Contactor for high current connection and manufacturing method therefor

Abstract

The present invention relates to a contactor (2) for high current connection, comprising an elastic support member (6) made of a conductive and elastic alloy material such as beryllium copper, wherein the elastic support member (6) has an elastic connection piece matrix assembly (14) configured on the entire contact bottom side by means of matrix X-axis and Y-axis processing by arranging elastic connection pieces (10) in a matrix on the entire contact bottom side, the elastic connection pieces (10) being heat treated so as to have elastic durability and each being provided with an elastic leg part (10a) integrally extending from a base part (8) in an inclined direction or in the shape of 'ㄹ', and an elastic contact foot part (10b) on the front end of the elastic leg part (10a).

Description

Contactor for high current connection and manufacturing method thereof

[0001] The present invention relates to a high-current connection device, and more particularly, to an improvement of a contactor for high-current connection that can minimize contact resistance when used for high-current battery charge / discharge testing or when making selective electrical connection to a high-current connection point of hundreds to thousands of amperes.

[0002] Generally, when the electrical contact between a wire and a switch, a wire and a terminal, or a terminal and an electrode is imperfect, the contact resistance of the connection increases, causing heat generation in this area. Typically, the heat generation pattern is determined by the increase in contact resistance and the magnitude of the load current. The greater the load current and the greater the contact resistance, the higher the heat generation temperature.

[0003] To improve the quality reliability of high-capacity batteries used in electric vehicles, a 100% battery inspection system is being introduced, in addition to simple battery sampling. This system conducts charge / discharge optimization tests on all batteries produced, as well as voltage and current tests. Electric vehicle batteries are manufactured in a variety of sizes and materials, and during testing, the current applied to the batteries by the testing equipment can be as high as 300-500 A, with peak currents reaching 1,800 A. Therefore, unstable or inconsistent electrical contact at contact points during testing can compromise the reliability of battery testing.

[0004] For example, there are cases where a charge / discharge test is continuously and repeatedly performed on a high-capacity battery pack using a secondary battery charge / discharge test device. When a load current of hundreds to thousands of amperes [A] flows due to battery charging / discharging using the secondary battery charge / discharge test device, if an imperfect electrical contact condition occurs at the contact point during the test, the increase in contact resistance and the resulting heat generation deteriorate the battery, acting as a variable that makes the measured value results for the battery pack unreliable.

[0005] If there is an imperfect electrical contact, the heat generation temperature will be low in the early stages of heat generation and will not cause any problems. However, as time passes, the heat generation temperature will increase rapidly due to factors such as increased load current and insufficient heat dissipation conditions. This increase in heat generation temperature will cause the contact resistance to increase further, and the increased heat generation due to the increased contact resistance will have a significant negative impact on the mechanical durability of the electrical connector.

[0006] Therefore, in implementing a contactor for high-current connection, a contactor for high-current connection with a structure that can minimize contact resistance when used for high-current battery charge / discharge testing or when making a switchable electrical connection to a connection point of high current of hundreds to thousands of amperes is required.

[0007] Accordingly, the purpose of the present invention is to provide a contactor for high-current connection and a method for manufacturing the same, which can minimize contact resistance when used for high-current battery charge / discharge testing or when making selective electrical connections to a connection point of high current of hundreds to thousands of amperes.

[0008] The present invention for the above purpose is characterized in that, in a contactor for high-current connection, the elastic support member is composed of an elastic support member made of an alloy material having conductivity and elasticity, and the elastic support member has elastic leg portions extending integrally in an inclined direction from a base portion through X-axis and Y-axis processing on the entire contact bottom side and elastic contact foot portions at the ends of the elastic leg portions, and elastic connecting pieces heat-treated to have elastic durability are arranged in a matrix on the entire contact bottom side to form an elastic connecting piece matrix assembly.

[0009] In the high-current connection contactor of the present invention, the elastic connection piece matrix assembly can be configured with left and right elastic connection piece matrix sections arranged so that the inclination directions of the elastic leg sections of the elastic connection pieces are symmetrical to each other on the left and right sides of the left and right center lines.

[0010] Additionally, the elastic connector matrix set can be configured so that all elastic legs of the elastic connectors face in one direction of inclination.

[0011] In another aspect of the present invention, a contactor for high-current connection is characterized in that it comprises an elastic support member made of an alloy material having conductivity and elasticity, wherein the elastic support member has an elastic leg portion in the shape of an "ㄹ" that is integrally extended from a base portion by X-axis and Y-axis processing on the entire contact bottom side, and an elastic contact foot portion at the tip of the elastic leg portion, and elastic connecting pieces heat-treated to have elastic durability are arranged in a matrix on the entire contact bottom side to form an elastic connecting piece matrix assembly.

