to electrical conductors such as busbars having intermediate segments with branched topologies, which could potentially allow for improved vibration damping, heat dissipation, thermal expansion capabilities, conductance and visibility, while potentially reducing the amount of material required.

[0328] The present invention has been demonstrated above with respect to specific examples of conductors and methods for purposes of illustration rather than limitation. Details such as specific method and system structures have been provided for the purpose of understanding the embodiments of the present invention. It should be noted that detailed descriptions of well-known systems, devices, circuits and methods have been omitted so as not to obscure the description of the present invention with unnecessary details. It should be understood that the present invention is not limited to the specific examples described above, and that those skilled in the art can implement the present invention in other embodiments without these specific details. Thus, the embodiments disclosed in the figures and specification can be combined in any manner. Thus, the present invention may be designed and modified in numerous variations within the scope of the present invention as defined in the claims. [Explanation of symbols]

[0329] 1 Conductor 2 First End Segment 3 Second End Segment 4 Middle Segment 5 Conductor Branch 6 Inside corner 7 Spatial separation 8 Transverse 9 Lengthwise 10 Branch diameter 11 Adjacent separation distance 12 Corner radius 13 Branched stem 14 Branch line 15 Transverse plane 16 Cooling Channels 17 Channel opening 18 Line 19 Inner bulk structure 20 Outer surface structure 21 Central body segment 22 Transverse branch offshoot 23 Fastening hole 24 Intersection 25 Air guide fin 26 Air flow direction 27 Cooling structure 28 Additional electrical components (e.g. solid or flexible busbars) 29 Nuts and Bolts 30 Ferrite core 31 Conductor web-like structures 32 Inductor / winding part

Claims

1. A conductor (1) for electrical equipment, comprising: a first end segment (2); a second end segment (3); an intermediate segment (4) formed by a plurality of conductor branches (5a-5d) electrically and mechanically connecting the first end segment (2) and the second end segment (3); A conductor (1) comprising: the first end segment (2) and the conductor branches of the plurality of conductor branches (5a-5d) are monolithically integrated by a connection, thereby forming an inside corner (6) between the first end segment (2) and the conductor branches of the plurality of conductor branches (5) and spatially separating the conductor branches of the plurality of conductor branches (5) in two different transverse directions (8a, 8b); Electrical conductor (1).

2. 2. The electrical conductor (1) according to claim 1, wherein the inside corner (6) is formed as a concavely rounded inside corner (6).

3. The electrical conductor of claim 1 or 2, wherein the plurality of conductor branches are monolithically integrated through the first end segment and through the second end segment.

4. 3. The conductor of claim 1, wherein the second end segment and a conductor branch of the plurality of conductor branches are monolithically integrated by a rounded joint, thereby forming a concavely rounded inside corner between the second end segment and a conductor branch of the plurality of conductor branches and spatially separating the conductor branches of the plurality of conductor branches in the two different transverse directions.

5. 3. The electrical conductor (1) according to claim 1 or 2, wherein the plurality of conductor branches (5) form a web structure (31) between the first end segment (2) and the second end segment (2).

6. 3. The electrical conductor (1) according to claim 1 or 2, wherein the plurality of conductor branches (5) are twisted together in the longitudinal direction of the intermediate segment (4) without physical contact between the individual conductor branches.

7. 3. The electrical conductor (1) according to claim 1 or 2, comprising a cooling structure (27) extending longitudinally from the intermediate segment (4).

8. The electrical conductor (1) according to claim 1 or 2, wherein one or more of the plurality of conductor branches has an internal cooling channel.

9. The electrical conductor of claim 1 or 2, wherein two of the plurality of conductor branches are mechanically and electrically coupled by a transverse branch offshoot.

10. 3. The electrical conductor of claim 1, wherein the intermediate segment is a first intermediate segment, and the electrical conductor further includes a second intermediate segment formed by a second plurality of conductor branches that similarly electrically and mechanically couple the first end segment and the second end segment.

11. 3. The electrical conductor of claim 1 or 2, which is monolithic.

12. 3. The electrical conductor according to claim 1 or 2, at least partially manufactured by an additive manufacturing process.

13. 3. The electrical conductor (1) according to claim 1 or 2, comprising two or more central body segments (21), the conductor portions connected to the same central body segment (21) having different geometries.

14. The electrical conductor according to claim 1 or 2, wherein a branch diameter of one of the plurality of conductor branches is less than 3 cm, such as less than 2.5 cm, such as less than 2 cm, such as less than 1.5 cm.

15. having a resonant vibration frequency associated with relative movement between the first end segment and the second end segment; the resonant vibration frequency is at most 300 Hz, such as 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, such as at least 500 Hz, for example at least 1 kHz, for example at least 5 kHz; The conductor according to claim 1 or 2.

16. 3. The electrical conductor of claim 1, comprising an inner bulk structure and an outer surface structure, said inner bulk structure and said outer surface structure having different material compositions.

17. 1. A method of coupling a first end segment of an electrical conductor to a second end segment of the electrical conductor within electrical equipment, comprising: monolithically integrating the first end segment and a conductor branch of the plurality of conductor branches via a coupling portion to form an inside corner between the first end segment and a conductor branch of the plurality of conductor branches and to spatially separate the conductor branches of the plurality of conductor branches in two different directions; electrically and mechanically coupling the first end segment and the second end segment through an intermediate segment of the conductor formed by the plurality of conductor branches; A method comprising:

18. 18. The method of claim 17, wherein the coupling is a rounded coupling that forms a concavely rounded inside corner between the first end segment and the conductor branch of the plurality of conductor branches.

19. 19. A method according to claim 17 or 18, comprising establishing a digital representation of the electrical conductor.

20. 20. The method of claim 19, comprising performing a digital geometry optimization of the digital representation of the electrical conductor to at least partially form the plurality of conductor branches.

21. 19. The method of claim 17 or 18, comprising additively manufacturing the electrical conductor based on the digital representation of the electrical conductor.

22. Electrical equipment for a renewable energy facility, comprising the conductor described in claim 1 or 2.

23. A renewable energy facility comprising electrical equipment including the conductor described in claim 1 or 2.

24. Use of additive manufacturing for at least partially manufacturing electrical conductors for electrical installations in renewable energy facilities.

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