Power line disconnect device

Abstract

Power line disconnecting device (1), comprising: a housing (2) surrounding a chamber (4), wherein: the housing (2) has an inner wall (24) facing the chamber (4) and deformable at least in sections; and a movable disconnecting element (3) arranged on the housing (2) and / or within the chamber (4) for disconnecting a power line;- an actuator (6) arranged on the housing (2) and / or within the chamber (4) for triggering a movement of the separating element (3), wherein - the housing comprises a housing upper part (21) and a housing lower part (22), wherein the housing lower part (22) has a housing lower part bottom (223) facing the chamber (4) and at least one housing lower part side wall (221) facing the chamber (4), which forms a partial section of the housing inner wall (24), and wherein - the housing lower part (22) comprises a housing lower part outer wall (222) which surrounds the housing lower part side wall (221) and the housing lower part bottom (223), characterized in that the elasticity or plasticity of the housing lower part side wall (221) is greater than the elasticity or plasticity of the housing lower part outer wall (222).

Description

The invention relates to a power line disconnecting device according to the preamble of claim 1, a vehicle component according to claim 11, a stationary device according to claim 12 containing this power line disconnecting device, and a method for manufacturing a power line disconnecting device using a 3D printing method according to claim 13. Electrically powered vehicles require batteries with very high voltages and currents. In the event of an accident, these high currents and voltages can pose a danger to vehicle occupants and emergency responders. This danger can be minimized, for example, by interrupting the current flow near the battery as quickly as possible. Interrupting the electrical circuit can be achieved using line disconnectors, such as high-voltage electric line cutters (HV-ELCs). Such emergency disconnect devices can switch off very high currents (several kiloamperes) and very high voltages (up to the kilovolt range) within milliseconds. In the prior art, line disconnectors are known that comprise a movable disconnecting element and an ignition unit. The disconnecting element can knock a section out of a busbar, thus interrupting the current flow. A disadvantage of known line disconnectors is that even after the busbar has been disconnected and the current interrupted, an undesirable re-arc with current flow (re-ignition) can occur due to the gap between the inner wall of the housing and the disconnecting element, or between the inner wall of the housing and the knocked-out section of the busbar. For example, DE 10 2018 125 059 A1 discloses a power line cutting device for high-voltage busbars with a two-part housing, a piston, an igniter, and a busbar. Furthermore, DE 10 2014 115 397 A1 describes a pyrotechnic drive device with a housing containing a combustion chamber filled with pyrotechnic material, the combustion chamber being bounded by a combustion chamber wall that is closed at least in one initial state. Power line cutting devices for high-voltage busbars with multi-part housings are known from US 2013 / 0 255 464 A1 and US 2019 / 0 172 669 A1. The problem underlying the invention is to provide a power line disconnect device that prevents reignition. This problem is solved by a power line disconnecting device having the features of claim 1. The invention relates to a power line disconnecting device, in particular for disconnecting high-voltage busbars or high-voltage power lines, with a housing that surrounds a chamber, wherein the housing has an inner wall facing the chamber, wherein the inner wall is deformable at least in sections. The deformable section prevents reignition. It can also serve to reduce the kinetic energy of the separating element and / or the section cut from the power line or busbar. The deformable section can absorb the kinetic energy of the separating element and / or the section cut from the power line or busbar and convert it into deformation work. The chamber is a space filled with gas or extinguishing agent, or one that can be filled with gas. The chamber is surrounded by a housing. The chamber is therefore located inside the housing. The chamber comprises a lower chamber section and an upper chamber section. The upper chamber section is defined as the area of ​​the chamber located above the mounting point for a busbar or above the (horizontally running) power conductor, in particular the busbar. The lower chamber section is defined as the area of ​​the chamber located below the mounting point for the (horizontally running) power conductor, in particular the busbar. The mounting point for the power conductor, in particular the busbar, is therefore located between the lower chamber section and the upper chamber section. The housing can be designed as a two-part or multi-part housing. The housing has an inner wall facing the chamber. The housing also has an outer wall that surrounds the inner wall. The housing can also have a base and a top, with the outer wall connected to both the base and the top, and the top and bottom being opposite each other. The housing comprises a lower housing part and an upper housing part. The upper housing part is defined as the area of ​​the housing located above the mounting point for a busbar or above the (horizontally running) power conductor, in particular the