Contactor for large current connection and manufacturing method thereof

Abstract

The present invention relates to a contactor (2) for high-current connection, comprising an elastic support member (6) made of an electrically conductive and elastic alloy material such as beryllium copper, the elastic support member (6) comprising an elastic tab matrix assembly (14) configured by arranging elastic tabs (10) in a matrix on the entire contact bottom side, the elastic connection piece (10) has elastic durability after heat treatment, and is provided with: an elastic leg section (10a) formed by integrally extending from a base section (8) in an inclined direction or in a # imgabs0 # form by matrix X-axis and Y-axis processing on the entire contact section side; and an elastic contact foot part (10b) at the front end of the elastic leg part (10a).

Description

Technical Field

[0001] The present invention relates to a high-current connection device, and more particularly to an improvement of a high-current connection contactor capable of minimizing contact resistance when used for high-current battery charge and discharge testing or for selective electrical connection with high-current connections of hundreds to thousands of amperes. Background Art

[0002] Generally speaking, when electrical contact is incomplete at connections such as between wires and switches, between wires and connectors, or between connectors and electrodes, the contact resistance at the connection increases, generating heat. Heat generation generally increases with increasing contact resistance and load current; higher load current and contact resistance lead to higher temperatures.

[0003] Recently, to improve the quality and reliability of high-capacity batteries used in electric vehicles, not only are battery sampling tests being conducted, but comprehensive battery testing systems are also being introduced. These comprehensive battery testing systems not only test all produced batteries for charge and discharge optimization, but also perform voltage and current testing. When testing electric vehicle batteries of various sizes and materials, the current applied to the batteries by the test equipment can be high, such as 300 to 500A, with peak currents reaching 1800A. If the electrical contact state at the contact points during testing is unstable or inconsistent, the reliability of the battery testing will be compromised.

[0004] For example, when using a secondary battery charge and discharge tester to continuously and repeatedly perform charge and discharge tests on a high-capacity battery pack, when using a secondary battery charge and discharge tester, when a load current of hundreds to thousands of amperes [A] flows depending on the charge and discharge of the battery, the contact points during the test will cause incomplete electrical contact. The increase in contact resistance and the resulting heat deteriorate the battery, becoming a variable that makes the battery pack measurement results unreliable.

[0005] If there is incomplete electrical contact, the initial heating temperature is low and does not cause any problems. However, over time, due to increased load current and insufficient heat dissipation conditions, the heating temperature will accelerate. This increase in heating temperature will cause the contact resistance to increase further. The increased heat generated by the increased contact resistance will have a number of adverse effects on the mechanical durability of the electrical connector.

[0006] Therefore, when implementing a high-current connection contactor, a high-current connection contactor with a structure that can minimize contact resistance is required for high-current battery charge and discharge testing or for selective electrical connection (switchable electrical connection) with high currents of hundreds to thousands of amperes. Summary of the Invention

[0007] Technical problems to be solved

[0008] Therefore, an object 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 and discharge testing or for selective electrical connection of high currents of hundreds to thousands of amperes.

[0009] Technical Solution

[0010] The contactor for high current connection according to the present invention for the above-mentioned purpose is characterized in that it includes an elastic support component made of an alloy material with conductivity and elasticity, and the elastic support component includes an elastic connecting piece matrix assembly composed of an elastic connecting piece matrix arranged on the entire contact bottom side, wherein the elastic connecting piece has elastic durability after heat treatment, and includes: an elastic leg portion that extends integrally from the base toward an inclined direction through X-axis and Y-axis processing on the entire contact bottom side; and an elastic contact foot portion at the front end of the elastic leg portion.

[0011] In the contactor for connecting a large current of the present invention, the elastic connecting piece matrix assembly may include: left and right elastic connecting piece matrix portions, on the left and right sides of the left and right center line planes, constituting the elastic legs of the elastic connecting pieces to be arranged symmetrically in their inclination directions;

[0012] In addition, the elastic connecting piece matrix assembly can be constructed so that all the elastic legs of the elastic connecting pieces are inclined toward one side.

