WELDED JOINT ARRANGEMENT FOR COOLED POWER TRANSMISSION

Abstract

A welded connection arrangement for cooled current transmission is disclosed. The welded connection arrangement includes a tubular electrical line designed to conduct current from an electrical load, such as a charging socket, to a storage medium, such as a battery. The tubular electrical line includes a first end for connection to the electrical consumer and a second end for connection to the storage medium. The tubular electrical line is furthermore designed to accommodate a coolant for cooling the tubular electrical line. The weld connection arrangement includes an electrically conductive contact part attached to a respective end of the tubular electrical line in order to contact the same electrically. The weld connection arrangement includes a sealing plug inserted into the tubular electrical line at the respective end and, together with the electrically conductive contact part, is welded to the tubular electrical line in order to seal the tubular electrical line against leakage of coolant.

Claims

1. A weld joint assembly for cooled power transmission from an electrical load to a storage medium, the weld joint assembly comprising: a tubular electrical line configured to conduct electricity and to accommodate a coolant configured and arranged to cool the tubular electrical line, the tubular electrical line comprising a first end configured to electrically connect to an electrical consumer and a second end configured to electrically connect to a storage medium; an electrically conductive contact member arranged attached to a respective end of the tubular electrical lead and configured to electrically contact the tubular electrical lead; and a sealing plug arranged inserted into the tubular electrical line at the first end or the second end and welded together with the electrically conductive contact part to the tubular electrical line in order to seal the tubular electrical line against leakage of coolant.

2. The weld joint assembly according to claim 1, further comprising a friction-welded connection arrangement in which the electrically conductive contact part together with the sealing plug is friction-welded to the tubular electrical line.

3. The weld joint assembly according to claim 1, wherein the electrically conductive contact part and the tubular electrical line comprise different metals welded together.

4. The weld joint assembly according to claim 1, wherein the tubular electrical lead and the sealing plug comprise aluminum and the electrically conductive contact part comprises a copper part welded together with the aluminum of the tubular lead and the aluminum of the sealing plug.

5. The weld joint assembly according to claim 1, wherein the electrically conductive contact part is arranged welded to the tubular electrical cable by means of the sealing plug.

6. The weld joint assembly according to claim 1, wherein: the electrically conductive contact part comprises a first section and a second section mechanically and rigidly connected to one another; and the first portion is tubular and is welded to the first end or the second end of the tubular electrical cable.

7. The weld joint assembly according to claim 6, wherein: the first portion comprises a tubular hollow body welded to an outer surface of the tubular electric wire at the first end or the second end of the tubular electric wire; and the sealing plug is arranged attached to the first end or the second end in the tubular electrical cable and is welded to an inner surface of the tubular electrical cable.

8. The weld joint assembly according to claim 6, wherein the second section is plate-shaped and comprises a bore configured for mechanical and electrical contacting.

9. The weld joint assembly according to claim 6, wherein the first portion comprises a rotationally symmetrical body welded at the first end or the second end of the tubular electrical lead to the sealing plug on an inner surface of the tubular electrical lead.

10. The weld joint assembly according to claim 6, wherein the first section is shaped as a rotationally symmetrical friction welding tool.

11. The weld joint assembly according to claim 6, wherein the second section comprises a rotationally symmetrical body comprising a plug contact configured for mechanical and electrical contacting.

12. The weld joint assembly according to claim 1, wherein: the tubular electrical cable comprises at least one lateral bore for the introduction of coolant; and a cooling connection is arranged in the lateral bore and configured to lead the coolant into or out of the tubular electrical line.

13. The weld joint assembly according to claim 1, wherein the sealing plug comprises a cooling connection arranged and configured to introduce the coolant into the tubular electrical line.

14. The weld joint assembly according to claim 1, wherein the tubular electrical line comprises a T-shaped connection piece comprising three tubular line connections and at least one of the ends.

15. The weld joint assembly according to claim 14, wherein: a first line connection of the three tubular line connections comprises a coolant connection, a second lead terminal of the three tubular lead terminals is arranged welded to the electrically conductive contact portion; and a third cable connection of the three tubular cable connections is arranged welded to the tubular electrical cable.

