CN115803834A - Power switch arranged in a switch fuse box and switch fuse box of a motor vehicle - Google Patents

Abstract

The invention relates to a circuit breaker (10) for arrangement in a switch fuse box of an at least partially electrically driven motor vehicle, comprising a housing (12) having a housing wall (14) with a housing inner side (16) and a housing outer side (18) arranged at a distance from the housing inner side (16) and having a through-opening (20) formed in the housing wall (14), and a bimetallic contact element (22) arranged in the through-opening (20), comprising a first section (24) made of a first metal and a second section (26) made of a second metal different from the first metal, the first section protruding beyond the first section (24), the second section being electrically conductively attached to the first section (24) and protruding beyond the housing outer side (18).

Description

Power switch arranged in the switch fuse box and the switch fuse of the motor vehicle box

technical field

The invention relates to a power switch for arrangement in a fused switch box of an at least partially electrically driven motor vehicle. The power switch according to the invention has a housing with a housing wall in which an edge-closed passage opening is formed, wherein a bimetallic contact element is arranged in the passage opening. Furthermore, the invention relates to a fused switch box, in particular a junction box, for an at least partially electrically driven motor vehicle, which has a power switch according to the invention.

Background technique

Power switches are basically known. Power switches can also be referred to as contactors. Contactors or contactor terminals are electrically or electromagnetically actuated switches for high electrical power, such as are found in electrically driven motor vehicles.

Usually, the contactor comprises a housing which has a housing wall, wherein openings are arranged in the housing wall and a contact element is formed in each opening. Arranged on the inside of the housing is a coil that can be actuated by a control current and has a coil armature in order to either electrically connect the two contact elements to one another or to interrupt the electrical connection between the two contact elements. The contact elements are made of copper. Therefore, these contact elements have high current conductivity. A disadvantage of known power switches is that power switches of this type are expensive. Furthermore, the known contactor has a bore on the contact surface, which bore has an internal thread, so that, for example, the conductor rail can be connected to the contact element in a non-positive manner. Since the contact element is made of copper, the conductor track to be electrically conductively attached to the contact element correspondingly also needs to be made of copper, so that high follow-up costs can arise here.

Contents of the invention

The object of the present invention is to provide a power switch for arrangement in a fused switch box of an at least partially electrically driven motor vehicle, which power switch can be produced cost-effectively.

This object is solved by the subject-matter of claim 1 . Preferred developments of the invention are given in the subclaims, the following description and the drawing, wherein each feature can form an aspect of the present aspect not only individually but also in combination.

According to the invention, a power switch is provided for arrangement in a fused switch box of an at least partially electrically driven motor vehicle, the power switch having a housing and a bimetallic contact element, the housing having a housing wall, The housing wall has a housing inner side and a housing outer side arranged at a distance from the housing inner side and has a through-opening formed in the housing wall, in which the contact element is arranged, the contact element having a A first section of a first metal and a second section of a second metal different from the first metal, the first section protruding beyond the inside of the housing, the second section conductively attached to the first section segment and protrudes beyond the outside of the housing.

In other words, one aspect of the present invention is to provide a power switch. In particular, a power switch is to be understood as a contactor or switching contactor. The power switch is intended to be arranged in a fused switch box of an at least partially electrically driven motor vehicle. The motor vehicle can preferably be driven entirely electrically. A fused switch box can also be referred to as a junction box. The fused switch box preferably contains a switching unit which electrically conductively connects the battery to the converter or disconnects them accordingly.

The power switch has a housing with a housing wall. The housing wall has a housing inner side that faces the interior of the power switch. For example, the inside of the housing faces the armature in the power switch, which is designed to be displaceable by the solenoid coil. Furthermore, the housing wall has a housing outer side which is arranged at a distance from the housing inner side and which faces outward. An edge-closed through-opening is formed in the housing outer side and extends between the housing inner side and the housing outer side. A bimetallic contact element is arranged in the through opening. The bimetallic contact element has a first section made of a first metal and a second section made of a second metal different from the first metal, which is attached to the first section in an electrically conductive manner. The second metal also serves for electrical conduction and is not formed as a coating of the first metal. The first section protrudes beyond the first section, and the second section protrudes beyond the outside of the housing. In other words, the contact elements of the power switch do not consist of a single metal, but are bimetallic. The contact element thus has two different metals which are arranged next to each other in the longitudinal direction of the contact element and are electrically conductively connected to each other. In this way, two different metals can be used for the contact element, one of the metals being more expensive than the other. In this way, the cost of the power switch can be reduced.

