WO2011098102A1

WO2011098102A1 - High-current contact element

Info

Publication number: WO2011098102A1
Application number: PCT/EP2010/006975
Authority: WO
Inventors: Wolfgang Langhoff; Michael Knödler; Till Beck
Original assignee: Amphenol-Tuchel Electronics Gmbh
Priority date: 2010-02-15
Filing date: 2010-11-16
Publication date: 2011-08-18
Also published as: EP2537209A1; DE102010008112A1

Abstract

The present invention relates to a high-current contact element for electrically contacting and mechanically connecting the high-current contact element with a corresponding mating contact by means of a contact surface (A) of the high-current contact element. The existing technical problems are solved in that the high-current contact element forms the mechanical connection in an automatically reinforcing manner as the temperature of the high-current contact element rises due to the current flow. An electrical connection comprising a high-current contact element and a mating contact is also provided according to the invention.

Description

High-current contact element

Description

The present invention relates to an electrical

High current contact element according to claim 1 and an electrical connector according to claim 9.

Such high current contact elements are, for example, i n

Motor vehicles, especially in the field of electrical

Hybrid drives, used. Technical problem in contacting the working with high currents current storage i st the heat occurring here. Because of the required reliability, the contacting is typically done using a resilient

Component that generates a mechanical contact force. The

Contact normal force must be sufficiently large and maintained over the service life to ensure proper functioning of the drive. The performance of the resilient component and thus the connector is mimicked by the thermal limitation of the resilient component l, as at higher temperatures

Softening takes place by reducing the residual stress. In addition, there is the technical problem that considerable line cross sections must be provided due to the high currents.

Another technical problem is the operation of

Vehicles occurring Vi brations and shocks.

The invention is therefore based on the object, an easy to

to provide a finished, low-wear high-current contact element, with a permanent and safe electrical connection is created especially at high temperatures.

This object is achieved with the features of claims 1 and 9. Advantageous further developments of the invention are given in the subclaims. All fall within the scope of the invention

Combinations of at least two of in the description, the

Claims and / or the figures given characteristics. at

specified value ranges should also be within the specified range

Limiting values are considered limit values and can be claimed in any combination.

The invention is based on the idea of increasing the contact force between the high-current contact element and a corresponding mating contact to be contacted by increasing the temperature in order to control the mechanical and / or electrical

Improve contact properties. The invention

High current contact element for transmitting current from a, in particular designed as a contact socket counter-contact, current source to one, in particular with the

High current contact element and the mating contact in electrical contact bringable, electrical conductor of a pantograph thus serves on the one hand for mechanical connection and on the other hand for electrical contacting of the pantograph with the Stromquel le over a

Contact surface A of the high current contact element with the mating contact. In that the mechanical connection increases as the temperature of the high-current contact element rises due to current flow

High current contact element is strengthened automatically, is solved in a simple manner existing especially at high temperatures problem of secure contact of the mating contact, which the use of the high current contact element and such electrical connectors at higher temperatures, in particular over 200 ° C and up to 400 ° C, allows.

The high current contact element can be provided with Vortei l as a plug, while the mating contact as the plug receiving

Contact socket is formed. In a particularly preferred

Embodiment i st also provided the contact socket with the features of the invention of the high current contact element, so that a double effect of the contact reinforcement is given.

The mechanical connection is influenced by the contacting force acting on the contact surface and the contact surface and, advantageously, the contact force and / or the contact surface

Increases heating when current flow, so that at higher temperature an ever firmer contact and / or a larger contact area is provided. A specific embodiment is that the contact pressure remains substantially constant by simultaneously increasing the contact force and the contact surface. According to an advantageous embodiment of the invention, it is provided that the high-current contact element is at

Temperature increase is formed automatically deforming in the direction of the mating contact. It must therefore be created in this embodiment, no articulated connections, as the ge selbsttäti

Reinforcement of the mechanical connection takes place solely by deformation of the high-current contact element. On an additional suspension for pressing the high current contact element and to ensure the electrical connection can be dispensed with according to the invention.

With advantage, it is further provided that the high-current contact element is integrally formed on a first electrical conductor, in particular

welded, is. This measure allows the movement of the high-current contact element in only one direction so that the ontacting of one of the two electrical conductors is already possible

Material is given.

