DE102024201596A1 - Electrical resistance - Google Patents

Abstract

Disclosed is a contact element (100), in particular a contact plate, comprising:- a first contact element side (100a) with a contact element contact section (100') which is designed to come into contact, directly or via an intermediate element, with a cooling element contact section (101') or with one or more heat-generating switching means (102) of an electrical resistor for introducing heat into the contact element (100) by means of thermal conduction;- a second contact element side (100b) for dissipating the heat to a coolant.Furthermore, a cooling element, a cooling circuit element and a coolable resistor are disclosed.

Description

The present invention relates to a contact element, in particular a contact plate, a cooling element, a cooling circuit element and a coolable resistor.

Particularly in the field of drive technology, especially in commercial vehicles, excess braking energy can be converted into braking resistors. The vehicle's kinetic energy is converted into electrical energy, for example, by a generator brake (drive motor in recuperation mode). If this energy cannot be used for other purposes (e.g., stored in a battery), it is converted into heat in a braking resistor. The resistor acts as a consumer, converting electrical energy into heat. This heat must then be dissipated accordingly to prevent the braking resistor from overheating.

Resistors of this type typically have two partial resistors connected in parallel, through which the power supplied via an electrical connection of the resistor is conducted. The electrical power is usually supplied to the partial resistors by switching devices that adjust the required current using pulse-width modulation (PWM).

Resistors of the above-mentioned type typically have a cooling circuit designed to cool the resistor elements. The cooling capacity is typically in the range of 50 to 250 kW. In addition, such a resistor requires an additional cooling circuit to cool the switching elements, which generate heat, particularly in PWM-based operation, due to the switching processes required for this. Cooling of the switching elements can be provided either permanently or on-demand. Cooling of the switching elements is particularly necessary at high switching frequencies of the PWM control and/or high currents to be switched and can then be carried out on an as-needed basis. Therefore, such resistors are complex in design and require intensive maintenance due to the two cooling circuits.

It is therefore an object of the present invention to show possibilities how such a resistance can be reduced in complexity, in particular by dispensing with one of the cooling circuits.

This problem is solved by the subject matter of the independent claims. Advantageous further developments are the subject matter of the dependent claims.

The following section describes the structure of a special resistor and its individual elements. Then, options for reducing the complexity of a resistor, and of a special resistor in particular, are described.

A plate is disclosed. The plate has a first side coated with an electrically insulating layer, wherein an electrical conductor is applied to and/or embedded in the electrically insulating layer. Furthermore, the plate has a second side on which elevations are provided. The plate is designed to be part of a coolable resistor or a coolable resistor unit.

The elevations are embossed into the plate as projections. When two plates are in contact, these projections can be in contact with the opposite projection of the plate and can be joined, for example, by laser welding. Multiple projections can form contact points during welding.

This enables the formation of flow channels. The raised portion also contributes to load transfer, which can minimize plate deformation, for example, initiated by coolant pressure. Furthermore, the raised portions increase the degree of turbulence and thus improve heat transfer into the coolant. Numerical simulations have shown that heat transfer can be increased by 15% compared to conventional beads.

Furthermore, there is no need to divert the flow, which avoids dead spaces and thus improves heat transfer.

Preferably, a groove is provided on one edge of the first side (more preferably running along the edge), which is adapted to receive the edge portion of a seal. This has the advantage that two first sides of two opposing plates do not need to be cast, as was the case in the prior art, but rather that they can be releasably connected to one another by a seal. The edge of the plates is also used to join the two plates on the second side by laser welding.

Preferably, the electrical conductor is arranged between elevations (the electrical conductor is arranged on the first side of the plate - the elevations on the second side of the plate are therefore designed as depressions or dents - the term "elevation" has been uniformly used, however). Further, it is preferably arranged in a meandering pattern around some or all of the elevations (or depressions/dents). This places the electrical conductor very close to the respective elevations (or depressions/dents), allows for a large length of electrical conductor to be accommodated, and also provides a very large surface area, which further increases heat transfer.

Preferably, electrical contact surfaces are provided at each end of the electrical conductor, each of which is adapted to be contacted by a spring element. This can be connected to a connector plug through which the electrical current is introduced into the board. This eliminates the need for soldering connectors, etc., which minimizes manufacturing costs. The contact surfaces are preferably printed and provided with an additional foil (using a soldering process) to serve as a sacrificial layer against abrasion of the spring contact.

Preferably, the plate further comprises at least one, preferably two, openings, with (further) elevations preferably being provided around the openings on the second side of the plate. These elevations serve to stabilize the openings, preventing deformation by fluid. Furthermore, a contact pressure is generated for the seals, which further improves the seal tightness.

The elevations are preferably point-shaped, cylindrical, or hemispherical, making them easy to emboss into the plate. Furthermore, this allows for the formation of a transient wake zone, which ensures heat dissipation in the wake area. Contours with a sharp edge, on the other hand, would create larger, stationary wake zones, which would prevent heat dissipation.

A plate pair comprises two plates, in particular as described above, in which the second sides of two plates are arranged opposite one another. The edges of the second sides of the two plates are tightly connected to one another, preferably by a weld.

The elevations on the second side of two plates are also preferably connected to each other (e.g. welded, e.g. by means of a spot weld or weld seam), thus forming smaller flow channels. The incoming coolant is distributed evenly within the gap or cavity between two plates and enables homogeneous heat dissipation. In this way, a stable unit can be formed, as the internal pressure forces can be dissipated by the inflow of the fluid, thus minimizing deformation. The stress on the electrically insulating layer can thus be minimized. Furthermore, the flow cross-section of the flow channels is maintained and does not bulge. The large heat exchanger surfaces are essentially made possible by the plate construction. However, the plate structure can be susceptible to deformation due to the internal pressure of the coolant. Load transfer is ensured with the help of the elevations and their connection to the opposite plate, in particular to the elevations on the opposite plate.

Preferably, a plurality of coolable resistor units and seals are provided, and a seal is always assigned to two coolable resistor units or arranged between two coolable resistor units (coolable resistor units and seal are stacked one on top of the other). A closure plate is provided as the outer boundary of each coolable resistor (a first side of a plate, as described above, for example, is in contact with the closure plate, but in this case is not provided with an electrical conductor), with all plate pairs and the connection plates being connected to one another with a fixing element. This fixing element is preferably a screw. This fixing element allows all coolable resistor units and all seals to be pressed together, thus creating a compact and, above all, leak-proof design. At the same time, however, the fixing element can be removed again if, for example, a plate pair (a coolable resistor unit) needs to be replaced due to a defect or a leak.

This makes it very easy to stack any number of plate pairs on top of each other; the number can be varied depending on the power requirements of the coolable resistor. The seals prevent liquid from penetrating parts with electrical conductors. The elevations in the plates also serve to transfer the load of the seals, particularly those elevations arranged around openings in the plate. Plastic deformation of the sheet metal structure, in particular of a plate, can thus be prevented. The seal preferably has an edge section that can engage with the grooves of two opposite first sides of plates of the plate pairs. This would accordingly establish a particularly efficient sealing effect.

It can also be provided that between the stack arrangement of the resistance units or the plate pairs described here and A further element, such as a cooling circuit element described below, is provided on one end plate of the stack or on both sides of the stack. Then, the respective first side of a plate of such a plate pair is not in contact with the respective end plate because the cooling circuit element is arranged between them.

The coolable resistor preferably has at least one inlet and one outlet, each of which is provided in a closure plate, e.g., as described above. A hydraulic connection is also preferably provided here. All openings of the plate are then arranged one below the other and form a first collection area, and all second openings of the plate are also arranged one below the other and form a second collection area. The inlet and outlet are either connected to the first collection area (or a section thereof) or to the second collection area (or a section thereof), or are divided between both collection areas—i.e., the first collection area is connected to the inlet and the second collection area to the outlet, or vice versa. The collection areas can be divided into several sections by closed plates.

