Temperature sensor for high voltage conductor and method of manufacturing temperature sensor

Abstract

The invention relates to a temperature sensor for a high voltage conductor. The temperature sensor includes a sensor housing for forming a chamber, the sensor housing having a substrate with a measurement window for attachment to a high voltage conductor and a cover for covering the chamber. The temperature sensor comprises a temperature sensor element for measuring the temperature of the high voltage conductor and for outputting an electrical temperature signal to the low voltage network, the temperature sensor element being arranged in the chamber. The temperature sensor includes a preformed elastomeric pad surrounded in the chamber between the substrate and the cover, the elastomeric pad having an insulating portion extending around the measurement window to electrically insulate the temperature sensor from the high voltage conductor, the elastomeric pad further including a heat exchange portion surrounded by the insulating portion, the heat exchange portion extends through the measurement window in a heat transfer direction to the high voltage conductor to conduct thermal energy in the heat transfer direction between the high voltage conductor and the temperature sensor element adjacent to the heat exchange portion.

Description

Technical Field

[0001] The present invention relates to a temperature sensor for high-voltage conductors and a method for manufacturing such a temperature sensor. Background Art

[0002] High-voltage conductors are used in high-voltage applications. High-voltage applications refer to the use of voltages in the high-voltage range, typically above a few hundred volts. These applications span various industries and technologies. In the automotive field, for example, high-voltage technology refers to the use of high-voltage batteries in electric and hybrid vehicles. The high voltage is typically 400 V to 600 V or even greater than 600 V. These high-voltage batteries are crucial for the performance and range of the vehicle.

[0003] In the electronics industry, high-voltage applications play a role in the power supply of electrical equipment, especially in high-voltage power supply units and transformers. High-voltage applications are also used in energy technology to transmit electrical energy over long distances and distribute it at different voltage levels.

[0004] The safe handling of high voltages is crucial because high-voltage applications can be potentially dangerous. Therefore, the development of protective measures, insulating materials, and safety standards is very important in order to prevent accidents and ensure the efficiency and reliability of high-voltage applications.

[0005] Temperature sensors can be used to monitor the temperature of high-voltage conductors. Temperature sensors for high-voltage applications are specially developed sensors for use in environments with high voltages. Typically, temperature sensors provide signals in the low-voltage range. For example, temperature sensors in vehicles are connected to the vehicle electrical system, which has a supply voltage of 12 V in a passenger car, for instance.

[0006] The above situations require that temperature sensors for high-voltage conductors be designed to take into account the increased risk of electrical discharge in high-voltage applications. In addition, special material selection may be required because these sensors must not only be electrically insulating but also heat-resistant to withstand the extreme conditions that may occur in high-voltage applications. Furthermore, in high-voltage applications, accurate temperature measurement may be crucial for safe and reliable operation. Therefore, these sensors must have high precision and stability to ensure accurate measurement over a wide temperature range. Due to the usually demanding operating conditions, temperature sensors for high-voltage applications must be long-term stable and reliable to ensure consistent performance over a long period of time.

[0007] For all these reasons, temperature sensors for high-voltage conductors are usually very expensive. Therefore, a major goal is also to reduce the manufacturing cost.

[0008] According to market trends, in particular high-voltage connectors are becoming more compact. Therefore, thermal monitoring of high-voltage conductors in high-voltage connectors is becoming increasingly important.

[0009] In particular, double or reinforced insulation can be achieved, for example, by a hermetically insulated sensor, which is realized, for example, by potting or a double-wall shrink tube. This double or reinforced insulation can prevent flashover. However, this insulation makes the sensor expensive and slow.

[0010] Alternatively, the sensor can include a ceramic or metal sensor plate to improve the response time. However, this increases the cost. Summary of the Invention

[0011] The present invention is based on the following object: to create a temperature sensor that better, more cost-effectively or more simply meets at least one of the above requirements.

[0012] The above task is solved by the subject matter of the independent patent claims. Advantageous further embodiments are the subject matter of the dependent patent claims.

[0013] In summary, the insulated sensor housing in combination with a preformed one-piece insulated elastomeric pad solves the above object, the insulated elastomeric pad being received in the sensor housing and carrying the temperature sensor element. In particular, the preformed insulated elastomeric pad has a heat exchange portion surrounded by an insulating portion.

[0014] Thus, the preformed insulated elastomeric pad fulfills two functions. The insulating portion helps to improve insulation. Additionally, the heat exchange portion enables a short response time of the sensor. In combination with a two-piece design of the sensor housing, a cost-effective linear integration of the elastomeric pad is possible.

[0015] In other words, the object is solved by using two insulated plastic half-shells that form a housing for holding a molded elastomeric pad for the sensor. The molded elastomeric pad transfers heat energy to the sensor element. The elastomeric pad enables tolerance compensation and firm contact between the sensor element and the current-carrying metal part whose temperature is to be monitored. This ensures good transfer of heat energy throughout the service life of the product.

[0016] This construction enables a sensor that does not require assembly with potting or heat shrink tubes, enabling the sensor to be mass-produced at low cost, for example in line production. Double or reinforced insulation is achieved by using a molded elastomeric pad around the sensor. This results in a sensor with lower cost compared to available sensor solutions.

[0017] Ribs can be provided to extend the creepage distance and clearance distance. In particular, a creepage distance of 10.6 mm can be achieved in this way. This allows the temperature sensor to be manufactured in a particularly compact manner.