By the high current contact element is a rolled, in particular roll-clad, preferably formed as a bimetallic strip of metal, the high-current contact element can be mass produced in a simple and inexpensive manner. The bi-metal 1 is preferably a bimetallic bimetal, preferably one of those listed in the following technical specification

Thermobimetals. Particularly preferred are the Thermobimetal le with the abbreviation GCuZ. For the inventive embodiment,

especially when used in high temperature ranges between 200 ° C and 400 ° C, so when high currents, is best GCuZ6. TECHNICAL SPECIFICATIONS THERMAL MALL

Abbreviation Abbreviation Linrary- Application- Description ^" , ^'' ^'' ·: · '· ^' ■ G.RAU 0IN1715 ^• rich from -20 ^e C-limit

Ge TB 1577 A to 200 "C 450" C Cost-effective bimetallic strip (TB) with good thermal

sensitivity

Ge15 TB 1577 B up to 200 ° C 450 ° C TB with the same thermal properties as TB Ge but with

higher permissible bending stress

M TS 20110 up to 200 "C 350 ^e C Standard thermal bimetal with high thermal sensitivity

M 80/20 to 200 ° C 350 "C Thermobimetal with good thermal sensitivity and optimum electrical resistance

MS up to 230 ° C 350 ° C Thermobimetal with maximum thermal sensitivity

G25 TB 1425 to 200 "C 450 ° C

G35 TB 1435 to 200 ° C 450 "C

Thermobimetals. which are derived from TB Ge, with

G38 to 220 ° C 450 ° C nickel liners and thus graded specific

G 5 to 200 ° C 450 ° C electrical resistances for applications

with direct electrical heating

G50 to 200 ° C 450 ° C

G55 TB 1555 to 200 ° C 450 ° C

GCuZ3 up to 200 "C 450 ° C

GCuZ6 up to 200 ° C 400 ° C

GCuZ 11 TB 1511 to 200 ° C 400 "C Thermobimetals derived from TB Ge with

Copper liners and thus graded specific

GCuZ 15 to 200 ° C 400 ° C electrical resistors for applications with

direct electrical heating

GCu217 to 200 ° C 400 ° C

GCuZ 19 to 200 ° C 400 ° C

MS up to 200 ° C 350 "C

IO up to 200 ° C 350 ° C

M IS up to 200 ° C 350 ° C Thermobimetals. derived from TB M, with copper or

M20 to 200 ° C 350 ° C nickel liners and thus graded specific

electrical resistors for applications with

M30 to 200 ° C 350 "C direct electrical heating

M 0 to 200 ° C 350 ° C

BO up to 200 ° C 350 ° C

H TB 1170 A to 380 "C 450 ° C Standard TB with medium thermal sensitivity for

Applications at higher temperatures

H 15 TB 1170 B to 380 ° C 450 ° C TB with the same thermal properties as TB H However, with

better spring properties

HCuZ TB 1109 to 380 ° C 400 ° C TB like TB H with Cu interlayer for faster reaction times

and better temperature distribution

H 6 TB 0965 to 425 ° C 450 ° C Thermobimetal similar to TB H for applications up to 450 ° C

RH 46 to 425 ° C 450 ° C Thermobimetal H 46 with corrosion protection coating on active

component

RGR up to 225 ° C 450 "C Thermobimetal Ge with corrosion protection coating on both sides

R100A up to 200 ° C 550 ° C Stainless steel with high application limit, linear behavior

but only up to 200 ° C

RR up to 550 ° C 550 ° C Stainless TB with high application limit and large

linearity range

RM up to 200 ° C 350 ° C Thermobimetal M with corrosion protection coating on active

component

RS up to 400 ° C 650 ° C Resistant corrosion resistant TB with medium thermal

Sensitivity and high application limit Furthermore, it is provided with advantage that the high-current contact element is not circumferentially closed and / or tubular, in particular in

The axial direction is at least partially conical, preferably cylindrical, and more preferably circular cylindrical. By providing a slot in the axial direction on the circumference of the high-current contact element, that is, the high-current contact element is not formed circumferentially closed, the high-current contact element on the one hand in a simple manner can be mounted and on the other hand schmiegt that

High current contact element optimally to the mating contact. By conical design of the high current contact element, on the one hand, the assembly is further facilitated and on the other hand realizes a rising automatically upon deformation of the high current contact element contact surface, so that the current transfer is even better with increasing temperature by the contact surface between the

Counter contact and the high current contact element is increased.