Further preferably, at least one of the first openings below the second opening of a coolable resistance unit is closed, while fluid can still flow from the inlet to the outlet. This makes it possible to connect a certain number of coolable resistance units in parallel or series, depending on the specific requirements. This can be arranged very flexibly without requiring major modifications to the individual elements – all that is required is to close some of the first openings and some of the second openings of the coolable resistance units in the overall system.

The closed first and second openings serve to connect some of the existing coolable resistance units in parallel and others in series, thus directing the cooling fluid or coolant accordingly. Both collection areas can thus be subdivided. This allows a certain number of coolable resistance units to be connected in parallel or in series, depending on the specific requirements. Furthermore, the variable arrangement of the connection also allows for a gradual increase in flow velocity (by reducing the number of plates in the parallel-connected segments), which serves to improve heat transfer and compensate for the preheating of the coolant.

• - Die Einzelströme an den Federkontakten zu minimieren
• - Die spezifische Belastung je Platte in Abhängigkeit der Kühlmitteltemperatur zu bringen. Dabei werden die Platten, die strömungstechnisch dem Einlass zugerichtet sind, stärker belastet (durch die niedrigere Temperatur des Kühlmittels, welches eine niedrige Temperatur des Leiters bewirkt, was wiederum einen geringeren Widerstandswert verursacht). Der relativ gesehen, geringere Widerstandswert am Einlass im Vergleich zum Auslass, führt zu einem höheren Stromfluss, der mit I² in die Leistungsberechnung eingeht. Respektive wird das strömungsseitig letzte kühlbare Widerstandselement mit geringerer Leistung beaufschlagt

The connection of the coolable resistance elements is deliberately designed for parallel connection in order to:

• - Minimize the individual currents at the spring contacts
• - To make the specific load per plate dependent on the coolant temperature. The plates that are fluidically aligned with the inlet are subjected to greater load (due to the lower coolant temperature, which results in a lower conductor temperature, which in turn results in a lower resistance value). The relatively lower resistance value at the inlet compared to the outlet leads to a higher current flow, which is included in the power calculation as I ² . Accordingly, the last coolable resistance element on the flow side is subjected to a lower power load.

A resistor as described above can have switching means which, in particular by means of PWM-based operation, take over the current and thus power supply to the partial resistors (also referred to above as plate pairs or coolable resistor units). The switching means are heated in the process and must therefore be cooled permanently or at least as needed (e.g., when heated accordingly). A separate cooling circuit is usually provided for this purpose. Therefore, options for reducing the complexity of such a resistor are described below. However, these are also generally applicable to other liquid-cooled resistors. Therefore, a combination of the elements described below with the resistor described above is possible; however, this should not be understood as a limitation of the invention.

• - eine erste Kontaktelementseite mit einem Kontaktelementkontaktabschnitt, der dazu ausgebildet ist, direkt oder über ein Zwischenelement zur Einleitung von Wärme mittels Wärmeleitung in das Kontaktelement mit einem Kühlelementkontaktabschnitt oder mit einem oder mehreren Wärme erzeugenden Schaltmitteln eines elektrischen Widerstands in Kontakt zu treten;
• - eine zweite Kontaktelementseite zur Abgabe der Wärme an ein Kühlmittel bzw. Kühlfluid.

Disclosed is a contact element comprising:

• - a first contact element side with a contact element contact section which is designed to come into contact with a cooling element contact section or with one or more heat-generating switching means of an electrical resistor directly or via an intermediate element for introducing heat into the contact element by means of thermal conduction;
• - a second contact element side for transferring the heat to a coolant or cooling fluid.

The contact element can be designed in particular as a contact plate. Preferably Then, the first contact element side is formed as the first contact plate side, and the second contact element side is formed as the second contact plate side. The first contact plate side and the second contact plate side are preferably opposite each other. They thus form the top and bottom of the contact plate, respectively. The first contact plate side has the contact element contact section and the contact plate contact section, respectively.

Preferably, the contact element contact section is kept free from other elements that introduce heat into the contact element by thermal conduction, so that only the cooling element contact section can introduce heat into the contact element contact section and thus into the contact element by thermal conduction when the cooling element contact section is in contact with the contact element contact section. This ensures that the contact element can act as the deepest possible heat sink relative to the cooling element contact section in order to improve heat transfer from the cooling element contact section to the contact element contact section.

Preferably, the contact element contact section is kept free of other elements that introduce heat into the contact element by conduction, so that only the switching means(s) can introduce heat into the contact element contact section and thus into the contact element by conduction when the switching means(s) are in contact with the contact element contact section. This ensures that the contact element can act as the deepest possible heat sink relative to the switching means(s) in order to improve heat transfer from the switching means(s) to the contact element contact section.

The second contact element side is preferably designed to enable sufficient heat transfer to the coolant.

Preferably, the contact element contact section is identical to the first contact element side or forms at least 25%, preferably at least 50%, of the area of the first contact element side. The larger the contact element contact section, the larger the area over which heat can be introduced into the contact element by thermal conduction. Furthermore, a homogeneous heat distribution in the contact element contact section can be achieved over the largest possible area.

Preferably, a region of the first contact element side that lies outside the contact element contact section is coated with an electrically insulating layer. An electrical conductor can be applied to the electrically insulating layer or embedded in it. Current flowing through the conductor heats it, so that the resulting heat can also be introduced into the contact element.

The conductor can in particular be designed like the conductor of the plate described above, preferably when the contact element is designed as a contact plate described above.

The electrically insulating layer can also extend additionally onto the contact element contact section, so that, particularly when the contact element is plate-shaped, the first contact element side can be covered with the layer. The electrical conductor can be applied to the layer or embedded in it. It can extend into the area of the contact plate contact section or leave it omitted. Particularly when the contact element is designed as a plate, it is advisable to apply the layer to the first contact element side, both to the contact element contact section and to an area lying outside the contact element contact section, so that a plane-parallel design of the plate is possible and no bulges arise. Covering the first contact element side as completely as possible with the layer, which is printed on, for example, thus reduces weak points in the plate structure, particularly when the contact plate is made of very thin, sheet-like material. The layer is preferably applied over the entire surface of the first contact element side. The layer can be printed on, in particular using a screen printing process.

Preferably, the second contact element side has elevations.

Preferably, the elevations of the contact element are point-shaped, cylindrical or hemispherical.

The elevations can in particular be designed like the elevations of the plate described above, preferably when the contact element is designed as a contact plate described above.

The elevations can be embossed into the contact element as humps, preferably when the contact element is designed as a contact plate as described above.

If the contact element, preferably when the contact element is designed as a contact plate as described above, is located with a cover element described later, which is preferably designed as cover plate, or a plate described above with the respective side having elevations against each other, the elevations, in particular the humps, are positioned on the contact element such that they are in contact with an opposite elevation, in particular an opposite hump, of the cover element or the plate described above.

The elevations can be connected or joined to each other, for example, by means of a material bond, particularly by laser welding. Multiple elevations can form contact points during welding.

The elevations enable the formation of flow channels on the second contact element side. The elevations can stiffen the contact element, preferably when the contact element is designed as a contact plate as described above. The elevations can contribute to load transfer, which can minimize deformation of the contact element, for example, initiated by the pressure of the coolant on the second contact element side, preferably when the contact element is designed as a contact plate as described above. Furthermore, the elevations increase the degree of turbulence and thus also improve the heat input into the coolant. Numerical simulation has shown that heat transfer could be increased by 15% compared to normal beads.

Furthermore, there is no need to divert the flow, which avoids dead spaces and thus improves heat transfer.