16. A method of manufacturing a welded joint assembly for cooled power transfer from an electrical load to a storage medium, the method comprising the steps of: providing a tubular electrical line with a first end configured for electrical connection to an electrical consumer and a second end configured for electrical connection to a storage medium, the tubular electrical line configured to accommodate coolant; inserting a sealing plug at the first end or the second end into the tubular electrical cable; attaching an electrically conductive contact member to the first end or the second end of the tubular electric wire thereby enabling electrical contacting with the tubular electric wire; and welding the sealing plug together with the electrically conductive contact part to the tubular electrical line at the first end or the second end of the tubular electrical line in order to seal the same against leakage of coolant.

17. The method according to claim 16, wherein the welding comprises friction welding, and the method further comprises the step of friction welding the electrically conductive contact part and the closure plug to the tubular electrical line.

18. The method according to claim, further comprising the steps of attaching a cooling connection to the tubular electrical line and introducing or discharging coolant via the cooling connection into the tubular electrical line.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0053] Further advantages, features, and details of the various embodiments of this disclosure will become apparent from the ensuing description of a preferred exemplary embodiment and with the aid of the drawings. The features and combinations of features recited below in the description, as well as the features and feature combination shown after that in the drawing description or in the drawings alone, may be used not only in the particular combination recited, but also in other combinations on their own, without departing from the scope of the disclosure. An advantageous embodiment of the present invention is set out below with reference to the accompanying figures, wherein:

[0054] FIG. 1 depicts an exploded view of the connection zone of a welded connection arrangement 100 according to the invention;

[0055] FIG. 2 depicts a schematic representation of a welded joint arrangement 200 according to the invention, in which both ends 110a, 110b are in contact;

[0056] FIG. 3 depicts a schematic representation of a welded joint arrangement 300 according to the invention, in which the electrical contact part is shaped as a friction welding tool;

[0057] FIG. 4 depicts a schematic representation of a welded joint arrangement 400 according to the invention with a cooling connection on the pipe;

[0058] FIG. 5 depicts a schematic representation of a welded joint arrangement 500 according to the invention with a cooling connection pin; and

[0059] FIG. 6 depicts a schematic representation of a welded joint arrangement 600 according to the invention with a terminal as a T-piece.

[0060] The figures are merely schematic representations and serve only to explain the invention. Identical or similarly acting elements are consistently provided with the same reference signs.

DETAILED DESCRIPTION OF THE INVENTION

[0061] As used throughout the present disclosure, unless specifically stated otherwise, the term or encompasses all possible combinations, except where infeasible. For example, the expression A or B shall mean A alone, B alone, or A and B together. If it is stated that a component includes A, B, or C, then, unless specifically stated otherwise or infeasible, the component may include A, or B, or C, or A and B, or A and C, or B and C, or A and B and C. Expressions such as at least one of do not necessarily modify an entirety of the following list and do not necessarily modify each member of the list, such that at least one of A, B, and C should be understood as including only one of A, only one of B, only one of C, or any combination of A, B, and C.

[0062] In the following detailed description, reference is made to the accompanying drawings, which form a part thereof and in which specific embodiments in which the invention may be practiced are shown by way of illustration. It is understood that other embodiments may be utilized and structural or logical changes may be made without departing from the concept of the present invention. The following detailed description is therefore not to be understood in a limiting sense. Furthermore, it is to be understood that the features of the various embodiments described herein may be combined with each other, unless specifically stated otherwise.

[0063] The aspects and embodiments are described with reference to the drawings, wherein like reference signs generally refer to like elements. In the following description, numerous specific details are set forth for explanatory purposes in order to provide an in-depth understanding of one or more aspects of the invention. However, it may be apparent to one skilled in the art that one or more aspects or embodiments may be carried out with a lesser degree of specific detail. In other instances, known structures and elements are shown in schematic form to facilitate the description of one or more aspects or embodiments. It will be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the concept of the present invention.

[0064] FIG. 1 shows an exploded view of the connection zone of a welded joint arrangement 100 according to the invention.