busbar. The lower housing part is defined as the area of ​​the housing located below the mounting point for the (horizontally running) power conductor, in particular the busbar. The mounting point for the power conductor, in particular the busbar, is therefore located between the lower housing part and the upper housing part. The lower housing part may be (detachably) connected to the upper housing part. The housing top has a housing top cover and at least one housing top side wall, wherein the at least housing top side wall is connected to the housing top cover. The lower housing part comprises a base facing the chamber and at least one side wall facing the chamber, the latter being connected to the base. The lower housing part also includes, for example, an outer wall surrounding the side wall and the base. The lower housing side wall can be designed to be deformable in at least one section. This at least one deformable section of the lower housing side wall can be elastically or plastically deformable. The lower housing part can, for example, be cylindrical, so that it has a curved side wall. If the lower housing part is triangular, square, or polygonal, it will have three, four, or more than four side walls. The upper housing part containing a chamber upper part and the lower housing part containing a chamber lower part can be connected to each other in such a way that the chamber upper part and the chamber lower part together form a chamber (separated from each other only by the electrical conductor, in particular a busbar). The upper housing part containing the chamber upper part and the lower housing part containing the chamber lower part can be connected to each other by positive locking, material locking, and / or force locking. The at least one side wall of the upper housing part can be connected to the at least one side wall of the lower housing part by positive locking, material locking, and / or force locking. The housing, especially the lower part, can be designed or contain at least partially or completely as an electrical insulator. This reduces or prevents sparking. Electrical insulators (non-conductors) are defined as chemical elements or materials with an electrical conductivity of less than 10⁻⁸ S·cm⁻¹ (and a resistivity greater than 10⁸ Ω·cm). The housing, e.g., the base and / or the upper and / or lower housing, can have at least one gas opening (gas outlet openings and / or gas inlet openings) for a gas or gas mixture. The base and / or lower housing can have at least one gas outlet opening for releasing expelled gases. The gas outlet opening of the lower housing can extend through the lower housing side wall and the lower housing outer wall into the external environment of the housing. Alternatively or additionally, at least one gas outlet opening of the lower housing can lead into at least one gas inlet opening of the upper housing. The upper housing can therefore have at least one gas inlet opening that is connected to the gas outlet opening of the lower housing. This allows expelled or displaced gases to be at least partially returned to the chamber.Firstly, the pressure of the returned gas or gas mixture allows the separating element, along with the section cut out of the power line or busbar, to be held in the lower area (lower part of the housing). Secondly, the gas or gas mixture can serve as an arc-quenching or arc-cooling element. The at least one gas opening can extend through the deformable section of the lower housing side wall. The power line disconnect device can have a receptacle for at least one power line or at least one busbar. The receptacle for the power line or busbar can be arranged on the housing and, in particular, extend within and / or through the chamber. The receptacle or busbar can be arranged (horizontally) between the upper and lower housing parts. The busbar can be guided or routed through at least one opening, e.g., a slot, in or through the housing. A power line is an electrical conductor (e.g., a cable) used to transport electrical energy or electric current. The power line can be connected to the vehicle's battery and battery-powered components. It can also be a high-voltage power line (and thus capable of carrying high-voltage currents). Furthermore, at least one power line can be configured as a busbar. A busbar is an electrical conductor (made of a rigid material) used to supply vehicles with electrical energy or current. The busbar is, for example, designed as a high-voltage busbar (and is therefore capable of carrying high-voltage currents). The busbar can be connected to the battery and at least one battery-powered component of an (electrically powered) vehicle. The power line or busbar can be made of or contain a suitable metal, e.g., aluminum, copper, iron, steel, or an alloy. The power line or busbar can have two ends that are located outside the housing (outside the upper and lower housing parts). A movable separating element for severing the power line is arranged on the housing, particularly inside the upper part of the housing, and / or inside the chamber, particularly inside the upper part of the chamber. An actuator for triggering movement of the separating element is arranged on the housing, particularly within the upper part of the housing, and / or within the chamber, particularly within the upper part of the chamber. The actuator may be located outside or inside the housing or the chamber. The actuator may be located at least partially or completely inside the