Preferably, the area of the second contact element side opposite the contact element contact section is not provided with elevations, preferably when the contact element is designed as a contact plate as described above. Particularly in the case of embossed elevations, embossing of the contact element can be omitted for full-surface contact of the cooling element contact section with the contact element contact section or the switching means(s) and the associated improved heat conduction in this area, because the elevations would possibly be formed as depressions on the first contact element side, which would make full-surface contact with the cooling element contact section or the switching means(s) more difficult at the contact element contact section. Nevertheless, embossing of the elevations or depressions in the contact element contact section should not be ruled out, even when the contact element is designed as a contact plate as described above. Measures to improve heat conduction may then be necessary, such as inserting an intermediate element, such as a thermally conductive paste, to improve the contact and thus the heat conduction between the cooling element contact section or the switching means(s) and the contact element contact section.

Preferably, and in particular when the contact element is designed as a contact plate as described above, the electrical conductor is arranged on the first contact element side between the elevations (the electrical conductor is arranged on the first contact element side - the elevations on the second contact element side are therefore designed as depressions or dents here - but the term "elevation" is used uniformly). Further preferably, the electrical conductor is arranged in a meandering shape around some or all of the elevations (or depressions/dents). In this way, the electrical conductor is arranged very close to the respective elevations (or depressions/dents) and a large length of the electrical conductor can be accommodated. Furthermore, the electrical conductor has or covers a very large surface area, which further increases heat transfer.

Preferably, at the end of the electrical conductor on the first contact element side, electrical contact surfaces are provided which are each adapted to be contacted by a spring element. This can be connected to a connection plug, in particular the one mentioned above, through which the electrical current is introduced into the contact element. Here, soldering of connection plugs, etc., can be omitted, which minimizes manufacturing costs. The contact surfaces are preferably printed and provided with an additional foil (by means of a soldering process) in order to use the foil as a sacrificial layer with regard to abrasion of the spring contact. Thus, a contact element can also be designed, like the plate described above, to absorb electrical current and release it as heat to the coolant.

Preferably, the contact element, particularly when the contact element is designed as a contact plate as described above, has at least one, preferably two, openings, wherein further preferably (further) elevations are provided around the opening(s) on the second contact element side. These elevations serve to stabilize the openings so that no deformation by fluid occurs here. Furthermore, a contact pressure is generated for the seals, which further improves the tightness. The elevations ensure in particular an increase in rigidity and thus an increased contact pressure on the seal, since thus the deformation of the contact element, in particular especially in the area of the openings, when pressure is applied to the seal.

The openings in the contact element make it possible, in particular, to allow coolant to flow to the second contact element side. In particular, the opening can be connected to a coolant inlet or outlet of an electrical resistor. Such a resistor is described, for example, above and below.

The elevations are preferably point-shaped, cylindrical, or hemispherical—this allows them to be easily embossed into the contact element, especially if the contact element is designed as the contact plate described above. Furthermore, a transient lag zone can be formed, which ensures heat dissipation in the lag region. Contours with a sharp edge, on the other hand, would form larger, stationary lag zones, which would prevent heat dissipation.

Preferably, the contact element contact section has increased thermal conductivity compared to a region of the first contact element side that lies outside the contact element contact section. This can be achieved, for example, by introducing a material that is more thermally conductive than the material surrounding the contact element contact section, such as Kapton, aluminum, or aluminum oxide. This ensures good heat transfer into the contact element, and preferably from the first contact element side to the second contact element side.

• - eine erste Kühlelementseite, die dazu ausgebildet ist, mehrere Wärme erzeugende Schaltmittel aufzunehmen;
• - eine zweite Kühlelementseite mit einem Kühlelementkontaktabschnitt , der dazu ausgebildet ist, mit einem Kontaktelementkontaktabschnitt eines Kontaktelements, insbesondere wenn das Kontaktelement als oben beschriebene Kontaktplatte ausgebildet ist, zur Einleitung von Wärme in das Kontaktelement mittels Wärmeleitung direkt oder über ein Zwischenelement in Kontakt zu treten, wobei zwischen der ersten Kühlelementseite und der zweiten Kühlelementseite ein Wärmeleitelement vorgesehen ist, das dazu ausgebildet ist, die Wärme von der ersten Kühlelementseite zu der zweiten Kühlelementseite zu übertragen.

A cooling element is disclosed, comprising:

• - a first cooling element side designed to accommodate a plurality of heat-generating switching means;
• - a second cooling element side with a cooling element contact section which is designed to come into contact with a contact element contact section of a contact element, in particular when the contact element is designed as the contact plate described above, for introducing heat into the contact element by means of heat conduction directly or via an intermediate element, wherein a heat conducting element is provided between the first cooling element side and the second cooling element side, which heat conducting element is designed to transfer the heat from the first cooling element side to the second cooling element side.

The thermally conductive element ensures that the heat generated by the switching means is conducted to the cooling element contact section. For this purpose, the thermally conductive element can preferably be made of a material with good thermal conductivity, such as Kapton, aluminum, or aluminum oxide.

In particular, it is advantageous if the heat conducting element extends from the first cooling element side to the cooling element contact section in order to provide continuous heat conduction.

The cooling element, in particular the heat-conducting element, is designed to serve as a heat buffer. Heat caused by temperature peaks, which is introduced into the heat-conducting element via the first cooling element side, is distributed and buffered within the heat-conducting element or across the extension of the heat-conducting element between the first cooling element side and the second cooling element side or the cooling element contact section, so that the most homogeneous heat flow possible can be released at the cooling element contact section. For this purpose, the extension of the heat-conducting element can be selected accordingly when designing the cooling element and/or the spatial volume of the heat-conducting element and/or the heat capacity of the heat-conducting element, thus adapting it to expected temperature peaks.

The heat-conducting element is preferably formed integrally with the cooling element.

The cooling element preferably has a fastening portion, such as a collar, with which it can be fastened to a resistor, as described above or later, for example by means of fastening means such as screws.

Preferably, the cooling element contact section is configured such that a projection of the cooling element contact section into a plane of the first cooling element side completely encloses the first cooling element side, or such that a section on the first cooling element side configured to accommodate the switching means is completely enclosed by the projection of the cooling element contact section into the plane of the first cooling element side. This ensures the best possible heat transfer from the switching means to the first cooling element side and effective transmission through the cooling element to the cooling element contact section. This prevents heat buildup or unnecessarily high thermal resistance within the cooling element.

• - ein Kontaktelement wie oben beschrieben und
• - ein Deckelement mit einer ersten Deckelementseite und einer zweiten Deckelementseite, wobei

das Kontaktelement und das Deckelement so angeordnet sind, dass sich die zweite Kontaktelementseite und die zweite Deckelementseite gegenüber liegen, wobei die zweite Kontaktelementseite und die zweite Deckelementseite so ausgebildet sind, dass dazwischen ein Hohlraum ausgebildet ist.Disclosed is a cooling circuit element comprising:

• - a contact element as described above and
• - a cover element with a first cover element side and a second cover element side, wherein

the contact element and the cover element are arranged such that the second contact element side and the second cover element side are opposite one another, wherein the second contact element side and the second cover element side are formed such that a cavity is formed therebetween.

The second contact element side and the second cover element side are, for example, facing each other.

Preferably, the second contact element side is tightly connected to the second cover element side, preferably by a weld seam. The contact element and cover element are designed here as two components that are joined together. This design makes it easy to separately machine the second contact element side or the cover element side before joining, so that, for example, the optionally located elevations can be mechanically reworked.

Alternatively, the contact element and the cover element are formed as a single piece. The cooling circuit element can then be manufactured without the step of joining the contact element and cover element. Potential weak points in the cavity regarding sealing are avoided by the lack of a joint.

Preferably, the cooling circuit element is designed as a plate pair, wherein the contact element is designed as a contact plate as described above and the cover element is designed as a cover plate and preferably the edge of the second contact element side is tightly connected to the edge of the second cover element side, preferably by a weld seam.