In an advantageous embodiment of the invention, it is provided that the first section protruding beyond the inner side of the housing consists of copper or silver, or at least partially comprises copper or silver. Both copper and silver are very good conductors of electricity. Copper is more expensive and more expensive than silver. By forming the first section from copper or silver or from a material comprising copper or silver, high electrical conductivity of the power switch can be provided within the power switch, for example for contacting the armature.

It is conceivable that the second section has a reduced and/or lower electrical conductivity than the first section. Thus, for example, it can be provided that the first section consists of copper and the second section consists of an electrically conductive material which has a reduced electrical conductivity compared to copper. It is provided here that the second section is not a coating, but rather directly adjoins the first section and is electrically conductively connected and/or in contact with the first section.

Further advantageously, it can be provided that the second section has a reduced density compared to the first section. It can therefore preferably be provided that the second section not only has a reduced or lower electrical conductivity than the first section, but also has a lower weight. Due to the reduced density of the second section relative to the first section, the weight of the power switch can be reduced, which can be advantageous for use in motor vehicles.

A preferred embodiment of the invention consists in that the second section consists of aluminum or at least partially comprises aluminum. Aluminum has a low electrical conductivity compared to copper or silver. Likewise, aluminum has a lower density than copper or silver. Thus, on the one hand, the cost and weight of the power switch can be reduced, for example by forming the second section from aluminum.

In an advantageous development of the invention, it is provided that the second section has a contact surface for connection to the conductor rail, and that the contact surface of the second section is formed without drilling. The contact surface of the second section is preferably formed on that side of the second section facing away from the first section. The contact surface is preferably a flat surface. The planar surface is formed without drilling, so that the conductor track can preferably be electrically conductively connected to the contact surface of the contact element in a material-fit manner. By omitting drilling in the contact elements, the costs of the power switch can be reduced.

A preferred refinement of the invention consists in that the contact surface of the second section is raised in the form of puncta and/or ring-shaped. Thus, punctiform and/or annular projections can be used as centering elements. When the conductor track is arranged on the contact surface, recesses corresponding to the punctiform and/or annular projections are preferably formed in the conductor track, so that the recesses of the conductor track rest on the projections or the projections engage into the notch. Positioning of the conductor rail on the contact element for fastening the conductor rail by means of the contact element is thus possible. The conductor track is then preferably electrically conductively connected to the contact surface of the second section in a materially bonded manner. As a result, the punctiform and/or annular projections on the contact surface of the second section can simplify and/or speed up the assembly process for connecting the power switch to the conductor rail, thereby reducing costs.

In an advantageous development of the invention it is provided that the outer circumference and/or outer diameter of the second section is larger than the outer circumference and/or outer diameter of the first section. It can be provided that both the first section and also the second section are preferably of cylindrical configuration. Here, for example, it is provided that the second section has a larger diameter than the first section. The first section and the second section 2 are preferably arranged coaxially to one another. Therefore, the end side of the second section facing the first section has an annular surface, which preferably serves as a bearing surface, so that the contacts in the through-opening can be arranged in such a way that when the contacts are inserted from one side When arriving or being arranged in the through-opening, the contact rests at least on the housing, on the housing projection or on the wall projection without sliding off through the through-opening.

A preferred embodiment of the invention consists in that the contact element is arranged in the through-opening in such a way that the transition from the first section to the second section and/or the attachment structure is located on the housing wall at the height of the housing wall. between the inside and the outside of the housing. It is advantageously provided that boundaries, ie housing inner walls and housing outer walls, are excluded. However, it is also conceivable that boundaries, ie housing inner walls and/or housing outer walls, are included.

It is further advantageously provided that the contact element is arranged in the housing in a material-bonded manner for the material-bonded connection of the casting and/or weld of the contact element in the through-opening at the first section to the second section. The contact element is surrounded in the region of the attachment structure. As a result, the risk of galvanic corrosion occurring in the transition region between the first section and the second section can be reduced. In this way, the durability of the power switch can be improved.