housing, particularly within the upper part of the housing, and / or within the chamber, particularly within the upper part of the chamber. The actuator may be located on the housing ceiling. The actuator may be (detachably) connected to the separating element. Activation of the actuator accelerates the separating element towards the power line or busbar, causing it to impact the power line or busbar. The momentum transfer from the separating element to the power line or busbar is so strong that a section is torn from the busbar. A separating element is understood to be a three-dimensional body suitable for separating at least a section (at least partially or completely) from a power line or busbar. The separating element is designed in such a way that it allows for significant deformation with energy absorption. The separating element can be blunt, pointed, or have a sharp edge. For example, the separating element can be cuboid, cube-shaped, cylindrical, stamp-shaped, conical, or pyramidal. The separating element can also be bolt-shaped (e.g., as a separating bolt). The separating element is designed and arranged in such a way that, after activation of the actuator, it impacts the power line or busbar and cuts it (at least partially or completely), thus interrupting the current flow within the power line or busbar. The power line disconnect device thus enables protection against damage and risks from short circuits of high-voltage batteries by separating the load circuit from the battery. The separating element can, for example, be made of a material with a lower hardness (e.g., Shore, Mohs, or Rockwell hardness) than the busbar to be cut. The separating element can also be made of a plastic (e.g., a polymer) with a lower hardness than copper. The separating element can be designed (at least partially or completely) as an electrical insulator (non-conductor) or contain one. This reduces or prevents sparking. The separating element can consist, for example, of non-conductive carbon, a (non-conductive) polymer or (non-conductive) plastic, a (non-conductive) ceramic, or a (non-conductive) glass. An actuator is a component that can trigger or initiates movement of the separating element in response to a signal and / or impulse (e.g., from a vehicle crash detection system). The actuator can be an igniter or micro gas generator, which may, for example, contain a pyrotechnic propellant charge. The actuator or igniter can be activated by a signal, in particular an electrical or electronic signal (from the vehicle crash detection system). The actuator or igniter can, for example, be activated (triggered by the signal) by a sensor, such as an airbag sensor, impact sensor (crash sensor), accident sensor, and / or acceleration sensor. Electrical connections may be located on the actuator or igniter. The actuator can be a pyrotechnic igniter that triggers movement of the separating element through pyrotechnic ignition. Activating the actuator triggers movement of the movable separating element. Due to the actuator's activation, the separating element can be moved towards the receptacle for the busbar or power line (so that the separating element and the busbar or power line come into contact with each other). The power line may (before being cut) have at least one predetermined breaking point. The busbar (before being cut) may have at least one predetermined breaking point. The at least one predetermined breaking point or break point in the power line may have a smaller cross-section than the remaining sections of the busbar or power line. The predetermined breaking point or break point in the busbar or break point in the power line may be formed by a material narrowing or weak point. The predetermined breaking point or break point in the busbar or break point in the power line may be a notch (indentation or recess). The at least one predetermined breaking point or break point in the busbar or break point in the power line is designed to break, at least partially, upon impact of the cutting element on the busbar.The at least one busbar break point or power line break point can be arranged in such a way that the separating element hits it. When the separating element impacts the power line or busbar, a section of the busbar can be partially or completely torn (broken out). This interrupts the current flow between the battery and the battery-powered component of the vehicle. The section torn from the power line or busbar may be shaped like a conductive coin. After the power line has been cut, the separating element is brought into contact with the (elastically or plastically) deformable section of the inner housing wall, in particular the lower housing side wall. A deformable section (or deformable section) is a section of the inner housing wall, particularly the lower housing side wall, which changes its shape as a result of contact between the separating element and / or the section cut out of the busbar. This prevents the cut-out section and / or the separating element from rebounding and thus prevents arcing and ignition of the power line disconnect device (or the vehicle). For example, only the lower housing side wall has at least one deformable section, but not the lower housing base. The deformable section of the housing inner wall, particularly the lower housing side wall, can be made of a plastic (polymer), a composite material (a composite of two or more materials), or it can be made of or contain an elastomer, such as a thermoplastic