In general, the cavity within the cooling circuit element, in particular within the plate pairing, serves as a coolant channel through which coolant can flow, wherein heat can be transferred to the coolant from the second contact element side, which has been conducted in particular into the contact element contact section.

The cavity can be formed, for example, by a locally recessed surface of the second contact element side, in particular the second contact plate side, and/or by a locally recessed surface of the second cover element side, in particular the second cover plate side.

The cavity has an inflow area and an outflow area so that coolant can flow through the cavity between these areas and also leave it again.

The cavity may be formed as part of a cooling circuit of an electrical resistor described above or below.

In particular, the inflow area can be connected to the coolant inlet and the outflow area can be connected to the coolant outlet of such a resistor.

Preferably, the first cover element side is coated with an electrically insulating layer, with an electrical conductor applied to or embedded in the electrically insulating layer. In this way, heat generated by electrical current passing through this conductor can be dissipated via the second cover element side to the coolant in the cavity. Preferably, electrical contact surfaces are provided at the end of the electrical conductor on the first cover element side, each of which is adapted to be contacted by a spring element. This can be connected to a connector plug or the aforementioned connector plug through which the electrical current is introduced into the cover element. Here, soldering of connector plugs, etc., can be omitted, which minimizes manufacturing costs. The contact surfaces are preferably printed and provided with an additional foil (using a soldering process) in order to use the foil as a sacrificial layer with respect to abrasion of the spring contact. Thus, a cover element can also be designed, like the plate described above, to absorb electrical current and dissipate it as heat to the coolant.

Preferably, elevations are provided on the second cover element side, particularly when the cover element is designed as a cover plate as described above. These elevations can be designed and manufactured in the same way as the elevations of the contact plate described above. In particular, the elevations on the cover element can be located at the same location as the elevations of the contact element, particularly the contact plate, when the cover element and contact element are combined to form the cooling circuit element, and in particular the cover plate and contact plate are combined to form the cooling circuit element designed as a plate pair.

The elevations of the cover element can be point-shaped, cylindrical or hemispherical.

If the contact element, in particular the contact plate, has elevations, the elevations of the contact element are preferably connected to the elevations of the cover element, in particular the cover plate. The connection is preferably materially bonded, in particular by a weld spot or a weld seam.

If the cover element is designed as a cover plate, the cover element can in particular be designed as a plate, as described above. Heat introduced into this plate (i.e., the cover plate) can then be dissipated via the second side of this plate (i.e., the second cover plate side) to the coolant in the resulting cavity.

A disclosed cooling circuit element, which is designed as a plate pair, comprises a contact plate as described above and a cover plate as described above. The second contact plate side and the second side of the plate, which functions as a cover plate, are arranged opposite one another. The edges of the second contact plate side and the second side of the plate are tightly connected to one another, preferably by a material bond, in particular by a weld seam.

The raised portions on the second contact plate and the plate described above, used as a cover plate, can be connected to each other (e.g., welded, e.g., by means of a spot weld or weld seam), thus creating smaller flow channels. The incoming coolant is distributed evenly within the gap or cavity between the contact plate and the plate described above, used as a cover plate, enabling homogeneous heat dissipation.

In this way, a stable unit can be formed because the internal pressure forces can be dissipated by the inflow of the fluid, thus resulting in minimal deformation. The load on the electrically insulating layer on the plate described above used as the cover plate, and if such a layer is also present on the contact plate, can thus be minimized. Furthermore, the flow cross-section for the flow channels is maintained and does not bulge. The large heat transfer surfaces are essentially made possible by the plate-based construction. However, the plate structure can be susceptible to deformation due to the internal pressure of the coolant. Load transfer is ensured by the elevations and, in particular, their connection to the opposite plate.

Preferably, one or one or a plurality of coolable resistor units (each formed by the plate pairs described above) and seals as well as a plate pairing are present, and a seal is always arranged between two coolable resistor units (coolable resistor units and seal are stacked one above the other) or between a coolable resistor unit and a plate pairing comprising the contact plate. The plate pairing with the contact plate is arranged relative to the other coolable resistor unit(s) such that the contact plate contact section of the first contact plate side faces outward. This enables contact between the contact plate contact section and the cooling element contact section of the cooling element described above.

A closure plate is provided as the outer boundary of each coolable resistor (a first side of a plate described above can be in contact with the closure plate, but in this case is not provided with an electrical conductor, or the first contact plate side can be in contact with the closure plate, but in this case is not provided with an electrical conductor), whereby preferably all plate pairs and the plate pairing as well as the connection plates are connected to one another with a fixing element. This fixing element is preferably a screw. This fixing element allows all coolable resistor units and all seals to be pressed together, resulting in a compact and, above all, leak-proof design. At the same time, however, the fixing element can be removed again if, for example, a plate pair (a coolable resistor unit) or the plate pairing needs to be replaced, for example if there is a defect or a leak.

This makes it very easy to stack any number of plate pairs together with the plate pair; the number can be varied depending on the power requirements of the coolable resistor. The seals prevent liquid from penetrating parts with electrical conductors. The elevations in the plates also serve to transfer loads from the seals, particularly those arranged around openings. Plastic deformation of the sheet metal structure can thus be prevented. The seal preferably has an edge section which can engage with the grooves of two opposite first sides of the above-described plates of the plate pairs or the cover plate of the plate pair. This would accordingly establish a particularly efficient sealing effect.

The end plate preferably has an opening through which the cooling element can extend, so that the cooling element contact section and the contact plate contact section can come into contact for heat conduction directly or via an intermediate element. Alternatively, it can also be provided that the cooling element is arranged below the end plate, so that it is located on the same side as the plate pair. If plate pairs and plate pairs as well as end plates are connected to one another with the fixing element, the configuration is preferably designed such that the cooling element is not located in the force flow of this connection. In this way, bending stress on the plate pair is avoided by the cooling element, which could otherwise be pressed onto the plate pair by the end plate facing the cooling element.

Both the contact element and the cover element can, particularly if they are designed as a contact plate or a cover plate, have a groove on the first contact element side or on the first cover element side at the edge of the respective side, which groove is adapted to receive the edge section of a seal. The seal, which is in contact with the first contact element side, can in particular be clamped to the above-mentioned end plate. The seal, which is in contact with the first cover element side, can in particular be clamped to a first side of an above-mentioned plate, in particular of an above-mentioned pair of plates. Thus, a sealed space can be formed in which an electrical conductor as described above can be provided. This has the advantage that the seals create detachable connections.

• - eine Kühlkreislaufelement wie oben beschrieben,
• - mehrere Schaltmittel, die so angeordnet sind, dass von den Schaltmitteln erzeugte Wärme mittels Wärmeleitung in den Kontaktelementkontaktabschnitt eingeleitet wird,
• - einen Kühlkreislauf, und
• - mindestens einen, vorzugsweise eine Vielzahl von parallel geschalteten Teilwiderständen, insbesondere als oben beschriebene Widerstandseinheiten ausgebildet, wobei der Kühlkreislauf zur Kühlung des Teilwiderstands oder der Vielzahl von Teilwiderständen ausgebildet ist, wobei die Schaltmittel dazu ausgebildet sind, die einzelnen Teilwiderstände anzusteuern und der Hohlraum des Kühlkreislaufelements mit dem Kühlkreislauf verbunden ist und von Kühlmittel durchströmt werden kann.

Disclosed is a coolable resistor comprising:

• - a cooling circuit element as described above,
• - a plurality of switching means arranged so that heat generated by the switching means is introduced into the contact element contact section by means of thermal conduction,
• - a cooling circuit, and
• - at least one, preferably a plurality of partial resistors connected in parallel, in particular designed as resistor units as described above, wherein the cooling circuit is designed to cool the partial resistor or the plurality of partial resistors, wherein the switching means are designed to control the individual partial resistors and the cavity of the cooling circuit element is connected to the cooling circuit and can be flowed through by coolant.