[0012] In another aspect of the present invention, a contactor for high-current connection is characterized in that it comprises an elastic support member made of an alloy material having conductivity and elasticity, wherein the elastic support member is formed by forming a matrix-shaped standing support member integrally standing up from a base by X-axis and Y-axis processing to prepare elastic connecting pieces arranged in a matrix on the entire contact bottom side, and each of the standing support pieces is obtained by bending it obliquely, and has an elastic leg portion and an elastic contact foot portion at the tip of the elastic leg portion, and the elastic connecting pieces heat-treated to have elastic durability are arranged in a matrix on the entire contact bottom side to form an elastic connecting piece matrix assembly.

[0013] In addition, the present invention is characterized in that the elastic contact portions of the elastic connecting pieces are configured to form a flat processing surface of the same level through flatness custom processing.

[0014] In addition, the elastic connecting piece assembly of the elastic support member is plated with an electrical contact material, and an electrical contact plating layer is further formed on the elastic contact portion of the elastic connecting piece.

[0015] In addition, the present invention is characterized in that a stopper dam portion is further provided on a part of the contact bottom side of the elastic support member to limit the elastic depth of the elastic connection piece matrix assembly.

[0016] In addition, as another aspect of the present invention, a method for manufacturing a contactor for high-current connection is characterized by comprising the steps of: obtaining a base material of a contactor with an elastic support member made of an alloy material having conductivity and elasticity; obtaining an elastic connection piece matrix assembly in which elastic connection pieces are formed by processing the entire contact bottom side of the elastic support member of the contactor base material along the X and Y axes to have elastic leg portions extending integrally in an oblique direction from the base and elastic contact foot portions at the tips of the elastic leg portions, and arranging them in a matrix on the entire contact bottom side; and performing an aging treatment as a heat treatment to increase elastic durability, fatigue resistance, and conductivity of the elastic connection piece matrix assembly constituting the elastic support member.

[0017] In addition, as another aspect of the present invention, a method for manufacturing a contactor for high-current connection is characterized by comprising the steps of: obtaining a base material of a contactor with an elastic support member made of an alloy material having conductivity and elasticity; forming a matrix-shaped standing support member integrally extended from a base by machining the elastic support member of the base material along the X-axis and Y-axis in a matrix to prepare elastic connecting pieces arranged in a matrix on the entire contact bottom side; obtaining an elastic connecting piece matrix assembly in which elastic connecting pieces are formed to have elastic leg portions and elastic contact foot portions at the tips of the elastic leg portions by bending each of the above-mentioned standing support pieces at an angle and are arranged in a matrix on the entire contact bottom side; and performing an aging treatment as a heat treatment to increase elastic durability, fatigue resistance, and conductivity of the matrix assembly of elastic connecting pieces constituting the elastic supporting member.

[0018] The present invention has the advantage of minimizing contact resistance when used for high-current battery charging / discharging tests or when making selective electrical connections to high-current connection points of hundreds to thousands of amperes by improving the structure of a contactor for high-current connection.

[0019] Figure 1 is a perspective view of a contactor for high-current connection according to an embodiment of the present invention;

[0020] Figure 2 is a front view of Figure 1;

[0021] Figure 3 is a side view of Figure 1;

[0022] Figure 4 is a plan view of Figure 1;

[0023] FIG. 5 is a perspective view of a battery endurance test device as an example of a high-current battery charge / discharge test device employing a high-current connection contactor according to an embodiment of the present invention.

[0024] Fig. 6 is an exploded perspective view of the clamp jig portion of Fig. 5 equipped with a contactor for high-current connection of the present invention.

[0025] Figure 7 is an operating state diagram of a high-current connection contactor of the present invention employed in the battery endurance test device of Figure 5.

[0026] Figures 8 to 11 are front and enlarged configuration views of a contactor for high-current connection according to other embodiments of the present invention.

[0027] Figure 12 is an exemplary diagram of a manufacturing process for a contactor for high-current connection according to another embodiment of the present invention.

[0028] Fig. 13 is a schematic diagram of a magnetic contactor (MC) employing a contactor for high-current connection according to another embodiment of the present invention.

[0029] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings.

[0030] When selectively connecting to a high-current connection point of hundreds to thousands of amperes, the contact surfaces on both sides (e.g., the switch terminals of an electrical connector such as a no-fuse breaker (NFB)) or the contact surfaces of the electrode terminals of the battery pack under test and the contact surfaces of the high-current connection contactor of the charge / discharge test device are not perfectly flat.

[0031] A close examination of the contact surface of the switching element reveals a subtle unevenness. Therefore, the actual contact area between the two conductors is much smaller than the apparent contact area and is formed locally.