elastomer. The deformable section can also be made of or contain a silicone (polysiloxane or polyorganosiloxane). The deformable section of the inner housing wall, particularly the lower side wall, can consist of or contain an electrical insulator. This can reduce or prevent sparking, thus preventing or reducing the likelihood of the electrical disconnect device igniting. The deformable section of the inner housing wall, particularly the lower housing side wall, can be made of a flame-retardant material, especially a halogen-free material, or contain a flame retardant. This can prevent or reduce the likelihood of the electrical disconnect device igniting. The deformable section of the inner housing wall, particularly the lower side wall, may be made of or contain a self-extinguishing material. This can protect the electrical disconnect device and, under certain circumstances, the vehicle component and / or the entire vehicle from being completely destroyed by fire. The deformable section of the inner housing wall, in particular the lower housing side wall, may, for example, be made of or at least contain a flame-retardant and / or self-extinguishing and / or electrically insulating material. The deformable section of the inner housing wall, particularly the lower housing side wall, can project into the chamber. This deformable section can be conically shaped. For example, it can project 0.1 mm to 0.5 mm into the lower chamber. This allows the separating element to come into contact with the deformable section after pyrotechnic ignition and disconnection of the electrical conductor, thus preventing reignition. The deformable section of the inner housing wall, in particular the lower housing side wall, may have a lamellar or ribbed structure. The outer wall of the lower housing can be pressure-resistant. In particular, the outer wall of the lower housing can be pressure-resistant against the pyrotechnically triggered ignition of the pyrotechnic detonator for the separating element. The elasticity or plasticity of the lower housing side wall can be greater than the elasticity or plasticity of the lower housing outer wall. The hardness (e.g., Shore, Mohs, or Rockwell hardness) of the lower housing outer wall can be greater than the hardness of the lower housing side wall. The outer wall of the lower housing can be made of a plastic (polymer), a composite material, a metal, an alloy, or a ceramic. A composite material, for example, can contain at least one plastic (suitable for injection molding) and at least one filler, such as fibers like glass fibers or carbon fibers. For example, a power line disconnect device is described with a housing that surrounds a chamber, wherein the housing comprises a housing upper part and a housing lower part, and the housing lower part has at least one housing lower part side wall facing the chamber, which is connected to a housing lower part bottom facing the chamber, and the housing has a housing lower part outer wall that surrounds the housing lower part side wall and the housing lower part bottom, wherein the housing lower part side wall is designed to be elastically or plastically deformable at least in one section; - a receptacle for a power line, in particular a busbar, which is arranged between the housing upper part and the housing lower part;- optionally a power line, in particular a busbar, which is arranged in the receptacle for the busbar; - a movable separating element which is arranged within the upper part of the housing and is movable in the direction of the receptacle for the power line, in particular the busbar, (and / or in the direction of the power line, in particular the busbar,) and in the direction of the lower part of the housing; - an actuator for triggering a movement of the separating element; wherein the separating element is designed and arranged such that, after activation of the actuator, it impacts the power line and cuts it, and wherein, after cutting the power line, the separating element can be brought into contact with the elastically or plastically deformable section of the lower part of the housing.; Such a power line disconnect device can interrupt a current flow in less than 2 milliseconds in response to a signal, for example an electrical signal. At least one of the aforementioned power line disconnect devices can be installed in an electrically powered vehicle. Therefore, an (electrically powered) vehicle with at least one of the aforementioned power line disconnect devices is also described. Electrically powered vehicles can be, in particular, land vehicles, watercraft, or aircraft. Land vehicles include, for example, passenger cars, trucks, bicycles, or motorhomes. Watercraft include, for example, motorboats, and aircraft include, for example, airplanes. A vehicle component is also described that includes one of the aforementioned power line disconnect devices (and a conductor rail arranged in a receptacle of the power line disconnect device). The power line disconnect device can also be used in stationary installations, such as photovoltaic systems or energy storage units. Therefore, stationary installations, such as solar power systems or energy storage units, are also described as using one of the aforementioned power line disconnect devices. Furthermore, a method for cutting a power line, in particular a high-current line, using such a power line cutting device is described. For example, a method for cutting a busbar, in particular a high-current busbar, using