[0018] By using an elastomeric pad with high thermal conductivity, heat is rapidly transferred from the contact portion of the high-voltage conductor to the temperature sensor element. Heat can be transferred from the current-carrying metal component to the temperature sensor element without an air gap, since the heat transfer of the elastomeric pad compensates for tolerances and geometric deviations.

[0019] When assembled, the lower housing shell and the upper housing shell form a protected product. The sensor can also be equipped with a strain relief for the cable.

[0020] In particular, the molded elastomer can be a silicone resin with increased thermal conductivity, while the plastic half-shell has low thermal conductivity. This improves the performance and, in particular, enables a fast response time and high accuracy for temperature measurement.

[0021] According to the first example, a temperature sensor for a high-voltage conductor includes a sensor housing for forming a chamber, the sensor housing having a substrate and a cover, the substrate having a measurement window for attachment to the high-voltage conductor, and the cover for covering the chamber.

[0022] The sensor housing is preferably made of a resistant material. In particular, the sensor housing is preferably made of an electrically insulating material.

[0023] An enclosure including a substrate and a cover connected to each other or consisting of a substrate and a cover connected to each other enables protection of electronic or mechanical components from external influences. The substrate forms a base on which the components are placed, while the cover closes the housing and provides a wide range of protection. The housing does not have to completely surround the chamber, but has openings such as a measurement window and a connection opening for connecting the temperature sensor element to the power supply network.

[0024] In addition, the connection between the substrate and the cover provides mechanical stability, which helps to protect the internal components (such as the temperature sensor element and its contact portion) from mechanical stress.

[0025] Separation of the substrate and the cover enables easy assembly of the internal components. In particular, linear production is possible.

[0026] The substrate is mounted on the high-voltage conductor and thus is in contact with the high-voltage conductor. Thermal energy can be conducted into the chamber through the measurement window.

[0027] According to the first example, the temperature sensor includes a temperature sensor element for measuring the temperature of the high-voltage conductor and for outputting an electrical temperature signal to a low-voltage network, wherein the temperature sensor element is arranged in the chamber.

[0028] The temperature sensor element measures the temperature and converts it into an electrical signal. It can include different types of sensors or be composed of different types of sensors, such as thermocouples, resistance temperature detectors (RTDs), or thermistors.

[0029] To output an electrical temperature signal, the temperature sensor element is connected to a low-voltage network via typically two or more connection terminals. For example, an RTD is a temperature sensor whose resistance varies with temperature. The change in resistance is measured and converted into a temperature signal. The electrical connection can vary depending on the sensor and the application.

[0030] In a first example, the temperature sensor further includes a preformed elastomeric pad. The preformed elastomeric pad is a sheet or pad made of an elastomeric material that has been molded into a specific shape and / or has specific properties. An elastomer is a polymeric material with rubber-like properties that can deform when stretched and then return to its original shape. Rubber is an example of an elastomeric material. The preformed elastomeric pad makes it particularly easy to install the temperature sensor because no injection molding is required during final assembly.

[0031] Furthermore, the elastomeric pad is enclosed between a substrate and a cover in a chamber. In other words, the elastomeric pad, which includes a single piece or is composed of a single piece, is held (e.g., clamped) within the boundaries of the sensor housing. This stacked construction contributes to the ease of assembly of the temperature sensor because it can be produced using a production line and only one component needs to be positioned.

[0032] Furthermore, the elastomeric pad has an insulating portion that extends around a measurement window to electrically insulate the temperature sensor from high-voltage conductors. The insulating portion extends around the measurement window on the substrate, thus increasing the creepage distance and clearance distance between the high-voltage conductor and the temperature sensor. In other words, the distance between the edge of the measurement window that is open to the high-voltage conductor and the temperature sensor element arranged in the chamber is increased. As described below, the temperature sensor element is preferably arranged in the elastomeric pad, but can also be arranged on the side of the elastomeric pad facing the cover.

[0033] The terms creepage distance and clearance distance are used in electrical engineering, particularly in relation to insulation coordination and safety standards.

[0034] The creepage distance is the longest conductive path across the surface of the insulator between two conductive components. In other words, it is the distance that an electric arc can travel along the surface. Increasing it ensures that if foreign substances (such as dirt or condensate) enter the housing, there is still sufficient insulation on the surface of the insulator to protect the conductors from short circuits.

[0035] The clearance distance is the shortest air path between two conductive or electrical components separated by an insulating material or air. This term is particularly important when evaluating the insulation strength between different components in a circuit or device. An increase in the clearance distance means that the air resistance between the components or the insulating material provides sufficient protection against breakdown or arcing.

[0036] The elastomeric pad further includes a heat exchange portion surrounded by an insulating portion, and the heat exchange portion extends in the heat transfer direction through the measurement window to the high-voltage conductor to conduct thermal energy in the heat transfer direction between the high-voltage conductor and the temperature sensor element adjacent to the heat exchange portion.

[0037] The heat energy transfer between the three elements (i.e., the high-voltage conductor, the heat exchange portion, and the temperature sensor element) depends on several factors. In particular, the thermal conductivity of the materials of the elements, the contact surfaces between the elements, the geometric arrangement, shape, and type of heat transfer of the elements must be considered.

[0038] The arrangement of the high-voltage conductor and the temperature sensor element on the heat exchange portion increases the contact surface between the three elements. This allows for efficient transfer of heat energy and enables rapid measurement feedback.

[0039] In addition, this arrangement enables heat transfer by thermal conduction, which is generally more efficient than other types of heat transfer such as thermal radiation. In this way, heat energy can be effectively transferred and rapid measurement feedback can be provided.