[0032] Therefore, when current flows through the contact interface between two conductors, the actual contact area through which the current can pass is much smaller than the apparent contact area, and the current flows concentrated only at the actual contact point.

[0033] In this relationship, a large current flows through a limited actual contact point between the terminal surface of a connection point for a large current of hundreds to thousands of amperes and the contact interface between the contactor for a large current connection, or between the electrode terminal surface of a battery pack and the contact interface of a probe for a large current connection, so contact resistance occurs and the contact resistance causes heat generation.

[0034] The following mathematical expression 1 shows the relationship between the applied current (i) and the heat generated by the contact resistance (R), i.e., the contact heat (Q).

[0035]

[0036] Q: Contact heat [W], i: Applied current, R: Contact resistance

[0037] Contact resistance (R) is an electrical resistance resulting from the contact force, contact type, and the characteristics of the contact surface. It is determined by the constriction resistance of the actual contact area (effective contact area), regardless of the apparent contact area. Therefore, contact resistance (R) is also known as constriction resistance. Contact resistance (R) is inversely proportional to the actual contact area (effective contact area) between the contact interfaces.

[0038] Since the increase in heat generation due to contact resistance during contact between contact surfaces makes the measurement results for test objects such as battery packs unreliable, it is desirable to minimize the contact resistance value when making selective electrical connections to connection points with high currents of hundreds to thousands of amperes.

[0039] If the contact resistance value (R) of the contact surface of the high-current connection contactor that comes into contact with the terminal of the high-current connection point can be reduced, the contact heat amount (Q) generated in the high-current connection contactor can also be reduced as in mathematical expression 1, and reliable measurement results or reliable performance values ​​of the high-current connection contactor can be obtained.

[0040] In addition, the contact resistance (R) differs by several to ten times depending on the contact form of the contactor for connection. In the present invention, the contact resistance (R) is minimized in implementing a contactor for high-current connection, and the variation in the contact resistance value depending on the contact form is minimized.

[0041] In the present invention, in constructing a contactor for high current connection, first, a large number of real contact conducting spots are formed in a matrix structure on the contact bottom side of the contactor forming a contact interface, so that a large current can flow in a parallel path distributed through a large number of real contact conducting spots arranged in a matrix, thereby minimizing contact resistance, and the large number of real contact conducting spots are constructed to form a matrix cluster.

[0042] Secondly, the contact bottom side of the contactor forming the contact interface is designed to have a reliable spring tension to ensure low contact resistance, and each of the numerous actual contact conductive spots is configured to have an independent spring force.

[0043] Fig. 1 is a perspective view of a contactor (2) for high-current connection according to an embodiment of the present invention, Fig. 2 is a front view of Fig. 1, and Fig. 3 is a side view of Fig. 1. And, Fig. 4 is a plan view of Fig. 1.

[0044] It should be understood that the high-current connection contactor (2) of the present invention illustrated in FIG. 1 is an example form that can be employed in a high-current battery charge / discharge test device such as the example of FIG. 5, and can be manufactured in a contactor shape suitable for electrical connection to a high-current connection point.

[0045] The contactor (2) for high current connection of the present invention is composed of a base member (4) made of copper having excellent electrical conductivity and an elastic support member (spring support member) (6) made of a beryllium copper [BeCu] alloy material having conductivity and elasticity as a base metal welded to one side of the base member (4).

[0046] The elastic support member (6) of the contactor (2) for high-current connection of the present invention is the contact bottom side of the contactor forming the contact interface, so it must be able to form a reliable spring tension contact and must also be made of a material with excellent electrical conductivity.

[0047] The beryllium copper alloy employed in the elastic support member (6) of the contactor (2) for high-current connection according to the present invention is a copper alloy having good electrical conductivity, good mechanical spring properties, and good workability. That is, the beryllium copper (BeCu) employed as the material of the elastic support member (6) of the present invention has excellent properties similar to those of a mixture of the high conductivity of copper and the high strength of steel, and is therefore optimal as a metal for the contact bottom side of the contactor.

[0048] In the present invention, the elastic support member (6) is selected and used from among beryllium copper alloys, which have good electrical conductivity, excellent spring properties, and a high stress relaxation resistance even at high temperatures.

[0049] The elastic support member (6) in the present invention is most preferably made of a beryllium copper alloy material, and if necessary, may include a chromium copper alloy, a tungsten copper alloy, a nickel copper alloy material, and other equivalents that are conductive and elastic.

[0050] First, in the present invention, as an initial step for manufacturing a contactor (2) for high-current connection, a contactor base material is obtained by welding an elastic support member (6) made of beryllium copper to a copper base material member (4).