It is particularly advantageous to use the high-current contact element as well

Bimetal lstrei fen with a facing away from the contact surface A first metal lschicht from egg nem material with a larger thermal

Expansion coefficient as a least tei lweise the contact surface A bi ldende second metal layer form. As a result, an automatically deforming high-current contact element can be provided in the smallest space, which at the same time has optimum conductivity, since it is completely made of metal. It is particularly advantageous to use the first metal layer made of aluminum and the second metal layer made of copper, in particular as copper alloy, particularly preferably as

Copper alloy of the first metal layer to form. In a further, vortei lhafte embodiment of the invention it is provided that the high-current contact element at least one end extending in the axial direction incisions for, in particular automatic locking of the high-current contact element with the

Has mating contact. The sections formed by the incisions at the end of the high current contact element roll due to the

Bimetallic automatically around the counter contact to be contacted by the sections formed by the incisions project beyond the mating contact.

According to the invention, an electrical connector comprising a high current contact element according to the above description and a corresponding mating contact is also provided, wherein the

High current contact element is an electrical contact and a mechanical connection with the mating contact on a contact surface A of the high-current contact element effecting ausgebi LODEN.

For especially high-quality and extreme ratios exposed compounds is according to an advantageous embodiment of the

Invention provided that the mating contact as the second

High current contact element with the features described above, but in reverse configuration to be contacted

High current contact element is formed. Thus, both work

High current contact elements in this embodiment 'in each case according to the invention.

Further advantages, features and details of the invention will become apparent from the description of preferred embodiments and with reference to the drawings. These show in: A radial view of an inventive

High current contact element i n a Ausgangsl age, a perspective view of the high current contact element according to Figure l a, a radial view of the invention

High current contact element in a deformed state, a perspective view of the high current contact element according to Figure 2a, a perspective view of an electrical connector according to the invention described, consisting of the high current contact element and a

Corresponding mating contact, a perspective view of the connector of Figure 3 in the inserted state and a perspective view of an alternative embodiment of the high current contact element with a partially conical deformation section.

In the figures, identical or equivalent components are identified by the same reference numeral. FIGS. 1 a, 1 b, 2 a and 2 b show a high-current contact element 1, which in the present case comprises an inner, first metal layer 2

Aluminum and an outer, second metal layer 3 is formed of copper. The outer metal layer 3 encloses the inner

Metal layer 2 over the entire surface and the first metal layer 2 and the second metal layer 3 have a common, extending in the radial direction slot 5, depending on the state of the

High current contact element 1 is smaller or larger.

In the case of the initial state shown in Figure la at

Normal temperature, for example during assembly of the

High current contact element 1, the slot 5 is small and extends over a circumferential angle section between 1 ° and 10 °, preferably between 1 ° and 5 °.

In the state shown in Figure 2a, compared with Figure la deformed state of the slot is further opened, in particular over a circumferential angle of 5 ° to 90 °, preferably 20 ° to 50 °.

As a result of the deformation shown, the diameter D1 increases according to FIG. 1a to a diameter D2 according to FIG. 2a. As a result, when the high-current contact element 1 in a contact socket

formed mating contact 20 is used according to Figure 4 and with a contact surface A, which corresponds to the outer surface of the second metal layer 3, is in electrical contact, one over the entire

Contact surface A acting higher contact force generated when a

Deformation of the high-current contact element 1 according to Figure 2a is effected by increasing the temperature. The temperature increase is due to the bimetallic property of the thermobimetal formed High current contact element 1 causes, because the inner, first metal lschicht 2 has a much higher thermal

Expansion coefficients on.

The first metal layer 2 and the second metal layer 3 are flush at their end faces 6, 7 and according to Figures l b and 2b on the circumference of the first and second metal layer 2, 3 distressed arranged incisions 4, which are due to the bimetallic property of

Hochstromkontaktelements 1 at the edge 2 1 of the mating contact 20 to unroll around the edge 2 1 of the mating contact 20 in the radial direction, when the mating contact 20 is surmounted by its edge 2 1 of the high current contact element 1 at the end faces 6 and 7. This will ei ne

Stabili tion of the radial position of the high current contact element 1 in the mating contact 20 achieved. This measure can also be applied to the

opposite side of the high current contact element 1 may be provided accordingly, so that in both directions with increasing temperature, an additional stabilization of the high-current contact element 1 i n the counter contact 20 takes place.

