Search

DE-102024133127-A1 - Electrical conductor element and electrical machine

DE102024133127A1DE 102024133127 A1DE102024133127 A1DE 102024133127A1DE-102024133127-A1

Abstract

The present invention relates to an electrical conductor element (100) comprising: a waveguide (2) forming a fluid channel (4), and a plurality of individual conductors (3), wherein the waveguide (2) and the plurality of individual conductors (3) are embedded in a resin body (1). The present invention further relates to an electrical machine (200) comprising: a winding system (6.1) comprising a plurality of electrical conductor elements (100) according to the invention, and a cooling system (8) fluidically connected to the fluid channel (4) of the plurality of electrical conductor elements (100).

Inventors

  • Maximilian Clauer

Assignees

  • DR. ING. H.C. F. PORSCHE AKTIENGESELLSCHAFT

Dates

Publication Date
20260513
Application Date
20241113

Claims (10)

  1. Electrical conductor element (100) comprising: a waveguide (2) forming a fluid channel (4), and a plurality of individual conductors (3), the waveguide (2) and the plurality of individual conductors (3) being embedded in a resin body (1).
  2. Electrical conductor element (100) according to Claim 1 , wherein the synthetic resin body (1) consists of a synthetic resin material which has a thermal conductivity increased by fillers.
  3. Electrical conductor element (100) according to one of the preceding claims, wherein the synthetic resin body (1) has a rectangular cross-section.
  4. Electrical conductor element (100) according to one of the preceding claims, wherein the waveguide (2) is arranged centrally in the resin body (1).
  5. Electrical conductor element (100) according to one of the preceding claims, wherein the individual conductors (3) are each designed as strands.
  6. Electrical conductor element (100) according to one of the preceding claims, further comprising at least one connecting component (5) which is arranged at one end of the electrical conductor element (100), which is electrically connected to the waveguide (2) and to the plurality of individual conductors (3), and which is fluidically connected to the fluid channel (4).
  7. Electrical conductor element (100) according to one of the preceding claims, wherein the at least one connecting component (5) comprises a coupling nozzle (5.1) which is fluidically connected to the fluid channel (4).
  8. Electrical conductor element (100) according to one of the preceding claims, wherein the electrical conductor element (100) is shaped in a wave-like form.
  9. Electric machine (200) comprising: a winding system (6.1) comprising a plurality of electrical conductor elements (100) according to one of the preceding claims, and a cooling system (8) fluidically connected to the fluid channel (4) of the plurality of electrical conductor elements (100).
  10. Electric machine according to Claim 9 , wherein the winding system (6.1) comprises a plurality of electrical conductor elements (100) according to Claim 8 It comprises and is designed as a wave winding system.

Description

The present invention relates to an electrical conductor element and an electrical machine with a winding system comprising a plurality of such electrical conductor elements. The present invention is based on the objective of enabling the realization of an electric machine that has a relatively high continuous operating power. This problem is solved according to the invention by an electrical conductor element having the features of claim 1 and by an electrical machine having the features of claim 9. The electrical conductor element according to the invention comprises a waveguide that forms a fluid channel. Specifically, the fluid channel is formed by the central cavity of the waveguide. The waveguide is made of a material with relatively high electrical conductivity, typically a metal, and preferably has a round or rectangular cross-section. The electrical conductor element according to the invention further comprises a plurality of individual conductors arranged adjacent to the waveguide. Preferably, the individual conductors run substantially parallel to the waveguide. However, it is also conceivable that the individual conductors run helically around the waveguide. The individual conductors also consist of a material with relatively high electrical conductivity, typically a metal. According to the invention, the waveguide and the plurality of individual conductors are embedded in a resin body and thus reliably and permanently connected to one another by the resin body. The resin body consists of an electrically insulating resin, preferably an epoxy resin, and completely surrounds the waveguide and the individual conductors when viewed in a cross-section of the conductor element, so that no additional insulating materials are required for the generally necessary electrical insulation of the conductor element. According to the invention, the individual conductors are thermally connected to the waveguide via the resin body, so that not only the waveguide but also the individual conductors can be effectively cooled by a cooling fluid conveyed through the fluid channel formed by the waveguide. This effective cooling makes it possible to subject the electrical conductor element according to the invention to particularly high current densities during operation. The use of the plurality of individual conductors effectively reduces AC losses compared to an electrical conductor element made of a solid material. The electrical conductor element according to the invention therefore enables the realization of an electrical machine that has a relatively high continuous operating power. Preferably, the resin body consists of a resin material that exhibits a relatively high thermal conductivity for a resin material, enhanced by fillers. This enables a particularly effective thermal connection of the individual conductors to the waveguide and thus particularly effective cooling of the individual conductors by a cooling fluid conveyed through the fluid channel. Since stator slots of electrical machines often have a rectangular cross-section, the resin body preferably has a rectangular cross-section to enable efficient filling of the stator slots by several stacked electrical conductor elements. Preferably, the waveguide - viewed in cross-section of the electrical conductor element - is arranged centrally in the resin body to achieve the best possible thermal connection to all individual conductors. Preferably, the individual conductors are each designed as strands, i.e., each conductor consists of a bundle of individual wires, in order to achieve particularly low alternating current losses. Preferably, the electrical conductor element according to the invention additionally comprises at least one connecting component arranged at one end of the electrical conductor element. The connecting component consists of a material with relatively high electrical conductivity, preferably a metal, and is electrically connected to the waveguide and to the plurality of individual conductors, so that the connecting component enables simple electrical contact of the waveguide and all individual conductors. Preferably, the connecting component is sleeve-shaped and encloses ends of the waveguide and the individual conductors on a radial outer surface and preferably also at least the ends of the individual conductors on their end faces. The connecting component is also fluidically connected to the fluid channel, so that the fluid channel formed by the waveguide can be easily connected to a cooling circuit via the connecting component. Preferably, the electrical conductor element comprises two connecting components, each located at one of the two are located at opposite ends of the electrical conductor element. Preferably, the at least one connecting component comprises a coupling nozzle which is fluidically connected to the fluid channel formed by the waveguide in order to enable easy connection of the electrical conductor element to a coo