[0065] A hollow body 110 (for example a tube made of aluminum) is used as a line for transmitting electricity, which is also referred to below as a tubular electrical line 110. The respective cable connection is connected to a contact part 120 by means of friction welding and a filler pin 130, also referred to below as a sealing plug 130.

[0066] A cooling medium can be placed in the pipe 110, which allows the pipe to cool down when heated.

[0067] FIG. 1 shows the connection zone or joining zone in more detail as an exploded view.

[0068] A copper contact part 120 serves as a possible screw-on point in the vehicle. The aluminum tube 110 serves on the one hand as a conductor and thus current carrier, on the other hand it can be filled with a cooling medium. The aluminum filler pin 130 serves as filler material for the friction welding process in order to completely close the joining zone. Closing the two joining zones, as shown in FIG. 2, creates a hollow area between the two contacts 121, which can be filled with a cooling medium.

[0069] In the following, the welded joint arrangement 100 is described in more detail in a more general embodiment.

[0070] The welded connection arrangement 100 is used for cooled power transmission from an electrical consumer, for example a charging socket, to a storage medium, for example a battery, for example a battery of an electrically operated vehicle. However, it can also be used for other purposes, for example for any type of power transmission that is associated with particular heat generation, so that cooling is necessary. Examples include use in electric motors, in a heat pump, in underfloor heating, in air conditioning units and in many other applications.

[0071] The welding connection arrangement 100 comprises a tubular electrical line 110, which is designed to conduct current from the electrical consumer, for example the charging socket, to the storage medium, for example the battery. The tubular electrical line 110 comprises a first end 110a for electrical connection to the electrical consumer, for example the charging socket, and a second end 110b for electrical connection to the storage medium, for example the battery. Only the first end 110a is shown in FIG. 1; both ends 110a and 110b are shown in FIG. 2. The second end 110b can be constructed analogously. The tubular electrical line 110 is also designed to accommodate a coolant for cooling the tubular electrical line 110.

[0072] The weld connection arrangement 100 comprises an electrically conductive contact part 120, which is attached to a respective end 110a, 110b of the tubular electrical line 110 in order to make electrical contact with the tubular electrical line 110. At the first end 110a, for example, an electrical contact can be made with the storage medium or the battery and at the second end 110b an electrical contact can be made with the electrical consumer or the charging socket.

[0073] The weld connection arrangement 100 comprises a sealing plug 130 which is inserted into the tubular electrical line 110 at the respective end 110a, 110b of the tubular electrical line 110, and is welded together with the electrically conductive contact part 120 to the tubular electrical line 110 in order to seal the tubular electrical line 110 against leakage of coolant.

[0074] The welded connection arrangement 100 can, for example, form a friction welded connection arrangement, in which the electrically conductive contact part 120 together with the sealing plug 130 is friction welded to the tubular electrical cable 110.

[0075] For example, the electrically conductive contact part 120 and the tubular electrical cable 110 can be made of different metals that are welded together.

[0076] For example, the tubular electrical conduit 110 and the closure plug 130 may be aluminum and the electrically conductive contact member 120 may be a copper member welded together with the aluminum of the tubular conduit 110 and the aluminum of the closure plug 130.

[0077] The electrically conductive contact part 120 can be welded to the tubular electrical cable 110 by means of the sealing plug 130. The electrically conductive contact part 120 can thus form a unit or a molded part with the sealing plug 130 and the electrical cable 110.

[0078] The electrically conductive contact part 120 may have a first section 120a and a second section 120b, as shown in more detail in FIG. 2, which are mechanically rigidly connected to each other. The first section 120a of the electrically conductive contact part 120 may be tubular and may be welded to the respective end of the tubular electrical line 110.

[0079] The first portion 120a may be a tubular hollow body that is welded to an outer surface of the tubular electrical conduit 110 at the respective end 110a, 110b of the tubular electrical conduit 110. The sealing plug 130 can be attached to the respective end 110a, 110b in the tubular electrical cable 110 and can be welded to an inner surface of the tubular electrical cable 110. The outer surface here refers to the cylindrical outer surface of the tube 110 at the respective end 110a, 110b. The inner surface here refers to the cylindrical-shell-shaped inner side of the tube 110 at the respective end 110a, 110b.