The switching means can be in thermally conductive contact with the contact element contact section directly or via intermediate elements.

The coolant flowing through the cavity of the cooling circuit element comes from the cooling circuit.

This makes it possible to transfer heat from the switching elements into the cooling circuit intended for cooling the switching elements. A separate cooling circuit for cooling the switching elements is therefore no longer necessary.

The cooling capacity of such a resistor can be over 50 kW. The cooling capacity of such a resistor can be under 250 kW.

The resistor can be designed as a braking resistor for an electrically or hybrid-powered vehicle, in particular a commercial vehicle. Alternatively, it can also be designed as a braking resistor for a rail vehicle.

Preferably, the resistor comprises a cooling element as described above, wherein
one or more of the switching means, in particular all switching means, are arranged on the first cooling element side,
the cooling circuit element and the cooling element are oriented to each other such that the contact element contact section and the cooling element contact section are in contact with each other directly or via an intermediate element.

In this way, it is possible to dissipate heat from the switching means via the cooling element and introduce it into the cooling circuit of the resistor, so that this cooling circuit now also takes over the cooling of the switching means. A separate cooling circuit for cooling the switching means can therefore be omitted. Furthermore, it is possible to arrange the switching means at a distance from the contact element, which depends on the extension of the cooling element between the switching means and the contact element contact section. In particular, an arrangement of the switching means can be provided in which, in addition to heat dissipation into the cooling element by heat conduction, heat can also be dissipated to the environment by means of thermal radiation and/or convection.

The coolable resistor preferably has at least one inlet and one outlet, each provided in a cover plate. Furthermore, a hydraulic connection is preferably provided here.

According to one embodiment, all openings of the plate pairs and of the cooling circuit element, which is designed in particular as the plate pairing described above, are arranged one below the other, in particular aligned, and form a first collection area, and all second openings are also arranged one below the other, in particular aligned, and form a second collection area. The inlet and the outlet are either connected to the first collection area (or a section thereof) or to the second collection area (or a section thereof), or are divided between both collection areas - the first collection area is thus connected to the inlet and the second collection area to the outlet, or vice versa. The collection areas can be divided into several sections by closed plates.

Further preferably, at least one of the first openings and/or the second openings of a coolable resistance unit is closed, although fluid can still flow from the inlet to the outlet. This makes it possible to connect a certain number of coolable resistance units in parallel or series, depending on the specific requirements. This can be arranged very flexibly without requiring major modifications to the individual elements – all that is required is to close some of the first openings and some of the second openings of the coolable resistance units in the overall system.

The closed first and second openings serve to connect some of the existing coolable resistance units in parallel and others in series, thus directing the cooling fluid accordingly. Both collection areas can thus be subdivided. This allows a certain number of coolable resistance units to be connected in parallel or in series, depending on the specific requirements. Furthermore, the variable arrangement of the connections also allows for a gradual increase in flow velocity (by reducing the number of plates in the parallel-connected segments), which serves to improve heat transfer and compensate for the preheating of the coolant.

Preferably, a thermally conductive material, such as a thermally conductive paste, is provided as an intermediate element between the contact element contact section and the cooling element contact section, or between the contact element contact section and the switching means. In this way, unevenness of the contact element contact section, the cooling element contact section, or the switching means can be compensated for, and thermal conduction can be improved. This can be advantageous, particularly in the case of a contact element with elevations on the second contact element side that form depressions on the first contact element side, such as when the contact element is designed as a contact plate, by filling the depressions with introduced thermally conductive material.

Preferably, the switching means provided on the first cooling element side or on the contact element contact section are connected by an insulating layer, in particular an electrical insulating layer, in particular Kapton. The insulating layer is preferably thermally conductive in order to distribute the temperature well between the switching means. This enables more even heat distribution among the switching means and the most homogeneous heat input possible into the cooling element via the first cooling element side or into the contact element via the contact element contact section. The insulating layer can also be provided below the switching means and connect the switching means indirectly to the first cooling element side or to the contact element contact section, thereby enabling good heat input into the first cooling element side or into the contact element contact section.

Alternatively or additionally, the switching means arranged on the first cooling element side or on the contact element contact section are evenly distributed, in particular arranged in a matrix arrangement. This also allows for a homogeneous heat input into the cooling element or the contact element contact section.

Preferably, the electrical resistor comprises a cooling circuit element configured as a plate pair as described above, wherein the partial resistors are configured as plates, in particular as a plate pair (e.g., as resistor units as described above), wherein the partial resistors and the cooling circuit element are arranged in a stack, and the first contact element side is oriented such that it forms a cover surface of the stack. Thus, contacting of the contact element contact section from the outside is possible via the switching means or via the cooling element, so that heat can be introduced into the cooling circuit.

• 1 zeigt eine erste Seite einer Platte für ein kühlbares Widerstandselement gemäß einer ersten Ausführungsform der vorliegenden Erfindung.
• 2 zeigt eine zweite Seite einer Platte für ein kühlbares Widerstandselement gemäß einer ersten Ausführungsform der vorliegenden Erfindung.
• 3 zeigt eine Dichtung, welche dazu angepasst ist, zwischen zwei Plattenpaaren angeordnet zu sein.
• 4 zeigt ein Plattenpaar (kühlbares Widerstandselement).
• 5 zeigt eine Dichtung zwischen den zwei Plattenpaaren in Querschnittsansicht.
• 6 zeigt eine Dichtung zwischen den zwei Plattenpaaren in Querschnittsansicht, wobei hier insbesondere die Federkontaktierung der Leiter gezeigt ist.
• 7 zeigt eine isometrische Ansicht zweier Plattenpaare, zwischen welchen eine Dichtung angeordnet ist.
• 8 zeigt eine Querschnittsansicht durch einen kühlbaren Widerstand.
• 9 zeigt eine Außenansicht eines kühlbaren Widerstands.
• 10a zeigt eine Schnittansicht eines Ausschnitts eines als Kontaktplatte ausgebildeten Kontaktelements.
• 10b zeigt eine Draufsicht eines Ausschnitts eines als Kontaktplatte ausgebildeten Kontaktelements .
• 10c zeigt eine Schnittansicht eines Ausschnitts einer Kontaktplatte, die eine Weiterbildung der in 10a gezeigten Kontaktplatte darstellt.
• 11 zeigt ein Kühlkreislaufelement, das als Plattenpaarung mit einer Kontaktplatte und einer Deckplatte ausgebildet ist.
• 12a zeigt eine Schnittansicht eines Kühlelements.
• 12b zeigt eine Draufsicht eines Kühlelements.
• 13a zeigt eine perspektivische Schnittansicht eines elektrischen Widerstands.
• 13b zeigt eine perspektivische Ansicht eines elektrischen Widerstands.

In the following, embodiments of the present invention are explained in more detail with reference to the accompanying figures.

• 1 shows a first side of a plate for a coolable resistance element according to a first embodiment of the present invention.
• 2 shows a second side of a plate for a coolable resistance element according to a first embodiment of the present invention.
• 3 shows a seal adapted to be arranged between two pairs of plates.
• 4 shows a pair of plates (coolable resistance element).
• 5 shows a seal between the two pairs of plates in cross-sectional view.
• 6 shows a seal between the two pairs of plates in cross-sectional view, showing in particular the spring contact of the conductors.
• 7 shows an isometric view of two pairs of plates with a seal between them.
• 8 shows a cross-sectional view through a coolable resistor.
• 9 shows an external view of a coolable resistor.
• 10a shows a sectional view of a section of a contact element designed as a contact plate.
• 10b shows a plan view of a section of a contact element designed as a contact plate.
• 10c shows a sectional view of a section of a contact plate, which is a further development of the 10a shown contact plate.
• 11 shows a cooling circuit element which is designed as a plate pair with a contact plate and a cover plate.
• 12a shows a sectional view of a cooling element.
• 12b shows a top view of a cooling element.
• 13a shows a perspective sectional view of an electrical resistor.
• 13b shows a perspective view of an electrical resistor.