such a power line cutting device is described. Furthermore, a method for manufacturing a (according to the invention) power line disconnecting device using a 3D printing process is described. Individual parts of the power line disconnecting device, e.g., the housing or housing parts and / or the disconnecting element, can also be manufactured using a 3D printing process. The invention is explained in more detail below with reference to exemplary embodiments and the figures. The figures show: Fig. 1A a current line disconnecting device before the current line is disconnected; Fig. 1B the current line disconnecting device from Fig. 1A after the current line is disconnected; Fig. 2 a current-voltage diagram. Fig. 1A shows a power line disconnector 1 before disconnecting a power line. The power line disconnector 1 comprises a movable disconnecting element 3 and an actuator 6 (e.g., a pyrotechnic detonator) for triggering movement of the movable disconnecting element 3. The power line disconnector 1 has a chamber 4 in which the disconnecting element 3 is arranged. The chamber 4 is surrounded by a housing 2. The housing 2 has an inner wall 24 facing chamber 4 and an outer wall 25 surrounding the inner wall 24. The housing 2 consists of a lower housing part 22 and an upper housing part 21. The lower housing part 22 is (detachably) connected to the upper housing part 21. The upper housing part 21 surrounds a chamber upper part 41, and the lower housing part 22 surrounds a chamber lower part 42, which are connected to each other such that the chamber upper part 41 and the chamber lower part 42 together form a chamber 4. The housing 2 has a base 23 and a top 26, with the outer wall 25 being connected to both the base 23 and the top 26, and the top 26 and the base 23 being opposite each other.The lower housing part 22 has a lower housing base 223 facing the chamber 4 and at least one lower housing side wall 221 facing the chamber, wherein the at least one lower housing side wall 221 is connected to the lower housing base 223. The housing base 22 also includes a housing base outer wall 222, which surrounds the housing base side wall 221 and the housing base bottom 223. The inner wall of the housing 24, in particular the lower housing side wall 221, has at least one deformable section 9. The (elastically or plastically) deformable section 9 has, for example, a lamellar or ribbed structure and / or is made of silicone. The deformable section 9 can project into the lower chamber part 42. The actuator 6 is arranged on the upper housing part 21, in particular on the housing cover 26. The separating element is arranged in the upper chamber part 41. The separating element 3 is detachably connected to the upper housing part 21 or the actuator 6 (so that the separating element 3 detaches from the upper housing part 21 or the actuator 6 when the actuator 6 is triggered, for example, during a pyrotechnic ignition of a pyrotechnic detonator). The housing 2 has a receptacle 7 for a power conductor 8 (here a busbar). A power conductor 8 can be inserted into the receptacle 7 provided for it. The receptacle for the power conductor 8 (and / or the power conductor 8) is located between the upper housing part 21 and the lower housing part 22 and between the upper chamber part 41 and the lower chamber part 42. The power conductor 8 can have at least one predetermined breaking point 81. The housing 2 has at least one gas opening 5. The gas opening 5 can be a gas outlet opening that extends through the housing lower side wall 221 and the housing lower outer wall 222 into the external environment of the housing 2. The gas opening 5 can extend through the deformable section 9. Fig. 1B shows the current-conductor disconnecting device 1 from Fig. 1A after the current conductor 8 has been cut. Activating the actuator 6 causes the disconnecting element 3 to move towards the current conductor 8, resulting in the disconnecting element 3 striking the current conductor 8. This impact of the disconnecting element 3 severs the current conductor 8, thus interrupting the current flow. At least one section 82 (e.g., a conductive coin, partially or completely) is removed from the current conductor 8. The disconnecting element 3 and / or the section 82 removed from the current conductor 8 are moved towards the lower housing part 22 and the base 23, and at least the section 82 removed from the current conductor 8 strikes the base 223 of the lower housing part. The separating element 3 and, optionally, the section cut out of the power line 8, come into contact with the deformable section 9 of the lower housing side wall 221. Thus, no (air) gap forms between the lower housing side wall 221 and the separating element 3, or between the lower housing side wall 221 and the cut-out section of the power line 82. This impact transfers the kinetic energy of the separating element 3 and, optionally, the section cut out of the power line 8, at least partially or completely, to the deformable section 9 of the lower housing side wall 221. This results in an elastic or plastic deformation of the deformable section 9 of the lower housing side wall 221. This prevents the separating element 3 and / or the section cut out of the power line 82 from rebounding towards the power line 8 and / or prevents an unwanted spark discharge (reignition). The movement of the separating element 3 and the section detached from the power line into the lower chamber 42 displaces the medium (e.g., air) located in the lower