[0040] The heat transfer direction is defined herein as the direction between the temperature sensor element and the contact surface between the heat exchange portion and the high-voltage conductor. The contact surface is laterally bounded by the contact window and is ideally centered and aligned with the contact window. The temperature sensor element is ideally arranged on the normal of the contact surface. This enables a short distance between the high-voltage conductor and the temperature sensor element. Thereby, heat energy can be efficiently transferred and rapid measurement feedback can be achieved.

[0041] Other aspects for improving the above first example are described in the following examples.

[0042] According to the second example, the insulating portion of the temperature sensor according to Example 1 further includes a heat-insulating shrinkage portion, wherein the thickness of the heat-insulating shrinkage portion in the heat transfer direction is less than the thickness of the heat exchange portion in the heat transfer direction to reduce the heat conduction between the heat exchange portion and the insulating portion.

[0043] In other words, the one-piece elastomeric pad is preformed, wherein the cross-section in the heat transfer direction at the heat transfer section is larger than the cross-section at the heat-insulating shrinkage portion of the insulating portion. Advantageously, the heat-insulating shrinkage portion is arranged adjacent to the heat transfer section.

[0044] Heat conduction is a physical process in which thermal energy is transferred from a region of higher temperature to a region of lower temperature. This energy exchange occurs at the molecular level through the collisions and movements of particles in the material. The cross-sectional area plays an important role in heat conduction. The smaller the cross-sectional area, the lower the heat flow because there are fewer paths available for heat transfer.

[0045] The heat-insulating shrinkage portion reduces the cross-section of the single-piece elastomeric pad at the heat-insulating shrinkage portion of the insulating part. Thereby, more thermal energy can be retained in the heat exchange portion, and rapid measurement feedback can be achieved.

[0046] According to a third example, the insulating part of the temperature sensor according to any of the above examples further includes an electrical insulating rib, wherein the electrical insulating rib protrudes from the elastomeric pad and at least partially surrounds the temperature sensor element to increase the creepage distance between the temperature sensor element and the measurement window.

[0047] A rib is an elongated raised structural element that protrudes from the surface of the elastomeric pad. In particular, the insulating rib protrudes from the surface of the elastomeric pad facing the cover.

[0048] The insulating rib surrounds the temperature sensor element and is thus arranged in the circumferential direction of the heat transfer direction. As a result, the insulating rib at least increases the creepage distance between the temperature sensor element and the edge of the measurement window.

[0049] The insulating rib can completely or partially surround the temperature sensor element, for example, surround it in a U-shape. The insulating rib that only partially surrounds can improve the contact of the temperature sensor element.

[0050] According to a fourth example, the heat exchange portion of the temperature sensor according to any of the above examples has a contact surface, wherein the contact surface protrudes from the elastomeric pad in the heat transfer direction from the measurement window of the sensor housing and / or the contact surface has a convex shape.

[0051] Contact between the heat exchange portion and the high-voltage conductor takes place at the contact surface. The contact surface that protrudes beyond the edge of the measurement window on the substrate facilitates bubble-free contact between the high-voltage conductor and the heat exchange portion. As described above, this enables more efficient transfer of thermal energy and rapid measurement feedback.

[0052] The convex shape refers to a geometric section in which, when two points are connected within the mold, the connecting section remains entirely within the mold. When the temperature sensor is attached to the high-voltage conductor, the convex contact surface prevents bubbles from remaining between the high-voltage conductor and the heat exchange portion because these bubbles are pushed outwards. As described above, this enables more efficient transfer of thermal energy and rapid measurement feedback.

[0053] According to the fifth example, the heat exchange part of the temperature sensor according to any of the above examples has a sensor cavity, and a temperature sensor element is accommodated in the sensor cavity.

[0054] As described above, the temperature sensor element can be accommodated in the heat exchange part. Since the elastomeric pad is preformed, a corresponding cavity, i.e., an empty space within the heat exchange part, can be preformed for the temperature sensor element. The sensor cavity contributes to a larger contact surface between the temperature sensor element and the heat exchange part. As described above, this enables more efficient transmission of thermal energy and rapid measurement feedback.

[0055] According to the sixth example, the heat exchange part of the temperature sensor according to any of the above examples includes a mounting surface, where the mounting surface faces the cover, and where the mounting surface includes an inlet for receiving the temperature sensor element into the heat exchange part through the inlet, where the inlet preferably includes an inclined (also referred to as chamfered in this text) edge, particularly where the heat exchange part includes a sensor cavity according to the fifth example.

[0056] The temperature sensor element can be partially accommodated in the heat exchange part, i.e., in the inlet that leads the surface of the mounting surface to the interior of the heat exchange part. The surface of the mounting surface (also referred to as the mounting surface) is positioned opposite to the cover of the sensor housing. This increases the creepage distance and clearance distance between the temperature sensor element and the high-voltage conductor. At the same time, the distance for heat conduction between the temperature sensor element and the high-voltage conductor is reduced.

[0057] The inclined edge of the inlet facilitates linear integration.

[0058] Particularly advantageously, the inlet leads to the sensor cavity according to the fifth example, because the above advantages are then synergistic.

[0059] According to a modification of the sixth example, the insulating part of the temperature sensor according to each of the above examples has a mounting surface, where the mounting surface is opposite to the cover, and where the mounting surface has a cable channel that opens towards the cover, in which the connection terminals of the temperature sensor element are exposed for connection to the power supply line of the low-voltage network.