In 1 The first side 19e of a plate 19 is shown. This plate 19 has a generally hexagonal shape (essentially consisting of two triangles and a rectangle), with an elongated part and a shorter part. A first opening 25a and a second opening 25b are provided at each end of the elongated part. These openings are at least partially surrounded by a plurality of second elevations 16, which, however, extend toward the second side 19z (not shown here)—i.e., the rear side. On the first side 19e, the second elevations 16 therefore have the shape of embossed depressions. A groove 23 is provided at the edge of the plate 19, in which a seal (not shown here) can be arranged. Furthermore, a plurality of first elevations 15 are distributed over the surface (in particular, the rectangular, elongated part) of the first side 19e, which also extend toward the second side 19z (not shown here) of the plate 19. On the first side 19e, the first elevations 15 therefore also have the shape of depressions. An electrical conductor 17 extends between the first elevations 15. This is arranged on an electrically insulating layer 18 that was previously applied to the first side 19e of the plate 19 – and is printed, for example, by a screen printing process. The electrical conductor 17 also has two electrical contact surfaces 13 on the first surface 19e. The electrical conductor 17 is arranged in a meandering shape around the first elevations 15. The electrical conductor 17 thus has the largest possible surface area. Arrows 21 also indicate the flow direction of a fluid, which serves for cooling purposes but flows on the second side 19z (not shown here) of the plate 19. Here, it can be clearly seen that the flow direction of the fluid is orthogonal to the main direction of the electrical conductor 17 (the direction in which the electrical conductor 17 primarily extends). At both outermost points (the apex of the triangles of the hexagon) receiving sections 26 are provided, here in the form of semicircular recesses - these serve to clamp several plates 19 by means of a fixing element 7 (not shown here), for example a screw.

This allows the coolant to move from zones with thermal stress to zones without. This greatly minimizes the thermodynamically swept contact length and prevents overheating.

Such a plate 19 can also be designed as a contact element 100 or contact plate 100, as is shown, for example, in 10a to 10c shown. For this purpose, a contact element contact section 100' must be created on the first side 19e of the plate 19.

This can be kept free from the electrical conductor 17. However, it can also be provided that the electrical conductor 17 also extends over the contact element contact section 100'. Otherwise, refer to the corresponding description above or to the 10a to 10c refer.

2 shows a second side 19z of the plate 19—that is, the back side of the first side 19e (not shown here)—this is the side toward which the coolant flows. The first opening 25a and the second opening 25b are visible again, as are the first elevations 15 and the second elevations 16.

At the edge of the plate 19, a connecting area 27 is provided, at which two plates 19 can be welded together (with opposite and mutually facing second sides 19z). The first elevations 15 are distributed over the cross-section of the plate 19, and several second elevations 16 are arranged around the first opening 25a and the second opening 25b. The first elevations 15 and the second elevations 16 can each be point-shaped or hemispherical. The receiving sections 26 are also in 2 to see.

In 3 It is shown that a sealing element C essentially follows the hexagonal cross-section of a plate 19 (not shown). The sealing element C consists of an outer section C1, which essentially follows the hexagonal shape of the plate, and two inner sections C2, which extend inwards from the outer corners of the hexagon and have a round shape. The outer section C1 is intended to seal the outer edge between two plates 19 (not shown here), and the inner sections C2 are intended to seal a first opening 25a and a second opening 25b (not shown here), respectively. Spring contacts 12 are arranged inwards on one long side of the sealing element C. These spring contacts extend upwards and downwards, and are therefore suitable for contacting two electrical contact surfaces 13 (not shown here), which are arranged above and below the sealing element C. An electrical connection 11 is provided on the other side of the spring contact 12. The combination of electrical connection 11 and spring contact 12 can be injected into the sealing element C, but can also simply be pushed through it.

Furthermore, in the area of the two inner sections C2, a protruding section C3 is present - this serves to ensure that this area can be pressed particularly firmly and elastically deformed, which leads to a better seal in the area of the first and second openings 25a and 25b (not shown here), which carry liquid accordingly.

4 shows a cross section along the line A' from 1 , here the inner region 20 is shown when two plates 19 are arranged next to each other. This creates a region 20 through which liquid can flow. Furthermore, welding contact points 14 are shown here, i.e. the first elevations 15 (not shown here) of two second surfaces 19z of the plates 19 are welded together. In order to prevent one-sided bending due to printing, the two plates 19 are first welded together and then alternately connected to the electrical conductor 17 (in 4 not shown). Due to the alternating pressure, the tensions are balanced and the plates 19 remain flat.

5 shows mainly the sealing element C, here it is shown that an outer section C1 of the sealing element C with the 1 shown groove 23 on the first side 19e of the plate 19. Furthermore, the sealing region 22 is shown here, which in particular seals a first collecting region 9a or second collecting region 9b through which coolant (for example, liquid) flows. This is essentially sealed by the inner section C2 of the sealing element C. The forces acting on the sealing element C are indicated by the reference symbol F.

6 shows two plate pairs B (consisting of two plates 19), between which a sealing element C is arranged. It can again be seen that forces F act on the plate pairs B. The sealing element C shows spring contacts 12 for electrically contacting the electrical contact surfaces 13 of the plate pairs B. Furthermore, an electrical connection 11 is provided here, which is electrically connected to the spring contacts 12. Furthermore, welding contact points 14 are shown here, i.e., the first elevations 15 (not shown here) of two second surfaces 19z of the plates 19 are welded together.

By pressing two pairs of plates B and a seal C together, a tight connection is created so that no liquid can flow along the second surfaces 19z (not shown here) in the area of the electrical conductor 17 (not shown here).

7 shows an isometric view of two pairs of plates B, between which a seal C is located. Also shown here are the electrical connections 11, which are connected to the spring contacts 12 (only partially shown here). A sealing element C is arranged between two pairs of plates B in a stacked arrangement. The first side 19e of a plate is visible at the top—with a meandering electrical conductor 17 and electrical contact surface 13. The first opening 25a and the second opening 25b are also visible.

8 shows a resistance device A (a liquid-cooled resistor). This contains several coolable resistance elements B (not all labeled in detail here). A pair of plates is therefore a coolable resistance element, as it is the smallest unit of a coolable resistor. A cover plate 6 is provided at the top and bottom. An inlet 5 is provided at the top of the upper cover plate 6, and an outlet 5' is provided at the bottom of the cover plate 6. It is also shown that a hydraulic connection 8 is present in the inlet 5 and the outlet 5'; this is provided in the quick-connect system. The flow guidance is also clear, as closed plates 10 are provided at regular intervals at openings on the left side, as well as on the right side. A first collection area 9a is provided on the left (this is divided into three sections 9a', 9a'', and 9a''' by closed plates 10). When coolant enters the first section 9a' through the inlet 5, several coolable resistance elements B flow through it in parallel. In the right-hand area, a collection area 9b (divided into sections 9b', 9b'') is provided. Here, too, a closed plate 10 is provided for subdivision. The coolant then reaches section 9b' of the second collection area 9b. Here, a certain number of coolable resistance elements B can again be flowed through in parallel until the first collection area 9a (now section 9a'') is reached again. Here, at a certain distance, a closed plate 10 is again provided, so that the fluid is again deflected to the right (until it reaches section 9b'' of the second collection area 9b) - from there it is deflected again to the left until it reaches section 9a''' of the first collection area 9a, so that it can flow out through outlet 5'. By providing closed plates 10, any number of parallel or almost parallel flowing plate pairs B can be provided, so that the resistance device A can be variably adjusted to specific cooling capacities.