Against this background, an advantageous refinement of the invention consists in that the casting and/or the weld are configured to be bubble-free. In this context, bubble-free means that the casting or solder has less than 5% air inclusions, preferably less than 3% and quite particularly preferably less than 1%, relative to the volume of the casting or solder.

In principle, the casting can be designed in such a way that it ensures a permanent, secure and materially bonded connection of the contact elements in the through-opening of the housing. It is conceivable for the potting to consist of a plastic material and/or comprise plastic.

It is very particularly preferably provided that the casting consists of a permanently elastic material, in particular rubber.

In a preferred development of the invention it is provided that the contact element rests at least in sections on a wall projection of the housing wall which protrudes at least partially into the through-opening. A wall projection of this type can be, for example, a projection which is formed and fastened to the housing inner wall and protrudes into the through-opening. The wall projection can be circumferential. However, it is particularly preferred that the wall projection is not formed circumferentially.

It is also conceivable for the through opening to have a first cross section and a second cross section different from the first cross section. For example, it can be provided that the through opening has a first diameter and a second diameter. The second diameter is preferably smaller than the first diameter. It is conceivable that, starting from the outside, the larger cross-section is formed in the housing wall, and that, starting from the housing inner wall, the smaller cross-section is arranged in the through-opening. If the contact element also has two mutually different cross-sections, then, for example, the contact element can be introduced forward into the through-opening starting from the outside of the housing with the first section, so that the contact element is located between the first section and the second section. At least partially in the transition region of the section rests on the projection with the second diameter, so that the contact element does not slide off through the through-opening, but rests at least in sections on the wall projection with the smaller cross section .

It is further advantageously provided that a plurality of through-openings are arranged in the housing, each having a contact element arranged therein, wherein a separating plate is formed between the two contact elements on the outer side of the housing. In this way, the risk of electric arcs electrically conductively connecting the two contact elements to one another can be reduced by means of the separating plate.

Furthermore, the invention relates to a fused switch box of an at least partially electrically driven motor vehicle, which has a power switch according to the invention.

Finally, in an advantageous refinement of the invention, the fused switch box has a conductor rail which is arranged in a materially bonded and electrically conductive manner on the contact surface of the contact element. The materially bonded connection is preferably a welded connection and/or an adhesive connection. It is very particularly preferred that the connection is non-positive locking. An inexpensive and durable attachment of the conductor track to the contact element can be achieved by means of an adhesive connection and in particular by a soldered connection.

Further features and advantages of the invention emerge from the dependent claims as well as from the examples below.

Description of drawings

The examples are not restrictive but are to be understood rather as exemplary. The examples are intended to enable those skilled in the art to practice the invention. The applicant reserves the right to make individual and/or several of the features disclosed in the exemplary embodiments the subject-matter of the claims or to add these features to existing claims. An exemplary embodiment is explained in more detail with reference to the figures.

Shown in the accompanying drawings:

Fig. 1 is a cross section of a power switch according to an embodiment of the present invention;

Fig. 2 is a top view of a power switch according to a preferred embodiment of the present invention;

Figure 3 is a view of a contact element according to a second embodiment of the invention;

Figure 4 is a view of a contact element according to a third embodiment of the invention;

FIG. 5 is a detailed view of the top view of the power switch in the region of the contact elements.

Detailed ways

FIG. 1 shows a section through a power switch 10 intended to be arranged in a fused switch box of an at least partially electrically driven motor vehicle. The power switch 10 is understood to be a contactor. The power switch 10 has a housing 12 with a housing wall 14 . The housing wall 14 comprises a housing inner side 16 and a housing outer side 18 formed at a distance from the housing inner side 16 . The housing inner side 16 faces the interior of the power switch 10 . In contrast, housing exterior 18 faces the exterior of power switch 10 . An edge-closed through-opening 20 is arranged in the housing wall 14 . The through opening 20 is a through opening. In other words, the through opening 20 extends from the housing inner side 16 to the housing outer side 18 . A connecting element 22 is arranged in the through-opening 20 . The contact element 22 is designed as a bimetallic contact element 22 and has a first section 24 and a second section 26 adjoining the first section 24 and electrically conductively connected thereto. The first section 24 consists of a first metal. In the present exemplary embodiment, the first section 24 consists of copper. The second section 26 is composed of an electrically conductive material having a reduced electrical conductivity relative to the first section 24 . In the present case, the second section 26 consists of aluminum or at least comprises aluminum. In this way, a power switch 10 is provided which can have reduced costs compared to conventional power switches 10 with contact elements 22 made of copper, since aluminum is cheaper as contact element 22 than copper. Furthermore, the weight of power switch 10 can be reduced, which is advantageous especially in the case of motor vehicles.