[0060] A cable duct is a device or structure for organizing, protecting, and routing cables or lines. The cable duct arranged on the mounting surface facilitates linear integration because the connection terminals can be easily connected to the power supply line of the low-voltage network. At the same time, the arrangement on the mounting surface can increase the creepage distance and clearance distance. Advantageously, the above-mentioned insulating ribs also surround the cable duct.

[0061] According to the seventh example, the heat exchange part of the temperature sensor according to any of the above examples has a mounting surface, where the mounting surface faces the cover and the mounting surface has clamping ribs, where the clamping ribs project towards the cover and contact the cover.

[0062] The elastomeric pad is elastically deformed in the heat exchange section by the contact between the cover and the clamping ribs. In particular, the heat exchange section is pressed in the direction of the measurement window. This achieves bubble-free contact between the high-voltage conductor and the heat exchange section. As described above, this enables more efficient heat transfer and rapid measurement feedback to be achieved.

[0063] In combination with the use of the fifth example described above, it is particularly advantageous to arrange the temperature sensor element in the sensor cavity, since the heat exchange section is pressed in the direction of the temperature sensor element. Two clamping ribs in the same direction (for example, parallel clamping ribs pressing on the temperature sensor element arranged in the sensor cavity from both sides) are particularly advantageous.

[0064] The clamping ribs on the mounting surface reduce the thermal coupling between the cover and the elastomeric pad, since it is located away from the measurement window. It is particularly advantageous that the clamping ribs are only provided in the heat exchange section in order to reduce the thermal coupling between the cover and the elastomeric pad.

[0065] According to the eighth example, the heat exchange section of the temperature sensor according to any of the above examples has a first material, and the insulating section has a second material, where the thermal conductivity of the first material is greater than the thermal conductivity of the second material, in particular where a filler is mixed in the region of the heat exchange section.

[0066] This enables the thermal conductivity of the heat exchange section to be increased compared to the thermal conductivity of the isolation section.

[0067] The thermal conductivity of the elastomeric pad can be increased, for example, by adding fillers with high thermal conductivity such as graphite, alumina, and / or boron nitride.

[0068] According to the ninth example, the thermal conductivity of the elastomeric pad of the temperature sensor according to any of the above examples is higher than the thermal conductivity of the substrate, preferably where the thermal conductivity of the elastomeric pad is higher than the thermal conductivity of the cover.

[0069] This increases the thermal isolation of the housing component compared to the elastomeric pad.

[0070] According to the tenth example, the cover of the temperature sensor according to any of the above examples includes cover ribs, where the cover ribs extend from the cover into the chamber and at least partially surround the heat exchange section, and where the inclined side surfaces (also called chamfered side surfaces) of the cover ribs contact the heat exchange section to align the elastomeric pad perpendicular to the heat transfer direction.

[0071] The cover ribs reduce the thermal coupling between the cover and the elastomeric pad, since the contact surface is located away from the measurement window. It is particularly advantageous that the cover ribs touch the edge of the heat exchange section, for example, the edge of the mounting surface, in order to reduce the thermal coupling between the cover and the elastomeric pad.

[0072] According to the eleventh example, the cover of the temperature sensor according to any of the above examples includes cover ribs, wherein the ends of the cover ribs extend from the cover into the chamber and at least partially surround the heat exchange portion. In particular, an air cavity is provided between the ends of the cover ribs and the insulating portion to prevent heat conduction between the air cavity and the insulating portion.

[0073] Thus, the cover ribs increase the clearance distance between the heat exchange portion and an edge of the isolation portion.

[0074] To prevent heat conduction between the cover and the elastomeric pad, an air cavity can be provided between the insulating portion and the cover ribs. This also has the advantage of increasing the mounting tolerance.

[0075] According to a modification of the eleventh example, in addition to the second and third examples, the cover of the temperature sensor includes cover ribs that project into a heat insulation groove formed by a heat insulation shrinkage portion and at least partially surround the heat exchange portion. This produces a labyrinth portion that increases the creepage distance and the clearance distance.

[0076] According to the twelfth example, the cover of the temperature sensor according to any of the above examples has a connecting element, and the substrate of the temperature sensor according to any of the above examples has a mating connecting element for holding the cover and the substrate together in a connecting direction, which is preferably in the heat transfer direction.

[0077] This makes the assembly easier. In particular, the connecting direction can be selected such that it corresponds to the heat transfer direction, which enables cost-effective linear production.

[0078] According to a modification of the twelfth example, the temperature sensor element according to each of the above examples is arranged at the measuring end of the sensor housing, and the sensor housing has a strain relief for the power supply line of the low voltage network at the connector housing end opposite the measuring end.

[0079] This enables a firm connection between the sensor housing side and the power supply line. This is particularly advantageous if the temperature sensor is part of a high voltage connector.

[0080] According to the thirteenth example, the substrate of the temperature sensor according to any of the above examples has a positioning member, and the insulating portion of the elastomeric pad of the temperature sensor according to any of the above examples has relative positioning elements for aligning the elastomeric pad perpendicular to the heat transfer direction.

[0081] The relative positioning elements on the insulating portion reduce the thermal coupling between the substrate and the elastomeric pad because the contact surface is positioned away from the measuring window. Particularly advantageously, the positioning elements touch the edge of the insulating portion in order to reduce the thermal coupling between the substrate and the elastomeric pad.