[0051] Using the contact base material obtained in this way, it is possible to manufacture various contact shapes (test probes or contact pads) suitable for the characteristics of the connection point, and in the case of Fig. 1, it can be manufactured in a form in which a flat square body exists at the head of a cylindrical rod, for example, so that it can be used as a high-current connection contact (2) of a high-current battery charging / discharging test device.

[0052] After obtaining the contact base material in this way, in the present invention, the contact bottom side of the beryllium copper (BeCu) material elastic support member (6) located at the leading side of the contact base material is cut and heat-treated in a matrix shape to form an elastic contact matrix assembly (14) such as the example of Fig. 1, which minimizes contact resistance even at high currents of hundreds to thousands of amperes.

[0053] That is, the elastic contact matrix assembly (14) of the present invention forms a matrix cluster of actual contact conductive spots that allows a large current to flow simultaneously in a parallel path form at the contact interface, and at the same time, each actual contact conductive spot of the matrix cluster of actual contact conductive spots has a reliable spring tension, thereby minimizing contact resistance.

[0054] To explain more specifically, the elastic connector matrix assembly (14) of the contactor (2) for high-current connection of the present invention is formed by machining the entire contact bottom side of the elastic support member (6) made of beryllium copper (BeCu) in a matrix shape, as shown in FIGS. 2 and 3, and has elastic leg portions (10a) integrally extended from the base (8) of the elastic support member (6) made of beryllium copper and elastic contact foot portions (10b) at the tips of the elastic leg portions (10a), and the elastic connector matrix assembly (14) is formed in a matrix arrangement as in FIG. 4. Each elastic connector (10) arranged in a matrix in the elastic connector matrix assembly (14) has a spring tension and corresponds to an actual contact conductive spot of a group of actual contact conductive spots that are distributed in a high current and form each parallel path.

[0055] It is preferable to obtain the design configuration of an elastic connection matrix assembly (14) having a matrix structure of numerous elastic connection pieces (10) such as the examples shown in FIGS. 1 to 4 by using an X-axis and Y-axis cutting processing method during matrix X-axis and Y-axis processing.

[0056] Among the matrix X-axis and Y-axis cutting processing methods according to the present invention, the wire cutting method using a wire is preferable. The wire cutting method may include the wire cutting electric discharge machining method and the diamond wire cutting processing method, and in a specific embodiment of the present invention, the wire cutting electric discharge machining method is more preferable.

[0057] The wire cutting electrical discharge machining method is a machining method that uses sparks generated by generating an electric discharge between a moving wire electrode and the contact bottom of an elastic support member (6) like a saw blade to cut a workpiece. Since a thin conductor of 0.05 to 0.3 mm is used, much more precise work is possible than with a laser or hydraulic pressure. In addition, an elastic connecting piece (10) with a matrix arrangement structure can be processed into a desired precise dimension and shape through numerical control (NC).

[0058] The diamond wire cutting processing method is a processing method that uses a diamond wire cutting machine that uses a diamond loop wire coated with diamond powder to cut the workpiece with ultra-precision.

[0059] Referring again to FIG. 2, the entire contact bottom side of the elastic support member (6) in the contactor base material is subjected to X-axis (row) and Y-axis (column) cutting processing, preferably X-axis (row) and Y-axis (column) cutting processing by wire cutting discharge machining, using numerical control, so that an elastic leg portion (10a) extending integrally in the oblique direction from the base portion (8) and an elastic contact foot portion (10b) are provided at the tip of the elastic leg portion (10a), thereby forming elastic connecting pieces (10) of the elastic connecting piece matrix assembly (14).

[0060] As shown in Fig. 2, in order to increase the actual contact area (effective contact area) of the contactor (2) for high-current connection, the left-right width (based on Fig. 2) of the elastic contact portion (10b) can be processed and formed to be larger than the left-right width (based on Fig. 2) of the elastic leg portion (10a) that acts as a spring, and as a result, as shown in Fig. 2, residual pins that are excluded from the wire cutting discharge machining may remain between the elastic leg portions (10a).

[0061] In constructing an elastic connecting piece matrix assembly (14) prepared by cutting the matrix X-axis (row) and Y-axis (column) according to the present invention, it can be constructed with left and right elastic connecting piece matrix sections arranged so that the inclination directions of the elastic leg sections (10a) of the elastic connecting pieces (10) are symmetrical to each other on the left and right sides of the left and right center lines, as in the example of FIG. 1 or the example of FIG. 9.

[0062] In one example of Fig. 1, the left and right center lines become the axis of symmetry, and the elastic leg parts (10a) of the elastic connecting pieces (10) on the left and right are inclined in a form in which they face each other and greet each other, and in another example of Fig. 9, the left and right center lines become the axis of symmetry, and the elastic leg parts (10a) of the elastic connecting pieces (10) on the left and right are inclined in a form in which they turn their backs to each other and greet each other in the opposite form.