To assess the contact quality, a temperature measurement may be used

Temperature sensor may be provided on the high-current contact element 1 or integrated in this, in particular between the first metal layer 2 and the second metal layer 3. This is particularly suitable for wear-prone applications such as

Battery replacement systems or charging plug advantageous.

In addition to the high current contact element 1, the

Mating contact as a high current contact element 1 'ausgebi LET is n and opposite to the high current contact element 1 acting provided in that the position shown in FIG. 2a represents the initial position and the position illustrated in FIG. 1a represents the position deformed at a higher temperature and the contact surface A 'on the inside of the

High current contact element 1 ^'is arranged.

Thus, two opposing high-current contact elements 1, can be provided, the mechanical connection is automatically formed mutually reinforcing.

The high-current contact element 1 shown in FIGS. 3 and 4 is provided with a contact terminal 8, to which an electrical conductor or a printed circuit board can be electrically contacted, in particular by

Welded joint. The high current contact element 1 consists in this embodiment of a deformation section 9 mi t

Bimetal and a contact terminal 8 having terminal portion 1 0 for connecting a rule electrical conductor or a printed circuit board. Particularly advantageous here is that the

High current contact element 1 made of one piece i st, here egg nem walzplattierten, at least partially bimetal leigenschaften having metal lstreifen, the manufacture of this high-current contact element 1 is possible in high production speed and extremely low cost in mass production.

The embodiment shown in Figure 5 a

High-current contact element 1 "is characterized by a tapered first section 1 1 in the deformation section 9 and a two th section 1 2, which is gebi as in Figure 3 gebi LENGTHEN with increasing current flow and thus increasing temperature of the

High current contact element 1 ", the contact surface A is self-acting increased by the high-current contact element 1 "expands in the first section 1 1. Simultaneously, the assembly of

High current contact element 1 "facilitates by the first portion 1 1 is arranged in a direction of insertion S of the high current contact element 1".

High current contact element B e c u s e c ia l e s t e

A contact surface

D diameter D

1, 1 ', i "high current contact element

2 first metal layer

3 second metal layer

4 cuts

5 slot

6 faces

7 faces

8 contact connection

9 deformation section

10 deformation section

11 first, conical section

12 second section

20 mating contact

21 edge

Claims

High current contact element

1. high-current contact element (1) for electrical contacting and mechanical connection of the high-current contact element (1) with a corresponding mating contact (20) via a

Contact area A of the high current contact element (1),

characterized in that

the high current contact element (1) the mechanical connection at rising by current flow temperature of the

High current contact element (1) is formed automatically reinforcing.

Second high-current contact element (1) according to one of the preceding claims, wherein the high-current contact element (1) is automatically deformed in temperature increase in the direction of the mating contact (20).

3. High current contact element (1) according to one of the previous

Claims in which the high-current contact element (1) is integrally formed, in particular welded, on a first electrical conductor.

4. High current contact element (1) according to one of the previous

Claims in which the high-current contact element (1) is a gerol older, in particular roll-clad, preferably as a bimetal

trained, metal lstreifen is.

5. High current contact element (1) according to one of the previous

Claims in which the high-current contact element (1) tubular and / or not circumferentially closed, in particular in the axial direction at least tei lweise conical, preferably cylindrical, more preferably circular cylindrical, is formed.

6. High current contact element (1) according to one of the previous

Claims in which the high current contact element (1) as

Bimetal lstreifen with egg ner facing away from the contact surface A first metal lschicht (2) made of a material having a greater thermal expansion coefficient than an at least partially the contact surface A bi ldendende second metal layer (3)

is trained. High current contact element (1) according to one of the preceding

Claims, wherein the first metal layer (2) of aluminum and the second metal lschicht (3) made of copper, in particular as

Copper alloy of the first metal layer, are expired.

High current contact element (1) according to one of the preceding

Claims in which the high-current contact element (1) at at least one end in the axial direction incisions (4) for, in particular automatic, locking the

High current contact element (1) with the mating contact (20) aufwei st.

Electrical connector consisting of a

High current contact element (1) according to one of the preceding

Claims and a corresponding mating contact (20), wherein the high-current contact element (1) has an electrical cal

Contacting and a mechanical connection with the

Counter contact (20) at a contact surface A of the

High current contact element (1) is designed to effect.

An electrical connector according to claim 9, wherein the

Counter-contact (20) as high-current contact element (Γ) according to one of claims 1 to 8 is ausgebi ended.