[0082] According to a modification example of the thirteenth example, a cavity is provided between the edge of the measurement window and the heat exchange part to prevent heat conduction between the heat exchange part and the edge of the measurement window.

[0083] For example, one side of the heat exchange part protruding through the measurement window is inclined. This creates an isolated cavity. This also has the following advantage: the installation tolerance is increased.

[0084] The fourteenth example relates to a method for manufacturing a temperature sensor for a high-voltage conductor, the method comprising:

[0085] providing a substrate and a cover, the substrate having a measurement window for attachment to a high-voltage conductor, the cover being for covering the chamber;

[0086] providing a preformed elastomeric pad having an insulating part and a heat exchange part, the elastomeric pad being enclosed between the substrate and the cover in the chamber;

[0087] arranging a temperature sensor element on the elastomeric pad to measure the temperature of the high-voltage conductor and output an electrical temperature signal to a low-voltage network;

[0088] forming a chamber in the sensor housing by connecting the substrate to the cover;

[0089] wherein the heat exchange part is surrounded by the insulating part to electrically insulate the temperature sensor from the high-voltage conductor, and

[0090] wherein the heat exchange part extends through the measurement window in the heat transfer direction to the high-voltage conductor to conduct heat energy between the high-voltage conductor and the temperature sensor element adjacent to the heat exchange part.

[0091] To avoid repetition, the above examples of the temperature sensor are used for the manufacturing process. In particular, this manufacturing method is used to manufacture a temperature sensor according to one of the above examples.

[0092] According to the fifteenth example, in the manufacturing process according to the fourteenth example, the preformed elastomeric pad is provided as an injection molded part before the substrate is connected to the cover.

[0093] This means that the elastomeric pad can be preformed particularly cost-effectively, i.e., not injection molded in the substrate or the cover.

[0094] To better understand the present invention, the present invention is explained in more detail using the example embodiments shown in the following drawings. The same components are provided with the same reference numerals and the same component names. In addition, the individual features or combinations of features of the various examples shown and described can also represent independent, creative solutions or solutions according to the present invention. Description of the Drawings

[0095] The present invention will now be described with reference to the accompanying drawings.

[0096] It shows:

[0097] Figure 1 An exploded view which is an example of a temperature sensor;

[0098] Figure 2 is Figure 1 a second view of

[0099] Figure 3 is Figure 1 a cross-sectional view of the temperature sensor shown, where the sensor is assembled;

[0100] Figure 4 is Figure 1 a second cross-sectional view of the temperature sensor shown, where it is assembled;

[0101] Figure 5 Shows a high-voltage connector with the temperature sensor from the above figure. Detailed Description

[0102] As Figure 1 and Figure 2 shown, the temperature sensor 10 for a high-voltage conductor (not shown) includes a sensor housing for forming a chamber, the sensor housing including a substrate 100 and a cover 200, the substrate 100 having a measurement window 110 for attachment to the high-voltage conductor, and the cover 200 for covering the chamber.

[0103] The sensor housing extends in a longitudinal direction L from a measurement end to an opposite connector housing end, at the measurement end there is arranged the measurement window 110, and at the connector housing end there is an opening for the strain relief 120 for electrical connection to a supply line for a low-voltage network.

[0104] Figures 1 to 4 The stacking direction of the housing shown in Figure 3 extends along an axis W which is perpendicular to the longitudinal direction L. As shown, heat is transferred along the stacking direction W from the high-voltage conductor (not shown) through the measurement window 110 to the sensor unit. In particular,

[0105] perpendicular to the heat transfer direction W and the longitudinal direction L, the sensor housing extends in a transverse direction Q.

[0106] As Figure 1 shown, the substrate 100 has positioning elements 116, 117, a strain relief 120, a side wall 130 surrounding the measurement end, and mating connection elements 140. The substrate 100 having the above components can be manufactured in one piece, for example, manufactured as an injection molded part.

[0107] The positioning elements 116, 117 are ribbed protrusions that can be connected to the substrate 100 in one piece. They protrude from the substrate 100 in the direction of the axis W and can be connected to the side wall 130.

[0108] The strain relief 120 includes protrusions that protrude from the substrate in the direction of the axis W and can be connected to the substrate in one piece. They form a cable duct for the power supply line, which extends in the longitudinal direction L and the transverse direction Q.

[0109] The side wall 130 surrounds the substrate 100 and protrudes from it in the direction of the axis W. In the example shown, it surrounds three of the four edges of the rectangular substrate 100. The side wall 130 and the substrate 100 form a cup-shaped receiving portion, where the strain relief 120 is arranged on the fourth edge.

[0110] Furthermore, the mating connection element 140 is provided in the side wall 130 in the form of a through-opening.

[0111] As Figure 2 shown, the cover 200 has cover ribs 210, positioning elements 216, 217, a side wall 230, and a connection element 240. The cover 200 having the above components can be integrally manufactured, for example, as an injection molded part.

[0112] As Figure 3 shown, the cover ribs 210 protrude from the cover 200 into the chamber and at least partially surround the heat exchange portion 330 of the elastomeric pad 300 described later. Furthermore, the cover ribs 210 have inclined sides 212 and ends 214.

[0113] The inclined sides 212 contact the heat exchange portion 330. As Figure 3 and Figure 4 shown, only the portion of the cover ribs 210 that extends in the longitudinal direction L has inclined sides 212. This enables the heat exchange portion 330 to be aligned, particularly in the transverse direction, whereby the contact surface is minimized.