[0063] In addition, in forming an elastic connecting piece matrix assembly (14) prepared by X-axis (row) and Y-axis (column) cutting processing according to embodiments of the present invention, as in another example of FIG. 8, the elastic leg portions (10a) of the elastic connecting pieces (10) may all be formed to be inclined to one side.

[0064] In addition, in forming an elastic connecting piece matrix assembly (14) prepared by X-axis (row) and Y-axis (column) cutting processing according to embodiments of the present invention, the elastic connecting piece (10) may be formed not as a simple inclined shape but as a complex bending shape as in another example of FIG. 10 or FIG. 11.

[0065] That is, as in another example shown in FIGS. 10 and 11, the elastic support member (6) has an elastic leg portion (10a) in the shape of an “ㄹ” that is integrally extended from the base portion (8) by X-axis and Y-axis cutting processing on the entire contact bottom side, and an elastic contact foot portion (10b) at the tip of the elastic leg portion (10a), and elastic connecting pieces (10) that are heat-treated to have elastic durability are arranged in a matrix on the entire contact bottom side to form an elastic connecting piece matrix assembly (14).

[0066] Fig. 10 shows a structure in which an “ㄹ” shaped elastic leg part (10a) is formed in one stage, and Fig. 11 shows a structure in which an “ㄹ” shaped elastic leg part (10a) is formed in two stages.

[0067] On the other hand, the elastic connection piece matrix assembly (14) of the high-current connection contactor (2) of the present invention can be shaped by using cutting processing such as X-axis and Y-axis wire cutting processing, but can also be implemented by precision wheel cutting and bending processing as another modified example as in Fig. 12.

[0068] Fig. 12 is an example of another embodiment for constructing an elastic connection matrix assembly (14) of the present invention, implemented using wheel cutting and bending processing methods.

[0069] Referring to Fig. 12, in order to prepare elastic connecting pieces (10) arranged in a matrix on the entire contact bottom side of the elastic support member (6) of the contact base material, a number of cutting grooves (31) are prepared on the base (8) along at least one of the matrix X-axis and Y-axis by wheel cutting, as shown in Fig. 12 (a). At this time, a stopper dam (16) is also prepared in advance to limit the elastic depth of the elastic connecting piece matrix assembly (14).

[0070] By doing so, the standing support pieces (30) in the form of a matrix extending from the base (8) are left with the cutting groove (31) provided on the base (8) in between.

[0071] Next, as shown in (b) of Fig. 12, a steel core (32), etc. is inserted into the cutting groove (31), and as shown in (c) of Fig. 12, the standing support pieces (30) arranged in a matrix structure are bent obliquely to form elastic connecting pieces (10) having elastic leg parts (10a) and elastic contact points (10b) at the ends of the elastic leg parts (10a). Thus, the elastic connecting pieces (10) prepared in this manner are arranged in a matrix on the entire bottom side of the elastic support member (6), thereby implementing the elastic connecting piece matrix assembly (14) of the present invention, and the elastic connecting piece matrix assembly (14) is also provided with a stopper dam part (16) on one side to limit the elastic depth of the elastic connecting piece matrix assembly (14).

[0072] In preparing the elastic connection matrix assembly (14) of the present invention described above, it is preferable to prepare it by an X-axis and Y-axis cutting processing method such as wire cutting discharge processing, and if necessary, it can also be prepared by a precision wheel cutting processing and bending processing method such as the example of FIG. 12.

[0073] In addition, when forming the elastic connection matrix assembly (14) of the high-current connection contactor (2) of the present invention by cutting, as shown in FIG. 2, it is preferable to further provide a stopper dam (16) on a part of the contact bottom side of the elastic support member (6) to limit the elastic depth of the elastic connection pieces (10) of the elastic connection piece matrix assembly (14), and it is more preferable to form it on the deep side of the contact bottom side.

[0074] Although FIGS. 8 to 11 do not show a state in which a stopper dam (16) as in FIG. 2 is provided, it is preferable that a stopper dam (16) as in FIG. 2 be provided on the deep side of the contact bottom side of the elastic support member (6).

[0075] After the elastic connecting pieces (10) constituting the elastic connecting piece matrix assembly (14) of the present invention are prepared by cutting, the upper surface of each elastic contact portion (10b) of the elastic connecting pieces (10) constituting the elastic connecting piece matrix assembly (14) is subjected to flatness custom processing using wire cutting, electrical discharge machining, or the like, so that a flat processing surface of the same level is formed on the elastic contact portion (10b) of the elastic connecting pieces (10).