9 shows an isometric view of a resistance device A. It also shows a terminal box 4, to which dampers 2 for mounting and connecting cables 1 are provided. Hydraulic connections 8 are also shown.

The items described above are not limited to the versions therein.

The geometry of the plates 19 can be arbitrary; it does not have to be hexagonal. Furthermore, flow channels can be implemented in a variety of ways; connections or openings are not necessarily required on two opposite sides of the hexagon.

10a shows a sectional view of a section of a contact element designed as a contact plate. Therefore, the term "contact plate" is used below instead of "contact element."

A contact plate 100 is shown, which has an upwardly facing first contact plate side 100a and an opposite second contact plate side 100b facing downward. The first contact plate side 100a has a contact plate contact section 100', the boundaries of which are marked in the drawing from left to right by the dashed vertical lines.

As described above, the contact plate contact section 100' can be increased in its thermal conductivity compared to the material adjacent to the contact plate contact section 100', for example, by appropriately introduced material. The contact plate contact section 100' is designed to contact a cooling element contact section 101' or a heat-generating switching means 102 of an electrical resistor, directly or via an intermediate element for introducing heat into the contact element 100 by means of thermal conduction.

The second contact plate side 100b is designed to dissipate heat to a coolant that flows past the second contact plate side 100b (indicated by the arrow pointing to the right).

10b shows a top view of a section of a contact element designed as a contact plate.

The section shown can be used for the contact plate 100 from 10a belong, but a different contact plate may also be shown.

Shown is a section of a first contact plate side 100a of a contact plate 100 in plan view. The entire extension of the contact plate 100 to the left and right is as in 10a not shown. The contact plate contact section 100' is formed here as a rectangular region that extends over a part or a partial area of the first contact plate side 100a.

In an embodiment not shown, the contact plate contact section 100' may be identical to the first contact plate side 100a. Alternatively, the contact plate contact section 100' forms at least 25%, preferably at least 50%, of the area of the first contact plate side 100a.

10c shows a sectional view of a section of a contact plate, which is a further development of the 10a shown contact plate 100.

The contact plate 100 has been further developed here such that the second contact plate side 100b has elevations 100c that extend downward and are also designed to be surrounded by the coolant. The elevations 100c can be formed as described above and can be realized, in particular, by embossing the contact plate 100. For example, the elevations 100c are shown here as hemispheres. The elevations 100c are located behind the section plane in the illustration, which is why they are not hatched here.

Due to the embossing, the contact plate 100 may have depressions at the locations of the elevations 100c on the first contact plate side 100a. This may complicate contacting for heat conduction, particularly if the depressions on the first contact plate side 100a are located in the contact plate contact section 100'. This limitation can be accepted in the design of the contact plate 100. Alternatively, a contact-enhancing agent, such as a thermally conductive paste or similar material, may be incorporated into the depressions to improve the thermal conductivity in the contact plate contact section 100'.

11 shows a cooling circuit element which is designed as a plate pair with a contact plate and a cover plate.

The cooling circuit element 105 shown here is formed as a plate pairing of a contact plate 100 and a cover plate 19, 103.

The contact plate 100 corresponds to the contact plate 100 from 10a . It can be used as shown in 10c Elevations 100c on the second contact plate side 100b, which is why these are optional and are therefore shown in dashed lines.

The cover plate 19, 103 has a first cover plate side 19e, 103a and a second cover plate side 19z, 103b.

In particular, the cover plate 19 may be formed as the plate 19 which is in the 1 and 2 is shown. For the corresponding description, please refer to the above.

Independently of this, the second cover plate side 19z, 103b can also have elevations 15, 16, 103c. These are optional and therefore shown in dashed lines.

The contact plate 100 and the cover plate 19, 103 are oriented relative to each other such that the second contact plate side 100b and the second cover plate side 19z, 103b face each other, with a cavity 104 formed between these sides through which coolant can flow. The contact plate 100 and the cover plate 19, 103 are tightly connected to each other at the edge, for example, by a material bond, with an inflow and an outflow area (not shown) provided for the coolant.

The optional elevations 100c, 15, 103c are arranged on the respective plate sides 100b, 19z, 103b such that an elevation 100c of the contact plate 100 is in contact with an elevation 15, 103c of the cover plate 19, 103. These elevations 100c, 15, 103c are preferably connected to one another, for example, by a material bond.

In this way, a plate pair 105 is formed, which can be part of a coolant circuit of a resistor, wherein heat can be conducted via the contact plate contact section 100' into the contact plate 100 and further via the second contact plate side 100b into the coolant.

12a shows a sectional view of a cooling element.

A cooling element 101 is shown in section. The cooling element 101 has a first, upward-facing cooling element side 101a, on which switching means 102 can be provided. Opposite the first cooling element side 101a is a downward-facing second cooling element side 101b. Extending between the first cooling element side 101a and the second cooling element side 101b is a heat-conducting element 101c, which is designed to conduct heat from the first cooling element side 101a to a cooling element contact section 101' on the second cooling element side 101b.

In the illustration shown, the cooling element contact section 101' extends over the entire second cooling element side 101b. However, this is not absolutely necessary.

It can also be seen that the heat-conducting element 101c is formed integrally with the remaining cooling element 101 and that it is as wide as or wider than the arrangement of switching means 102. This reduces the thermal resistance between the first cooling element side 101a and the cooling element contact section 101' in order to achieve the best possible heat conduction.

Furthermore, a fastening section is shown, which is formed as a collar 101d of the cooling element in one piece with the latter. With this collar, the Cooling element 101 can be attached, for example, to a cover plate of a resistor.

12b shows a top view of a cooling element.

This can be the cooling element 101 made of 12a However, a different cooling element may also be shown.

Shown is the first cooling element side 101a of the cooling element 101, with switching elements 102 arranged on the first cooling element side 101a. The arrangement shown shows switching elements 102 arranged regularly, or equidistantly in the vertical and transverse directions, in a 3x3 matrix. This allows for the most homogeneous heat input possible into the first cooling element side 101a.

The switching elements 102, which are not necessarily considered part of the cooling element 101, can be electrically insulated from one another, for which purpose a suitable material is inserted into the gaps. This material can have good thermal conductivity in order to achieve the most homogeneous heat distribution possible across the surface.

13a shows a perspective sectional view of an electrical resistor.

The resistor shown has a stack of plate pairs formed by plates 19, as used, for example, in 4 are shown. These plate pairs form individual partial resistors that can be controlled by the switching means 102.

The plate pairs are arranged in a stack, with a plate pair at the top serving as a cooling circuit element 105, such as in 11 shown. This plate pairing is oriented such that the contact plate contact section 100' of the first contact plate side still points upwards, ie away from the stack of plate pairs.

Above the cooling circuit element 105, a cooling element 101 is arranged, as is shown, for example, in 8 is shown. In addition, a cover plate 6 is provided above the cooling circuit element 105. The cover plate 6 has an opening through which the cooling element 101 extends with its heat-conducting element 101c. The cooling element contact section 101' is in contact with the contact plate contact section 100', so that heat can be transferred from the switching means 102 through the cooling element 101 to the contact plate 100.

It is also shown that the cooling element 101 is attached to the end plate 6 by means of the fastening section, which is designed here as a collar 101d. As a result, the end plate 6 also bears the main load of the cooling element 101, preventing excessive support of the cooling element 101 on the contact plate 100 or on the cooling circuit element 105.

13b shows a perspective view of an electrical resistor.

The resistance shown may be the resistance of 13a However, a different resistance may also be shown.

The cooling element 101 is shown here as it is attached to the end plate 6 of the resistor by means of the collar 101d, for example, by means of a screw connection. On the first cooling element side 101a, new switching elements 102 are arranged in a uniform arrangement according to a 3x3 matrix. An inlet 5 and an outlet 5' for coolant are shown in the front area, with the coolant flowing through the plate pairs and the cooling circuit element between the inlet 5 and the outlet 5'.