[0114] As Figures 3 to 4 shown, in the assembled state, a cavity 614 is provided between the end 214 of the cover rib 210 and the insulating portion 310 of the elastomeric pad 300 described later.

[0115] The positioning elements 216, 217 are ribbed protrusions that can be integrally connected to the cover 200. They protrude from the cover 200 in the direction of the axis W and partially form the side wall 230.

[0116] The side wall 230 surrounds the cover 200 and projects from it in the direction of the axis W. It surrounds three of the four edges of the rectangular cover 200. The side wall 230 and the cover 200 form a can-shaped accommodation part, whereby the fourth wall is partially open.

[0117] Furthermore, a connecting element 240 in the form of a latch hook is provided in the side wall 230.

[0118] As Figure 4 shown, the cover 200 and the substrate 100 are held together in the connecting direction W by the connecting element 240 and the mating connecting element 140. Here, the connecting direction corresponds to the heat transfer direction W. In particular, the side wall 230 of the cover 200 is located inside the side wall 130 of the substrate, which increases the creepage distance and the clearance distance between the high-voltage conductor and the temperature sensor element 410.

[0119] As Figures 3 to 4 shown, during assembly, an air cavity 614 is provided between the side wall 230 of the cover and the insulating part 310 described below.

[0120] Furthermore, the temperature sensor 10 includes a sensor unit having a temperature sensor element 410 for measuring the temperature of the high-voltage conductor and for outputting an electrical temperature signal to the mating connection parts 520, 522 of the low-voltage network via two connection terminals 420, 422. The mating connection parts 520, 522 are guided through the strain relief part 120.

[0121] The temperature sensor element 410 is arranged in a chamber, i.e., the preformed elastomeric pad 300 accommodates the temperature sensor element 410. For this purpose, the preformed elastomeric pad 300 is surrounded in the chamber between the substrate 100 and the cover 200. This enables simple and cost-effective manufacturing because the temperature sensor element 410 is not molded into the elastomeric pad but placed therein.

[0122] Figure 3 and Figure 4 The elastomeric pad 300 shown in and includes an insulating part 310 and a heat exchange part 330 that extends around the measurement window. The theoretical boundary between the insulating part 310 and the heat exchange part 330 of the integrally formed elastomeric pad 300 is indicated by a dashed line that extends in the extension of the edge 112 of the measurement window.

[0123] Advantageously, the thermal conductivity of the elastomeric pad 300 is higher than the thermal conductivity of the substrate 100. Particularly preferably, the thermal conductivity of the elastomeric pad 300 is also higher than the thermal conductivity of the cover 200.

[0124] The insulating portion 310 of the elastomeric pad 300 extends along the substrate 100, i.e., in the longitudinal direction L and the transverse direction Q, whereby the temperature sensor, the temperature sensor element 410, and / or the connection terminals 420, 422 are electrically insulated from the high-voltage conductor. The cavities 612 and 614 allow the insulating portion 310 and the substrate to not be pressed together, but to lie loosely on top of each other. This reduces thermal coupling. Additionally, the mounting tolerances can be increased.

[0125] The insulating portion, in particular as Figure 3 shown, has a heat-insulating shrinkage portion 312, an electrical insulating rib 314, and a relative positioning element 316 perpendicular to the axis W from the heat exchange portion 330. Additionally, the insulating portion 310 has a cable duct 315 that is open towards the cover in the insertion direction W.

[0126] As Figures 1 to 4 shown, the heat-insulating shrinkage portion 312 surrounds and abuts the heat exchange portion 330. This reduces heat conduction in the longitudinal direction L and the transverse direction Q in the elastomeric pad 300 from the heat exchange portion 330 to the insulating portion 310.

[0127] In particular, from Figure 3 and Figure 4 it can be seen that the electrical insulating rib 314 protrudes from the elastomeric pad 300 in the heat transfer direction (i.e., along the axis W) and at least partially surrounds the temperature sensor element 410. This increases the creepage distance between the temperature sensor element 410 and the edge 112 of the measurement window.

[0128] As Figures 1 to 4 shown, the relative positioning element 316 is located on two opposite longitudinal sides of the electrical insulating rib 314. Together with the positioning element 116 of the substrate 100, it enables low-stress and simple positioning of the elastomeric pad 300 in the longitudinal direction L. The relative positioning element 316 also increases the creepage distance and the clearance distance between the temperature sensor element 410 and the edge 112 of the measurement window.

[0129] The cable duct 315 is arranged on the mounting surface, where the mounting surface is opposite to the cover 200 and the mounting surface faces the cover 200. The cable duct 315 is open towards the cover 200 such that the connection terminals 420, 422 of the temperature sensor element 410 are exposed to the mating connection portions 520, 522 of the power supply lines of the low-voltage network before attaching the cover 200 and can be connected easily and inexpensively during manufacturing.

[0130] As Figure 3 shown in particular in

[0131] The heat exchange portion 330 may include a first material, and the insulating portion 310 may include a second material, where the thermal conductivity of the first material is advantageously greater than that of the second material. Thereby, heat can be conducted to the temperature sensor element 410 more efficiently.

[0132] As Figures 1 to 4 shown, the mounting surface of the heat exchange portion 330 faces the cover 200. An inlet is provided on the mounting surface, and the inlet has an inclined edge 342. In addition, clamping ribs 344 are provided on the mounting surface.

[0133] The contact surface 334 contacts a high-voltage conductor (not shown). As shown, for example, in Figure 1 , Figure 2 and Figure 4 , the contact surface 334 is convex in at least one direction. This reduces the formation of cavities between the heat exchange portion 330 and the high-voltage conductor, and thus increases the thermal coupling between the high-voltage conductor and the temperature sensor element 410.