[0076] The flat processing surface of the same level formed on all elastic contact points (10b) of the elastic connector matrix assembly (14) increases the effective contact area, which allows a perfect plane to be approached and reduces contact resistance. In other words, it maximizes the elastic connector (10) of the elastic connector matrix assembly (14) to become an actual contact conductive spot of the actual contact conductive spot matrix group.

[0077] In the present invention, after forming an elastic connecting piece matrix assembly (14) on an elastic support member (6) by cutting processing as described above, the elastic support member (6) including the elastic connecting piece matrix assembly (14) is heat-treated to restore the elastic durability of the elastic connecting piece (10) damaged by heat generated during cutting processing, improve fatigue resistance, and increase conductivity.

[0078] The heat treatment method according to the present invention is age hardening treatment.

[0079] Age hardening is performed as a heat treatment for the elastic connector matrix assembly (14) made of beryllium copper, and is performed below the solution annealing temperature. During the age hardening process, hard, fine beryllium-rich particles are created and distributed within the beryllium copper structure, which plays a role in increasing the strength due to the heat treatment.

[0080] By performing heat treatment such as age hardening treatment on the elastic connecting piece matrix assembly (14) of the elastic support member (6), the elastic connecting pieces (10) of the elastic connecting piece matrix assembly (14) of the high-current connecting contactor (2) of the present invention are provided with complete mechanical spring properties. That is, the elastic connecting pieces (10) of the elastic connecting piece matrix assembly (14) of the high-current connecting contactor (2) of the present invention have elastic durability and fatigue resistance, and thus have reliable spring tension, and also have increased conductivity.

[0081] In addition, in the present invention, after performing heat treatment such as age hardening treatment, the elastic connecting piece assembly (14) of the age-hardened elastic support member (6) is plated with a material for electrical contact, thereby forming an electrical contact plating layer (12) on the elastic connecting pieces (10) as shown in FIGS. 2, 8 to 11.

[0082] In Fig. 12, although not shown, flat surface processing and heat treatment are performed, and a plating layer (12) for electrical contact is also formed [Fig. 12 (d)].

[0083] It is preferable to use a material with good conductivity and durability for the electrical contact plating layer (12) formed on the elastic connecting piece (10), and hard gold plating or hard silver plating is also included here.

[0084] As described above, the elastic connecting piece matrix assembly (14) of the high-current connecting contactor (2) of the present invention is cut so as to have elastic connecting pieces (10) that extend integrally from the base (8) of the elastic support member (6) made of beryllium copper, and is then cut so as to be arranged in a matrix in the range of tens to hundreds, and then heat-treated, so that the actual contact area (effective contact area) of the elastic connecting piece matrix assembly (14) is increased as close as possible to the entire bottom surface of the elastic support member (6) by the numerous elastic connecting pieces (10) arranged in a matrix. In other words, numerous actual contact conductive spots are formed by the elastic connecting pieces (10) arranged in a matrix on the contact bottom side of the high-current connecting contactor (2) that forms the contact interface.

[0085] As a result, in the high-current connection contactor (2) of the present invention, the high current flows in a distributed manner through the actual contact conductive spots of numerous elastic connecting pieces (10) arranged in a matrix, and since each elastic connecting piece (10) forms a reliable spring tension, the contact resistance at the contact interface is minimized.

[0086] The inventor of the present invention confirmed that the above contact resistance is minimized to approximately 1 / 10 of the contact resistance when the high-current connection contactor (2) of the present invention is not used.

[0087] FIGS. 5 to 7 show examples of applying the high-current connection contactor (2) of the present invention illustrated in FIGS. 1 to 4 to a high-current battery charge / discharge test device.

[0088] Fig. 5 is a perspective view of a battery endurance test device (100) as an example of a high-current battery charge / discharge test device employing the high-current connection contactor (2) of Fig. 1 according to an embodiment of the present invention, and Fig. 6 is an exploded perspective view of a clamp jig portion of Fig. 5 equipped with the high-current connection contactor (2) of the present invention. In addition, Fig. 7 is an operating state diagram of the high-current connection contactor (2) of the present invention employed in the battery endurance test device (100) of Fig. 5.

[0089] The contactor (2) for high current connection employed in the battery durability test device (100) is mainly called a probe, is connected to a high current power supply line (26), and is installed in a clamp jig (20) and is raised and lowered by the tester's operation of a knob (24).

[0090] After the battery pack (22) is placed in the battery endurance test device (100) as an example in Fig. 5, when the high-current connection contactor (2) of the present invention is lowered from the state (a) of Fig. 7 to the state (b) of Fig. 7 using the clamp jig (20) equipped with the high-current connection contactor (2), the elastic connection piece matrix assembly (14) of the contactor (2) is brought into elastic contact with the electrode terminal (22a) of the battery pack (22). Even if the high-current connection contactor (2) is lowered more excessively, the elastic connection pieces (10) arranged in a matrix in the elastic connection piece matrix assembly (14) are protected without losing elasticity by the stopper dam (16) formed in the deep part of the elastic support member (6).