[0080] The second section 120b can be plate-shaped or form a small plate and have a hole 121 for mechanical and electrical contacting. For example, the plate 120b can be screwed or clamped to a pole of the storage medium or the battery via the hole 121 or, for example, attached to a corresponding battery terminal in the vehicle.

[0081] FIG. 2 shows a schematic representation of a welded joint arrangement 200 according to the invention, in which both ends 110a, 110b are in contact.

[0082] In contrast to the illustration in FIG. 1, in which only one end 110a of the tubular electrical cable 110 is shown in an exploded state, in FIG. 2 both ends 110a, 100b of the tubular electrical cable 110 are shown in a joined state.

[0083] That is, the weld joint assembly 200 comprises a sealing plug 130 at each end 110a, 110b, which is inserted there into the tubular electrical conduit 110 and is welded to the tubular electrical conduit 110 together with the electrically conductive contact portion 120 to seal the tubular electrical conduit 110 against leakage of coolant at both ends 110a, 110b.

[0084] FIG. 3 shows a schematic representation of a welded joint arrangement 300 according to the invention, in which the electrical contact part is shaped as a friction welding tool.

[0085] The welding connection arrangement 300 can correspond to the welding connection arrangement 100 or 200 as described above with respect to FIGS. 1 and 2, with the difference that the electrical contact part 120 can be designed as a friction welding tool at least at one end 110a, 110b.

[0086] As described above, the electrically conductive contact part 120 can have a first section 120a and a second section 120b, whereby only the first section 120a is shown in more detail in FIG. 3, which are mechanically rigidly connected to one another.

[0087] The first section 120a of the electrically conductive contact part 120 can be formed as a rotationally symmetrical body, which can be shaped as a hollow body or a completely filled body. The rotationally symmetrical body can, for example, be constructed from several cylindrical sections arranged along an axis of rotation (in the x-direction, see FIG. 2), as shown in FIG. 3.

[0088] The first portion 120a of the electrically conductive contact portion 120 may be welded to the sealing plug 130 on an inner surface of the tubular electrical conduit 110 at the respective end 110a, 110b of the tubular electrical conduit 110. For example, the sealing plug 130 can be inserted into the tubular electrical line 110 at the respective end 110a, 110b and welded to the first section 120a of the electrically conductive contact part 120, which is also inserted into the tubular electrical line 110.

[0089] When manufacturing such a welded connection arrangement, the first section 120a of the electrically conductive contact part 120 can be inserted into a friction welding system as a friction welding tool and a friction weld can be produced with the friction welding system. After this friction welding has been produced, the friction welding tool can be removed from the friction welding system and remain in the welding connection arrangement 300 as electrically conductive contact part 120.

[0090] As mentioned above, the first section 120a may be formed as a rotationally symmetrical friction welding tool.

[0091] The friction welding tool can be designed as a CCS (Combined Charging System) DC PIN, for example.

[0092] The second section 120b can be a rotationally symmetrical body that has a plug contact 122 for mechanical and electrical contacting. Such a plug contact 122 can, for example, be plugged into an electrical consumer, for example a charging socket, in order to enable electrical contacting with the electrical consumer or the charging socket.

[0093] FIG. 4 shows a schematic representation of a welded joint arrangement 400 according to the invention with a cooling connection 140 on the pipe 110.

[0094] The welded joint arrangement 400 can correspond to the welded joint arrangement 100 or 200 as described above for FIGS. 1 and 2.

[0095] In addition, the tubular electrical conduit 110 may have one or more lateral bores for introducing or discharging coolant. A cooling connection 140 may be provided in the lateral bore to introduce or discharge the coolant into the tubular electrical conduit 110.

[0096] A screw with a seal can be screwed, welded or glued into the bore, which forms the cooling connection 140, onto which a coolant line can be plugged or attached in some other way.

[0097] With such a cooling connection 140, the coolant can circulate through the cooling connection 140 on the tube 110. As described above with respect to FIGS. 1 and 2, the sealing plug 130 or filler pin closes the end-face connection during friction welding, so that a subsequent bore for the cooling connection 140, as shown here in FIG. 4, may be necessary.