[0134] In addition, a sensor cavity 334 is arranged within the heat exchange portion 330. The sensor cavity is partially open via an inlet leading to the mounting surface. In particular, the temperature sensor element 410 can be easily inserted into the preformed heat exchange portion 330 via the inclined edge 342 and is at least partially surrounded by the heat exchange portion 330. The arrangement in the sensor cavity increases the contact surface, and thus increases the thermal coupling between the high-voltage conductor and the temperature sensor element 410.

[0135] The clamping ribs 344 extend from the mounting surface 340 in the direction of the cover 200 along the axis W. In particular, when the cover 200 is mounted to the substrate 100, the clamping ribs 344 are used to deform the heat exchange portion 330. In particular, the sensor cavity 334 is then pressed together, resulting in a larger contact surface between the heat exchange portion 330 and the temperature sensor 410. In addition, the clamping ribs 344 enable the heat exchange portion to be pressed through the measurement window 110 in the direction of the high-voltage conductor, thus improving the contact between the contact surface 332 of the heat exchange portion 330 and the high-voltage conductor (not shown). This arrangement increases the contact force and thus increases the thermal coupling between the high-voltage conductor and the temperature sensor element 410.

[0136] Another measure for increasing the thermal coupling between the high-voltage conductor and the temperature sensor element 410 and the thermal isolation between the heat exchange portion 330 and the bottom element is the cavity 616 between the edge 112 of the measurement window and the heat exchange portion 330, which is also used to increase the mounting tolerance.

[0137] The above measures facilitate heat conduction along the thick line 333 in the heat exchange region 330. This is substantially in the direction of the axis W.

[0138] The sensor can be assembled cost - effectively by stacking components. First, a substrate 100 with a measurement window 110 is provided for attachment to a high - voltage conductor.

[0139] In the next step, a pre - formed elastomeric pad 300 having an insulating portion 310 and a heat exchange portion 330 is then incorporated into the substrate.

[0140] The temperature sensor element may already be arranged in the elastomeric pad or may be arranged after the elastomeric pad has been attached to the substrate.

[0141] Then a cover 200 is installed to cover the chamber such that the elastomeric pad 300 is enclosed in the chamber between the substrate 100 and the cover 200.

[0142] As described above, a heat exchange portion surrounded by an insulating portion is thus formed such that the insulating portion electrically insulates the temperature sensor 410 from the high - voltage conductor, and the heat exchange portion extends through the measurement window in the heat transfer direction to the high - voltage conductor to conduct thermal energy between the high - voltage conductor and the temperature sensor element adjacent to the heat exchange portion.

[0143] Finally, Figure 5 The connection of the temperature sensor to the high - voltage header is shown.

[0144] For example, the pre - formed elastomeric pad can be provided as an injection - molded part before the substrate is connected to the cover.

[0145] Even if not shown in the figures, the sensor housing can have different shapes and does not necessarily have to have a rectangular basic shape. This also applies to the measurement window.

[0146] List of reference numerals:

[0147] Reference numeral Description 10 Temperature sensor 100 Substrate 110 Measurement window 112 Edge of the measurement window 116、117、216、217 Positioning element 120 Strain relief portion 130、230 Side wall 140 Fitting connection element 200 Cover 210 Cover rib 212 Inclined side 214 End 230 Side wall 240 Connection element 300 Elastomeric pad 310 Insulating portion 312 Heat-insulating shrinkage portion 314 Electrically insulating rib 314 Cable duct 316 Relative positioning element 330 Heat exchange portion 332 Contact surface 333 Heat (Heatutsch) 334 Sensor cavity 410 Temperature sensor element 420、422 Connection terminal 520、522 Fitting connection portion 612、614、616 Cavity W Heat transfer direction and stacking direction L Longitudinal direction Q Transverse direction

Claims

1. A temperature sensor (10) for a high-voltage conductor, the temperature sensor (10) comprising: A sensor housing for forming a chamber, the sensor housing having a substrate (100) and a cover (200), the substrate (100) having a measurement window (110) for attachment to the high-voltage conductor, the cover (200) for covering the chamber; A temperature sensor element (410) for measuring the temperature of the high-voltage conductor and for outputting an electrical temperature signal to a low-voltage network, wherein the temperature sensor element (410) is arranged in the chamber; A preformed elastomeric pad (300) enclosed in the chamber between the substrate (100) and the cover (200), wherein the elastomeric pad (300) has an insulating portion (310) extending around the measurement window (110) to electrically insulate the temperature sensor from the high-voltage conductor, and wherein the elastomeric pad (300) further includes a heat exchange portion (330) surrounded by the insulating portion (310), the heat exchange portion (330) extending in a heat transfer direction (W) through the measurement window (110) to the high-voltage conductor to conduct thermal energy in the heat transfer direction (W) between the high-voltage conductor and the temperature sensor element (410) adjacent to the heat exchange portion.

2. The temperature sensor (10) according to claim 1, wherein, The insulating portion (310) further includes a heat-insulating shrinkage portion (312), wherein the thickness of the heat-insulating shrinkage portion (312) in the heat transfer direction (W) is less than the thickness of the heat exchange portion (330) in the heat transfer direction (W) to reduce heat conduction between the heat exchange portion (330) and the insulating portion (310).