[0091] In the present invention, since a matrix cluster of actual contact conductive spots is formed by the structure of the elastic contact member matrix assembly (14) of the high-current connection contact member (2), the actual contact area (effective contact area) with the electrode terminal (22a) of the battery pack (22) is maximized by numerous actual contact conductive spots. In addition, since the actual contact conductive spot by each elastic contact member (10) has a reliable spring tension, the contact resistance at the contact interface is minimized according to the present invention.

[0092] In addition, in the present invention, adaptive response is achieved due to the characteristic of forming a matrix cluster of actual contact conductive spots having reliable spring tension even when the contact form of the high-current connection contactor (2) changes due to environmental factors such as the weight of the power supply line (26) or the inability to precisely straighten the high-current connection contactor (2), so that the range of variation in the contact resistance value is not very large.

[0093] FIG. 13 shows a schematic configuration of an electromagnetic contactor (MC: Magnetic Contactor) (200) employing a contactor (2) for high-current connection according to another embodiment of the present invention illustrated in FIG. 12, and is an example in which the contactor (2) for high-current connection is applied to a moving tip (48).

[0094] The electronic contactor (200) illustrated in Fig. 13 is provided with a movable tip (48) and a fixed tip (50) as opening and closing contacts for opening and closing a line through which a large current flows, and a contactor (2) for connecting a large current of the same type as in Fig. 12 according to another embodiment of the present invention is installed on the movable tip (48).

[0095] The electronic contactor (200) of Fig. 13 is mainly used when remotely controlling a high-power load power source, and when power is applied to a coil (40) wound with an iron core, current flows in the coil (40), and the fixed core (42) mounted together with the coil (40) becomes an electromagnet and pulls the moving core (46) of the upper armature (44). Then, the movable tip (48) composed of the high-current connection contactor (2) of the present invention comes into contact with the fixed tip (50) at the bottom, and current is transmitted through which a high current flows, and a load such as a motor connected to the circuit is operated by the current.

[0096] According to the present invention, since a matrix cluster of actual contact conductive spots is formed by the structure of the elastic connection piece matrix assembly (14) of the high-current connection contactor (2) provided on the movable tip (48), the actual contact area (effective contact area) with the fixed tip (50) is maximized by the numerous actual contact conductive spots of the elastic connection pieces (10) of the matrix structure. In addition, since the actual contact conductive spot by each elastic connection piece (10) has a reliable spring tension, the contact resistance at the contact interface between the movable tip (48) and the fixed tip (50) is minimized.

[0097] When the power is turned off by remote control or the like while the movable tip (48) and the fixed tip (50) are in contact and are energized, the magnetism of the electromagnet formed in the fixed core (42) disappears and the armature (44) moves backward by the force of the spring (54) installed in the case (52), causing the contact point between the fixed tip (50) and the movable tip (48) to separate. Then, the line of the electromagnetic contactor (200) is cut off, so that no large current flows to the load.

[0098] As an example of the present invention that employs a contactor (2) for high current connection that allows selective electrical connection to a connection point of high current of hundreds to thousands of amperes, there is an electromagnetic contactor (MC) as shown in FIG. 13, and it should be understood that it can also be applied to a molded circuit breaker (NFB), a vacuum circuit breaker (VCB), a power circuit breaker, a switch, a transformer, etc., or other equivalents.

[0099] In the description of the best embodiment of the present invention described above, a specific embodiment in which both the matrix X-axis and the Y-axis are cut when forming the elastic connecting piece matrix assembly (14) has been described, but either the matrix X-axis or the Y-axis may be formed by extrusion molding, and various modifications may be made without departing from the scope of the present invention, such as forming a basic shape through a first extrusion process or other molding process and then forming it through a second detailed cutting process. Therefore, the scope of the present invention should not be defined by the described embodiment, but should be defined by the claims and equivalents of the claims.

[0100] The present invention can be used to minimize contact resistance during selective electrical connection in electrical contact devices such as a no fuse breaker (NFB) used for high-current battery charge / discharge testing or for cutting off current in abnormal conditions such as overload and short circuit.

Claims

1. In a contactor for high current connection, It is composed of an elastic support member made of an alloy material that is conductive and elastic, The above elastic support member is characterized in that the entire contact bottom side has an elastic leg portion extending in an inclined direction from the base through matrix X-axis and Y-axis processing, and an elastic contact foot portion at the tip of the elastic leg portion, and the elastic connecting pieces heat-treated to have elastic durability are arranged in a matrix over the entire contact bottom side to form an elastic connecting piece matrix assembly.