In the illustration shown here, it can also be seen that the seals C, which are mounted between the individual plate pairs and the plate pair, are designed differently. While the outer seals C have no electrical connections (the seal at the very bottom and the very top), the seals C in between do have connections. This means that no electrical conductor is applied to the first contact plate side of the plate pair, or to the first side of the plate that is at the bottom of the stack.

However, this can be implemented in an alternative embodiment.

It should also be noted that the stack of plate pairs shown here, the plate pairing, and the seals C arranged therebetween can be pressed together using fastening elements, such as the screws shown, to create sealed spaces for the coolant and sealed, coolant-free spaces between them. The fastening elements can, as shown, engage with the end plate(s) 6, which are then also arranged in the force flow of the pressing.

LIST OF REFERENCE SYMBOLS

A

resistance device

B

Pair of plates / coolable resistance element

C

Sealing element (with contacts)

C1

outer section

C2

inner section

C3

protruding section

F

Contact pressure

1

Connection cable (with EMC shield)

2

mute

3

Contact protection

4

Junction box

5

inlet

5'

Outlet

6

End plate

7

Fixing element / screw

8

Hydraulic connection (Quick Connect)

9a

first collection area

9a', 9a'', 9a'''

Section

9b

second collection area

9b', 9b''

Section

10

closed plate

11

electrical connection

12

spring contact

13

electrical contact surface

14

Welding contact point

15

first survey

16

second survey

17

electrical conductor

18

electrically insulating layer

19

Single plate

19e

first side of the single plate

19z

second side of the single plate

20

liquid-permeable area / interior area

21

Flow direction

22

Sealing area

23

Groove (for indexing the seal)

24

bead

25a

first opening

25b

second opening

26

Recording section

27

Connection area

100

Contact element

100'

Contact element contact section

100a

first contact element side

100b

second contact element side

100c

Surveys

101

Cooling element

101'

Cooling element contact section

101a

first cooling element side

101b

second cooling element side

101c

Heat-conducting element

101d

collar

102

Switching devices

103

Cover element

103a

first deck element side

103b

second deck element side

103c

Surveys

104

cavity

105

Cooling circuit element

Claims (21)

Contact element (100), in particular contact plate, comprising: - a first contact element side (100a) with a contact element contact section (100') which is designed to be in contact, directly or via an intermediate element for introducing heat by means of heat conduction into the contact element (100), with a cooling element contact section (101') or with one or more heat-generating switching means (102) of an electrical resistance - a second contact element side (100b) for transferring the heat to a coolant. Contact element (100) according to Claim 1 , wherein the contact element contact section (100') is identical to the first contact element side (100a) or forms at least 25%, preferably at least 50%, of the area of the first contact element side (100a). Contact element (100) according to one of the preceding claims, wherein a region of the first contact element side (100a) which lies outside the contact element contact section (100') is coated with an electrically insulating layer, wherein an electrical conductor is applied to the electrically insulating layer or is embedded in it. Contact element (100) according to one of the preceding claims, wherein the second contact element side (100b) has elevations (100c). Contact element (100) according to Claim 4 , wherein the elevations (100c) are point-shaped, cylindrical or hemispherical. Contact element (100) according to one of the preceding claims, which has at least one, preferably two, openings, wherein elevations are preferably provided around the opening(s) on the second contact element side (100b). Contact element (100) according to one of the preceding claims, wherein the contact element contact section (100') has an increased thermal conductivity compared to a region of the first contact element side (100a) which lies outside the contact element contact section (100'). Cooling element (101), comprising: - a first cooling element side (101a) designed to accommodate a plurality of heat-generating switching means (102); - a second cooling element side (101b) with a cooling element contact section (101') designed to come into contact with a contact element contact section (100') of a contact element (100) for introducing heat into the contact element (100) by means of heat conduction, directly or via an intermediate element, wherein a heat-conducting element (101c) is provided between the first cooling element side (101a) and the second cooling element side (101b), which heat-conducting element is designed to transfer the heat from the first cooling element side (101a) to the second cooling element side (101b). Cooling element (101) according to Claim 8 , wherein the cooling element contact section (101') is designed such that a projection of the cooling element contact section (101') into a plane of the first cooling element side (101a) completely encloses the first cooling element side (101a) or that a section on the first cooling element side (101a) which is designed to receive the switching means (102) is completely enclosed by the projection of the cooling element contact section (101') into the plane of the first cooling element side (101a). Cooling circuit element (105), comprising: - a contact element (100), according to one of the Claims 1 until 7 , and - a cover element (103) having a first cover element side (103a) and a second cover element side (103b), wherein the contact element (100) and the cover element (103) are arranged such that the second contact element side (100b) and the second cover element side (103b) are opposite one another, wherein the second contact element side (100b) and the second cover element side (103b) are formed such that a cavity (104) is formed therebetween. Cooling circuit element (105) according to Claim 10 , wherein the second contact element side (100b) is tightly connected to the second cover element side (103b), preferably by a weld seam. Cooling circuit element (105) according to Claim 10 , wherein the contact element (100) and the cover element (103) are formed in one piece. Cooling circuit element (105) according to Claim 10 , designed as a plate pair (105), wherein the contact element (100) is designed as a contact plate and the cover element is designed as a cover plate (19, 103) and preferably the edge of the second contact element side (100b) is tightly connected to the edge of the second cover element side (19z, 103b), preferably by a weld seam. Cooling circuit element (105) according to one of the Claims 10 until 13 , wherein the first cover element side (19e, 103a) is coated with an electrically insulating layer (2), wherein an electrical conductor (17) is applied to the electrically insulating layer (18) or is embedded therein. Cooling circuit element (105) according to one of the Claims 10 until 14 , wherein elevations (15, 16, 103c) are provided on the second cover element side (19z, 103b). Cooling circuit element (105) according to Claim 15 with a, especially as a contact plate made of formed, contact element (100) according to Claim 4 or 5 , wherein the elevations (100c) of the contact element (100) and the elevations (15, 16, 103c) of the cover element (103) are each connected to one another, preferably by a weld spot or by a weld seam. Coolable resistor, comprising: - a cooling circuit element (105) according to one of the Claims 10 until 16 , - a plurality of switching means (102) which are arranged such that heat generated by the switching means (102) is introduced into the contact element contact section (100') by means of thermal conduction, - a cooling circuit, and - a plurality of partial resistors connected in parallel, wherein the cooling circuit is designed to cool the plurality of partial resistors, wherein the switching means (102) are designed to control the individual partial resistors and the cavity of the cooling circuit element (105) is connected to the cooling circuit and can be flowed through by coolant. Resistance after Claim 17 with a cooling element according to one of the Claims 8 or 9 , wherein one or more of the switching means (102) are arranged on the first cooling element side (101a), the cooling circuit element (105) and the cooling element (101) are oriented relative to one another such that the contact element contact section (100') and the cooling element contact section (101') are in contact with one another directly or via an intermediate element. Resistance after Claim 18 , wherein a thermally conductive material, such as a thermally conductive paste, is introduced as an intermediate element between the contact element contact section (100') and the cooling element contact section (101'). Resistance after one of the Claims 18 or 19 , wherein the switching means (102) are connected by an insulation layer, in particular an electrical insulation layer, in particular Kapton, and/or wherein the switching means (102) are arranged uniformly distributed and in particular are arranged in a matrix arrangement. Resistance after one of the Claims 17 until 20 , with a cooling circuit element (105) according to Claim 13 , wherein the partial resistors are designed as plates, in particular as a pair of plates, wherein the partial resistors and the cooling circuit element (105) are arranged to form a stack, and the first contact element side (100a) is oriented such that it forms a cover surface of the stack.