3. The temperature sensor (10) according to any one of the preceding claims, wherein, The insulating portion (310) further includes electrical insulating ribs (314), wherein the electrical insulating ribs (314) project from the elastomeric pad (300) and at least partially surround the temperature sensor element (410) to increase the creepage distance between the temperature sensor element (410) and the measurement window (110).

4. The temperature sensor (10) according to any one of the preceding claims, wherein, The heat exchange portion (330) includes a contact surface (332), wherein the contact surface (332) projects from the elastomeric pad (300) against the heat transfer direction (W) beyond the measurement window (110) of the sensor housing, in particular wherein the contact surface (332) has a convex shape.

5. The temperature sensor (10) according to any one of the preceding claims, wherein, The heat exchange portion (330) includes a sensor cavity (334) in which the temperature sensor element (410) is received.

6. The temperature sensor (10) according to any one of the preceding claims, wherein, The heat exchange part (330) includes a mounting surface, wherein the mounting surface faces the cover (200), and wherein the mounting surface (340) includes an inlet through which the temperature sensor element (410) is received into the heat exchange part (330), and wherein the inlet preferably includes an inclined edge (342), and in particular wherein the heat exchange part (330) includes a sensor cavity (334) according to claim 5; and / or wherein the insulating part (310) has a mounting surface, wherein the mounting surface faces away from the cover (200), and wherein the mounting surface has a cable duct (315) that is open towards the cover (200), and the connection terminals (420, 422) of the temperature sensor element (410) are exposed in the cable duct (315) for connection to the supply line of the low voltage network.

7. The temperature sensor (10) according to any one of the preceding claims, wherein, The heat exchange part (330) includes a mounting surface, wherein the mounting surface faces the cover (200), and the mounting surface (340) includes clamping ribs (344), wherein the clamping ribs (344) project towards the cover (200) and contact the cover (200).

8. The temperature sensor (10) according to any one of the preceding claims, wherein, The heat exchange part (330) includes a first material and the insulating part (310) includes a second material, wherein the thermal conductivity of the first material is greater than the thermal conductivity of the second material, and in particular wherein a filler is mixed in a region of the heat exchange part (330).

9. The temperature sensor (10) according to any one of the preceding claims, wherein, The thermal conductivity of the elastomeric pad (300) is higher than the thermal conductivity of the substrate (100), and preferably, wherein the thermal conductivity of the elastomeric pad (300) is higher than the thermal conductivity of the cover (200).

10. The temperature sensor (10) according to any one of the preceding claims, wherein, The cover (200) includes cover ribs (210), wherein the cover ribs (210) extend from the cover (200) into the chamber and at least partially surround the heat exchange part (330), and wherein the inclined sides (212) of the cover ribs (210) contact the heat exchange part (330) to align the elastomeric pad perpendicular to the heat transfer direction.

11. The temperature sensor (10) according to any one of the preceding claims, wherein, The cover includes cover ribs, wherein the ends (214) of the cover ribs (210) project from the cover (200) into the chamber and at least partially surround the heat exchange part (330), and in particular, wherein an air cavity (612) is provided between the ends (214) of the cover ribs (210) and the insulating part (310) to prevent heat conduction between the ends (214) and the insulating part (310).

12. The temperature sensor (10) according to any one of the preceding claims, wherein, The cover (200) includes one or more connecting elements (240), and the substrate (100) includes one or more mating connecting elements (140) for holding the cover (200) and the substrate (100) together in the connecting direction (W), wherein the connecting direction (W) preferably extends in the heat transfer direction (W), and / or Wherein, the temperature sensor element (410) is arranged at the measurement end of the sensor housing, and the sensor housing has a strain relief portion (120) for the power supply line of the low-voltage network at the connector housing end opposite to the measurement end.

13. The temperature sensor (10) according to any one of the preceding claims, wherein, The substrate (100) includes positioning elements (116, 117), and the insulating portion (310) of the elastomeric pad (300) includes relative positioning elements (316) for aligning the elastomeric pad (300) perpendicular to the heat transfer direction, and / or wherein, an air cavity (616) is provided between the edge (112) of the measurement window (110) and the heat exchange portion (330) to prevent heat conduction between the heat exchange portion (330) and the edge (112) of the measurement window (110).

14. A method of manufacturing a temperature sensor (10) for a high-voltage conductor, the method comprising: Providing a substrate (100) and a cover (200), the substrate (100) having a measurement window (110) for attachment to the high-voltage conductor, and the cover (200) for covering the chamber; Providing a preformed elastomeric pad (300) having an insulating portion (310) and a heat exchange portion (330), wherein the elastomeric pad (300) is enclosed in the chamber between the substrate (100) and the cover (200); Arranging a temperature sensor element (410) on the elastomeric pad (300) to measure the temperature of the high-voltage conductor and output an electrical temperature signal to a low-voltage network; Forming a chamber in the sensor housing by connecting the substrate (100) to the cover (200); Wherein, the heat exchange portion (330) is surrounded by the insulating portion (310) such that the insulating portion (310) electrically insulates the temperature sensor from the high-voltage conductor, and Wherein, the heat exchange portion (330) extends through the measurement window (110) in the heat transfer direction (W) to the high-voltage conductor to conduct thermal energy between the high-voltage conductor and the temperature sensor element (410) adjacent to the heat exchange portion (330).

15. A method of manufacturing a temperature sensor (10) for a high voltage conductor according to claim 14, wherein, Before connecting the substrate (100) to the cover (200), the preformed elastomeric pad (300) is provided as an injection molded part.

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