The second section 26 of the contact element 22 has a contact surface 28 for connection to a conductor track (not shown). The contact surface 28 is formed on that side of the second section 26 facing away from the first section 24 . It can also be seen that the contact surface 28 of the second section 26 is formed without drilling. In this way, the costs of the power switch can be reduced, since no separate borehole is formed in the second section 26 of the contact element 22 for a non-positive connection to the conductor rail.

Both the first section 24 and the second section 26 are designed cylindrically. The first section 24 and the second section 26 are arranged coaxially with each other. The first section 24 has a first diameter. The second section 26 has a second diameter. The second diameter is larger than the first diameter. In this way, the second section 26 forms an annular bearing surface 30 on the side facing the first section 24 .

The through opening 20 has a first cross section and a second cross section different from the first cross section. Preferably, the second cross section is larger than the first cross section. The second cross section is preferably configured as a circle. The first cross section can be circular and can have a projection, in particular a wall projection, which is formed radially inwards. The second cross-section faces the outer side 18 of the housing. The first cross section is arranged near the housing inner side 16 . Due to the two different cross-sections in the through-opening 20 , a shoulder-shaped support 32 or wall projection is formed on which the contact element 22 rests at least partially with an annular support surface 30 . , so that it is possible to prevent the contact element 22 from sliding through the through-opening 20 . Furthermore, when the conductor rail (not shown) is welded to the contact element 22 , the contact force acting in the axial direction of the contact element 22 can be introduced or dissipated via the annular support surface 30 into the housing wall 14 . In the shoulder support portion 32 .

It can also be seen that the attachment structure of the first section 24 and the second section 26 is arranged in the through-opening 20 at the level of the housing wall 14 between the housing inner side 16 and the housing outer side 18 . The annular space between the contact element 24 and the housing wall 14 , or between the first section 24 and the housing wall 14 and the second section 26 and the housing wall 14 , is cast by means of a casting compound 33 . Galvanic corrosion can therefore be prevented, especially in the attachment region between the first section 24 and the second section 26 .

The power switch 10 has two through-openings 20 in the housing wall 14 that are configured at a distance from one another. A contact element 22 is arranged in each through opening 20 . An armature 36 made of electrically conductive material is formed in housing 12 , displaceable by solenoid coil 34 , in order to establish or interrupt an electrically conductive connection between two contact elements 22 . Solenoid coils are usually energized by a control current. If a current flows, the armature 36 is displaced in the direction of the contact elements 22 in order to enable a current flow between the two contact elements 22 . If the control current is interrupted, usually a spring ensures that the armature 36 is displaced away from the contact elements 22 so that a current flow between the two contact elements 22 is inhibited.

A separating plate 38 is arranged or formed between the two contact elements 22 on the housing outer side 18 . The separating plate 38 prevents possible arcing between the two contact elements 22 .

FIG. 2 shows a plan view of power switch 10 shown in FIG. 1 . In this plan view it can be seen that the two contact elements 22 are arranged at a distance from one another and that a separating plate 38 is formed between the two contact elements 22 .

