Power conductor and vehicle power distribution circuit incorporating the same

Patent metadata

Field	Value
Publication number	US-12016161-B2
Application number	US-202217810501-A
Country	US
Kind code	B2
Filing date	Jul 1, 2022
Priority date	Jul 1, 2021
Publication date	Jun 18, 2024
Grant date	Jun 18, 2024

Abstract

A power conductor for conducting electricity between a power source and a load is disclosed. A conductive body connects between the power source and the load. A sealed chamber is provided in the interior of the conductive body and contains a working fluid for changing phase when heated. A circuit, a vehicle power distribution circuit, and a vehicle incorporating the same are also disclosed.

First claim

What is claimed is:

1. A power conductor for conducting electricity, the power conductor comprising:
a conductive body configured to connect a power source and a load in a vehicle distribution circuit within a vehicle structure;
a sealed chamber in an interior of the conductive body;
a working fluid contained within the sealed chamber, the working fluid configured to change phase responsive to being heated;
a heatsink connector distinct and separate from the conductive body and thermally connecting the conductive body to the vehicle structure, wherein the heatsink connector surrounds i) a circumference of the conductive body, and ii) only a portion of the conductive body, and wherein the vehicle structure functions as a heatsink; and
an electrical insulator distinct and separate from the heatsink connector and disposed between the conductive body and a first portion of the heatsink connector in an area adjacent the vehicle structure, wherein the electrical insulator is not disposed between a second portion of the heatsink connector and the conductive body, and wherein the second portion is on an opposite side of the conductive body than the vehicle structure.

2. The power conductor of claim 1 , wherein the conductive body comprises:
a first connection terminal configured to connect to the power source; and
a second connection terminal configured to connect to the load.

3. The power conductor of claim 1 , further comprising:
a lining layer lining the sealed chamber,
wherein the lining layer includes a plurality of fluid channels configured to convey the working fluid by capillary action.

4. The power conductor of claim 1 , wherein the sealed chamber is sealed under a partial vacuum.

5. The power conductor of claim 2 , wherein the heatsink connector for thermally connecting the conductive body to the vehicle structure is located along a length of the conductive body between the first connection terminal and the second connection terminal.

6. The power conductor of claim 1 , wherein the working fluid is configured to vaporize from a liquid to a gas responsive to being heated.

7. The power conductor of claim 1 , wherein:
the sealed chamber has a vacuum; and
the vacuum of the sealed chamber and the working fluid are configured such that a boiling point of the working fluid corresponds to an operating temperature of the power conductor.

8. The power conductor of claim 1 , wherein the conductive body has a tubular construction.

9. The power conductor of claim 1 , wherein the conductive body comprises a metal envelope.

10. The power conductor of claim 1 , wherein the conductive body comprises a flexible envelope.

11. A circuit comprising:
a power source connection terminal configured to deliver a current from a power source;
a load connection terminal configured to deliver the current to a load in a vehicle distribution circuit within a vehicle structure; and
a power conductor configured to conduct electricity between the power source connection terminal and the load connection terminal, the power conductor including:
a conductive body configured to connect between the power source connection terminal and the load connection terminal;
a sealed chamber in an interior of the conductive body;
a working fluid contained within the sealed chamber, the working fluid configured to change phase responsive to being heated;
a heatsink connector distinct and separate from the conductive body and configured to connect the conductive body to the vehicle structure, wherein the heatsink connector surrounds i) a circumference of the conductive body, and ii) only a portion of the conductive body, and wherein the vehicle structure is configured to function as a heatsink; and
an electrical insulator distinct and separate from the heatsink connector and disposed between the conductive body and a first portion of the heatsink connector in an area adjacent the vehicle structure, wherein the electrical insulator is not disposed between a second portion of the heatsink connector and the conductive body, and wherein the second portion is on an opposite side of the conductive body than the vehicle structure.

12. The circuit of claim 11 , wherein:
the power conductor further includes a wick lining the sealed chamber of the power conductor; and
the wick comprises sintered metal powder.

13. A vehicle comprising:
a power source connection terminal configured to deliver a current from a power source;
a load connection terminal configured to deliver the current to a load in a distribution circuit of the vehicle within a structure of the vehicle; and
a power conductor configured to conduct electricity between the power source and the load, the power conductor including:
a conductive body configured to connect between the power source connection terminal and the load connection terminal;
a sealed chamber in an interior of the conductive body;
a working fluid contained within the sealed chamber, the working fluid configured to change phase responsive to being heated;
a heatsink connector distinct and separate from the conductive body and configured to connect the conductive body to the structure of the vehicle, wherein the heatsink connector surrounds i) a circumference of the conductive body, and ii) only a portion of the conductive body, and wherein the structure of the vehicle is configured to function as a heatsink; and
an electrical insulator distinct and separate from the heatsink connector and disposed between the conductive body and a first portion of the heatsink connector in an area adjacent the structure of the vehicle, wherein the electrical insulator is not disposed between a second portion of the heatsink connector and the conductive body, and wherein the second portion is on an opposite side of the conductive body than the vehicle structure.

14. The vehicle of claim 13 , wherein the heatsink of the vehicle comprises at least one of:
a vehicle chassis; or
a seat frame.

15. The vehicle of claim 13 , wherein a mass of the working fluid is configured such that the sealed chamber of the conductive body contains vapor and liquid over an operating temperature range of the vehicle at the power conductor.

16. The power conductor of claim 6 , wherein the sealed chamber is configured such that the working fluid in its vapor state is driven by a pressure differential to a region adjacent to the heatsink connector.

17. The power conductor of claim 7 , wherein the operating temperature is between 20 and 100 degrees Celsius.

18. The power conductor of claim 1 , wherein the working fluid comprises at least one of ammonia, methanol, and ethanol.

19. The power conductor of claim 1 , further comprising a first insulating layer surrounding a circumference of the conductive body in a first area not surrounded by the heatsink connector.

20. The power conductor of claim 19 , wherein the first area is i) between the power source and the heatsink connector, or ii) between the heatsink connector and the load.

21. The power conductor of claim 19 , further comprising a second insulating layer surrounding a circumference of the conductive body in a second area not surrounded by the heatsink connector and the first insulating layer.

22. The power conductor of claim 21 , wherein the heatsink is disposed between the first insulating layer and the second insulating layer.

Assignees

• Aptiv Technologies AG

Inventors

• Tournabien Guillaume
• Delas Leo

Classifications

• H05K7/2039

  characterised by the heat transfer by conduction from the heat generating element to a dissipating body (arrangements for increasing/decreasing heat-transfer, e.g. fins details, F28F13/00) · CPC title

• H05K7/20336

  Heat pipes, e.g. wicks or capillary pumps · CPC title

• H05K7/20327

  Accessories for moving fluid, for connecting fluid conduits, for distributing fluid or for preventing leakage, e.g. pumps, tanks or manifolds · CPC title

• H05K7/20318

  Condensers · CPC title

• H05K7/20309

  Evaporators · CPC title