chamber 42. The gas openings 5 ​​thus provide a path for the gas or gas mixture (e.g., air) displaced in the lower chamber 42. Fig. 2 shows a current-voltage diagram from various disconnection tests, comparing a current-line disconnecting device according to the invention (Model 2, solid line) with a deformable lower housing side wall to a current-line disconnecting device that, after disconnection of the busbar, has a gap between the inner housing wall and the disconnecting element or between the inner housing wall and the disconnected part of the busbar (Model 1, dotted or dashed line). It can be seen that the current-line disconnecting device according to the invention shows no further current flow after disconnection of the busbar, i.e., no re-ignition, whereas the other current-line disconnecting device shows a current flow after approximately 3 milliseconds.The current conductor disconnecting device according to the invention (solid line) with a deformable lower housing side wall thus represents a safer current conductor disconnecting device that prevents re-ignition and completely interrupts the current flow after the busbar is cut in less than 1 millisecond. Reference symbol list 1 Power line disconnect device 2 Housing 21 Housing top 22 Housing bottom 221 Housing bottom side wall 222 Housing bottom outer wall 223 Housing bottom bottom 23 Housing bottom 24 Housing inner wall 25 Housing outer wall 26 Housing top 3 Separating element 4 Chamber 41 Chamber top 42 Chamber bottom 5 Gas opening 6 Actuator 7 Receptacle for power line 8 Power line 81 Power line break point 82 Cut-out section of power line 9 Deformable section

Claims

Power line disconnecting device (1), comprising: a housing (2) surrounding a chamber (4), wherein: the housing (2) has an inner wall (24) facing the chamber (4) and deformable at least in sections; and a movable disconnecting element (3) arranged on the housing (2) and / or within the chamber (4) for disconnecting a power line;- an actuator (6) arranged on the housing (2) and / or within the chamber (4) for triggering a movement of the separating element (3), wherein - the housing comprises a housing upper part (21) and a housing lower part (22), wherein the housing lower part (22) has a housing lower part bottom (223) facing the chamber (4) and at least one housing lower part side wall (221) facing the chamber (4), which forms a partial section of the housing inner wall (24), and wherein - the housing lower part (22) comprises a housing lower part outer wall (222) which surrounds the housing lower part side wall (221) and the housing lower part bottom (223), characterized in that the elasticity or plasticity of the housing lower part side wall (221) is greater than the elasticity or plasticity of the housing lower part outer wall (222). Power line disconnecting device (1) according to claim 1, characterized in that the lower side wall of the housing (221) is deformable at least in one section (9). Power line disconnecting device (1) according to claim 2, characterized in that the at least one deformable section (9) of the housing lower side wall (221) is an elastically or plastically deformable section (9). Power line disconnect device (1) according to one of the preceding claims, characterized in that the lower outer wall of the housing (222) is pressure-resistant against a pyrotechnically triggered ignition of a pyrotechnic igniter (6) for the disconnecting element (3). Power line disconnecting device (1) according to one of the preceding claims as far as referenced to claim 2, characterized in that the elastically or plastically deformable section (9) projects into the chamber (4) such that, after pyrotechnic ignition, it comes into contact with the disconnecting element (3) and / or a cut-out section (82) of the power line (8). Power line disconnecting device (1) according to one of the preceding claims as far as referenced to claim 2 , characterized in that the elastically or plastically deformable section (9) of the housing lower side wall (221) has a lamellar or rib structure. Power line disconnecting device (1) according to one of the preceding claims as far as referenced to claim 2 , characterized in that the elastically deformable section (9) of the housing lower side wall (221) consists of a silicone. Power line disconnecting device (1) according to one of the preceding claims as far as referenced to claim 2 , characterized in that the elastically or plastically deformable section (9) consists of an electrical insulator. Power line disconnecting device (1) according to one of the preceding claims as far as referenced to claim 2 , characterized in that the elastically or plastically deformable section (9) consists of a flame-retardant material (9). Power line disconnecting device (1) according to one of the preceding claims as far as referenced to claim 2 , characterized in that the elastically or plastically deformable section consists of a self-extinguishing material. Vehicle component comprising a power line disconnect device (1) according to one of the preceding claims and a power line (8) arranged in the power line disconnect device (1). Stationary device comprising a power line disconnecting device (1) according to one of claims 1 to 10 and a power line (8) arranged in the power line disconnecting device (1). Method for manufacturing a power line disconnect device (1) according to any one of claims 1 to 10 using a 3D printing method.

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