FIG. 3 shows a section through a contact element 22 in a second embodiment. As shown in FIG. 1 , the contact element 22 has a first section 24 and a second section 26 arranged coaxially to the first section 24 . The first section 24 consists of a first metal and the second section 26 consists of a second metal different from the first metal. In the present case, the first section 24 consists of copper and the second section 26 consists of aluminum. In contrast to the contact element 22 shown in FIG. 1 , the contact element 22 according to FIG. 3 has punctiform and/or round projections 40 on the contact surface 28 . The projections 40 or protrusions serve as centering elements for centering the conductor rail (not shown). For this purpose, recesses corresponding to the projections 40 are arranged in the conductor track. When placing the conductor rail on the projection 40 , a positive fit thus takes place, so that slipping of the conductor rail on the contact element 22 during the fastening process for fastening the conductor rail to the contact element 22 can be avoided. It is then preferably provided that the conductor track is connected in a materially bonded manner to the contact surface 28 of the second section 26 of the contact element 22 . The materially bonded connection is preferably an adhesive connection or in particular a welded connection. In this way, the conductor track can be permanently, securely and cost-effectively electrically conductively connected to the contact element.

FIG. 4 shows a cross-section of the contact element 22 in a third configuration. In the third configuration, it is provided that the second section 26 is U-shaped in cross section. The first section 24 engages between the arms of a U-shaped second section 26 and is connected thereto in a materially bonded manner.

FIG. 5 shows a detailed view of the contact element 22 in the region of the through-opening 20 . It can thus be seen that radially formed projections or wall projections and/or shoulder-shaped supports 32 protrude into through-opening 20 , on which projections contact elements 22 rest with annular support surfaces 30 Or on the wall protrusion and/or on the shoulder-shaped support. The wall projections with corresponding shoulders 32 are formed only point by point, not circumferentially. The casting 33 for casting the contact element 22 in the through-opening 20 can thus surround the connection region between the first section 24 and the second section 26 , so that galvanic corrosion in this region can be prevented.

Claims (13)

1. A power switch (10) for arrangement in a fuse box of an at least partially electrically driven motor vehicle, said power switch having: Housing (12) having a housing wall (14) with a housing inner side (16) and a housing outer side (18) arranged at a distance from the housing inner side (16) ) and has a through-opening (20) configured in the housing wall (14), A bimetallic contact element (22), which is arranged in the through-opening (20), has a first section (24) made of a first metal and is formed with the first metal a second section (26) of a second, different metal, the first section (24) protruding beyond the inside of the housing (16), the second section (26) being conductively attached to at said first section (24) and protruding beyond said housing exterior (18). 2. The power switch as claimed in claim 1, characterized in that the first section (24) consists of copper or silver, or at least partially comprises copper or silver. 3. A power switch according to claim 1 or 2, characterized in that the second section (26) has a reduced and/or lower conductivity relative to the first section (24) . 4 . The power switch as claimed in claim 1 , characterized in that the second section ( 26 ) consists of aluminum or at least partially comprises aluminum. 5. Power switch according to any one of the preceding claims, characterized in that the second section (26) has a contact surface (28) for connection to a conductor rail, and the second section The contact surface ( 28 ) is formed without drilling. 6 . The power switch as claimed in claim 1 , characterized in that the contact surface ( 28 ) of the second section has punctiform and/or annular projections ( 40 ). 7. The power switch according to any one of the preceding claims, characterized in that, the outer circumference and/or outer diameter of the second section (26) is larger than the outer circumference of the first section (24) and/or outside diameter. 8. The power switch as claimed in claim 1, characterized in that the contact element (22) is arranged in the through-opening (20) such that from the first section (24) The transition to the second section (26) and/or the attachment structure is located between the housing inner side (16) and the housing outer side (18) at the level of the housing wall (14) between. 9. The power switch as claimed in claim 1, characterized in that the contact element (22) rests at least in sections on a wall projection of the housing wall (14), the The wall projection protrudes at least partially into the through-opening (20). 10. Power switch according to any one of the preceding claims, characterized in that the contact element (22) is arranged in the housing (12) in a material-bonded manner for the material-bonded connection of the The casting (33) of the contact element (22) in the through-opening (20) surrounds the Contact element (22). 11. The power switch as claimed in claim 1, characterized in that a plurality of through-openings (20) are arranged in the housing (12), each having a contact arranged therein. An element (22), wherein a separating plate (38) is formed between two contact elements (22) on the housing outer side (18). 12. A fused switch box for an at least partially electrically driven motor vehicle, the fused switch box having a power switch (10) according to claim 1. 13 . The fused switch box as claimed in claim 12 , having a conductor rail which is arranged on a contact surface ( 28 ) of the contact element ( 22 ) in a materially bonded and electrically conductive manner. 14 .

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