2. A contactor for high-current connection, characterized in that in the first paragraph, the elastic connection piece matrix assembly comprises left and right elastic connection piece matrix sections arranged so that the inclination directions of the elastic leg sections of the elastic connection pieces are symmetrical to each other on the left and right sides of the left and right center lines.

3. A contactor for high-current connection, characterized in that in the first paragraph, the elastic connection piece matrix assembly is configured such that all elastic leg parts of the elastic connection pieces face in one inclined direction.

4. In contactors for high current connection, It is composed of an elastic support member made of an alloy material that is conductive and elastic, The above elastic support member is a contactor for high-current connection characterized in that the entire contact bottom side has an elastic leg part in the shape of an “ㄹ” that is integrally extended from the base by matrix X-axis and Y-axis processing, and an elastic contact foot part at the tip of the elastic leg part, and elastic connecting pieces that are heat-treated to have elastic durability are arranged in a matrix over the entire contact bottom side to form an elastic connecting piece matrix assembly.

5. In a contactor for high current connection, It is composed of an elastic support member made of an alloy material that is conductive and elastic, The above elastic support member is characterized in that the entire contact bottom side is formed of a matrix-shaped standing support member that is integrally extended from the base by machining the X-axis and Y-axis in a matrix to prepare elastic connecting pieces arranged in a matrix, and each of the standing support pieces is obtained by bending them obliquely, and has an elastic leg portion and an elastic contact foot portion at the tip of the elastic leg portion, and the elastic connecting pieces that are heat-treated to have elastic durability are arranged in a matrix on the entire contact bottom side to form an elastic connecting piece matrix assembly.

6. A high-current connection contactor characterized in that the elastic contact portions of the elastic connection pieces are configured to form a flat surface of the same level through flatness custom processing in any one of the first, fourth and fifth clauses.

7. A high-current connection contactor characterized in that, in any one of paragraphs 1, 4, and 5, an electrical contact plating layer formed by plating with an electrical contact material is formed on an elastic contact portion of an elastic contact member of an elastic contact member matrix of an elastic support member.

8. A contactor for high-current connection, characterized in that a stopper dam portion for limiting the elastic depth of the elastic connection piece matrix assembly is further provided on a part of the contact bottom side of the elastic support member in any one of paragraphs 1, 4, and 5.

9. A contactor for high-current connection, characterized in that the X-axis and Y-axis processing in the first or fourth paragraph is one of wire-cutting discharge processing and diamond wire-cutting processing.

10. In a method for manufacturing a contactor for high current connection, A process for obtaining a contact base material using an elastic support member made of an alloy material that is conductive and elastic, A process for obtaining an elastic connecting piece matrix assembly in which the entire contact bottom side of the elastic support member of the contactor base material is processed in a matrix along the X and Y axes, and elastic connecting pieces are formed to have elastic leg parts extending integrally in the inclined direction from the base and elastic contact points at the ends of the elastic leg parts, and are arranged in a matrix on the entire contact bottom side. A method for manufacturing a contactor for high-current connection, characterized by comprising a process of performing age hardening treatment as a heat treatment to increase the elastic durability, fatigue resistance and conductivity of an elastic connecting piece matrix assembly constituting an elastic support member.

11. In a method for manufacturing a contactor for high current connection, A process for obtaining a contact base material using an elastic support member made of an alloy material that is conductive and elastic, A process of forming a matrix-shaped standing support member integrally extended from the base by machining the X-axis and Y-axis of the matrix to prepare elastic connecting pieces arranged in a matrix on the entire contact bottom side of the elastic support member of the contactor base material, A process for obtaining an elastic connecting piece matrix assembly in which elastic connecting pieces are formed by bending each of the above-mentioned standing support pieces at an angle and having elastic contact points at the ends of the elastic connecting pieces, and are arranged in a matrix on the entire contact bottom side; A method for manufacturing a contactor for high-current connection, characterized in that it comprises a process of performing age hardening treatment as a heat treatment to increase the elastic durability, fatigue resistance and conductivity of an elastic connecting piece matrix assembly constituting an elastic support member.

12. A method for manufacturing a contactor for high-current connection, characterized in that in the process of obtaining an elastic connection piece matrix assembly in the 10th or 11th clause, the method further comprises a process of forming a flat processing surface of the same level in the elastic connection piece matrix assembly by performing a flat processing on the elastic contact points of the elastic connection pieces.

13. A method for manufacturing a contactor for high-current connection, characterized in that the method further comprises a step of forming an electrical contact plating layer on the elastic contact pieces by plating an assembly of elastic contact pieces of an elastic support member that has been subjected to age-hardening treatment with an electrical contact material in accordance with claim 10 or 11.

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