[0098] FIG. 5 shows a schematic representation of a welded connection arrangement 500 according to the invention with a cooling connection pin.

[0099] The welded joint arrangement 500 can correspond to the welded joint arrangement 100 or 200 as described above for FIGS. 1 and 2.

[0100] The sealing plug 130 can have a cooling connection 140 or cooling connection pin in order to introduce the coolant into the tubular electrical line 110. The cooling connection 140 can be attached to the end face of the tube 110. The cooling connection 140 can be constructed in the same way as the cooling connection 140 of FIG. 4. A coolant hose can be connected to the cooling connection pin 140 in order to allow coolant to circulate in the tube 110. The cooling connection pin can establish a material connection to the tube 110 and to the contact part 120 and additionally comprise the cooling connection 140.

[0101] FIG. 6 shows a schematic representation of a welded joint arrangement 600 according to the invention with a terminal as a T-piece.

[0102] The weld joint arrangement 600 can correspond to the weld joint arrangement 100 or 200 as described above for FIGS. 1 and 2.

[0103] In addition, the tubular electrical line 110 can have a T-shaped connection piece 150 with three tubular line connections 150a, 150b, 150c at at least one of the ends 110a, 110b.

[0104] A first cable connection 150a of the three tubular cable connections 150a, 150b, 150c can be designed as a coolant connection. A second line connection 150b of the three tubular line connections 150a, 150b, 150c can be welded to the electrically conductive contact part 120. A third line connection 150c of the three tubular line connections 150a, 150b, 150c can be welded to the tubular electrical line 110.

[0105] The terminal can be designed as a T-piece with or without a coolant hose connection. The terminal can be electrically and mechanically connected to the tubular electrical cable 110, for example via a TIG weld (tungsten inert gas weld).

[0106] The invention also relates to a method of manufacturing a welded connection arrangement 100, 200, 300, 400, 500, 600 for cooled current transmission from an electrical consumer, for example a charging socket, to a storage medium, for example a battery, for example a battery of an electrically operable vehicle, as described above with respect to FIGS. 1 to 6.

[0107] Such a procedure comprises the following steps:

[0108] Provision of a tubular electrical line 110 with a first end 110a for electrical connection to the electrical consumer, for example the charging socket, and a second end 110b for electrical connection to the storage medium, for example the battery, as explained in more detail above, for example with regard to FIGS. 1 and 2, wherein the tubular electrical line 110 is designed to accommodate coolant.

[0109] Insertion of a sealing plug 130 at a respective end 110a, 110b of the tubular electrical cable 110 into the tubular electrical cable 110, as explained in more detail, for example, above with respect to FIGS. 1 and 2.

[0110] Attaching an electrically conductive contact part 120 to a respective end 110a, 110b of the tubular electrical line 110 for electrically contacting the tubular electrical line 110, as explained in more detail, for example, above with respect to FIGS. 1 and 2.

[0111] Welding of the sealing plug 130 together with the electrically conductive contact part 120 to the tubular electrical line 110 at the respective end 110a, 110b of the tubular electrical line 110 in order to seal the same against an escape of coolant, as explained in more detail, for example, above with respect to FIGS. 1 and 2.

[0112] The welding may comprise friction welding, in which the electrically conductive contact part 120 together with the sealing plug 130 is friction welded to the tubular electrical cable 110.

[0113] The method may further comprise the following step: Attaching a cooling port 140 to the tubular electrical conduit 110 and introducing or discharging coolant into the tubular electrical conduit via the cooling port 140, for example as discussed in more detail above with respect to FIGS. 4 and 5.

[0114] Since the devices and methods described in detail above are examples of embodiments, they can be modified to a wide extent by the skilled person in the usual manner without leaving the scope of the invention. In particular, the mechanical arrangements and the proportions of the individual elements with respect to each other are merely exemplary. Some preferred embodiments of apparatus according to the invention have been disclosed above. The invention is not limited to the solutions explained above, but the innovative solutions can be applied in different ways within the limits set by the claims.