[0013] As another aspect of the present invention, a contactor for connecting a large current includes an elastic support member made of an alloy material having conductivity and elasticity, wherein the elastic support member includes an elastic connection piece matrix assembly formed by configuring an elastic connection piece matrix on the entire contact bottom side, wherein the elastic connection piece has elastic durability after heat treatment, including: the entire contact bottom side is processed by X-axis and Y-axis, from the base to An elastic leg portion extending in an integral manner; and an elastic contact point foot portion at the front end of the elastic leg portion.

[0014] As another aspect of the present invention, a contactor for high current connection includes an elastic support component made of an alloy material with conductivity and elasticity, wherein the elastic support component includes an elastic connection piece matrix assembly formed by configuring a matrix of elastic connection pieces on the entire contact bottom side, wherein the elastic connection pieces have elastic durability after heat treatment, including: in order to set the matrix-configured elastic connection pieces, the entire contact bottom side is processed by X-axis and Y-axis to form a matrix-shaped standing support piece extending from the base as a whole, and each standing support piece is obliquely bent to obtain an elastic leg; and an elastic contact foot at the front end of the elastic leg.

[0015] In addition, the present invention is characterized in that the elastic contact foot of the elastic connecting piece is formed into a flat surface processed at the same level by flatness alignment processing.

[0016] In addition, the invention is characterized in that the elastic connection piece assembly of the elastic support member is plated with an electrical contact material, thereby further comprising an electrical contact plating layer formed on the elastic contact feet of the elastic connection piece.

[0017] Furthermore, the present invention is characterized in that a portion of the elastic supporting member on the side in contact with the bottom further includes a limiting embankment for limiting the elastic depth of the elastic connection piece matrix assembly.

[0018] In addition, as another aspect of the present invention, in the manufacturing method of the contactor for large current connection, it is characterized in that it includes: a step of obtaining a contactor base material using an elastic supporting component of an alloy material having conductivity and elasticity; a step of arranging an elastic connecting piece matrix on the entire contact bottom side to obtain an elastic connecting piece matrix assembly, wherein the contact bottom side of the elastic supporting component of the contactor base material is processed as a whole in the X-axis and Y-axis to form an elastic connecting piece including an elastic leg extending integrally from the base toward an inclined direction, and an elastic contact foot at the front end of the elastic leg; and a step of performing an aging hardening treatment as a heat treatment, wherein the heat treatment is used to increase the elastic durability, fatigue resistance and conductivity of the elastic connecting piece matrix assembly constituting the elastic supporting component.

[0019] In addition, as another aspect of the present invention, in the manufacturing method of the contactor for large current connection, it is characterized in that it includes: a step of obtaining a contactor base material using an elastic supporting component of an alloy material with conductivity and elasticity; a step of processing the elastic supporting component of the contactor base material through the matrix X-axis and Y-axis to form a matrix-shaped standing supporting piece extending from the base as a whole in order to set the elastic connecting piece arranged in a matrix on the contact bottom side; a step of obtaining an elastic connecting piece matrix assembly in which the elastic connecting piece matrix is arranged on the contact bottom side as a whole, wherein the elastic connecting piece includes: an elastic leg portion obtained by obliquely bending the standing supporting piece, and an elastic contact foot portion at the front end of the elastic leg portion; and a step of performing an aging hardening treatment as a heat treatment, wherein the heat treatment is used to increase the elastic durability, fatigue resistance and conductivity of the elastic connecting piece matrix assembly constituting the elastic supporting component.

[0020] Beneficial effects

[0021] The present invention has the advantage of improving the structure of a contactor for high-current connection, and can minimize contact resistance when used for high-current battery charge and discharge testing or selective electrical connection at connections with high currents of hundreds to thousands of amperes. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is a three-dimensional diagram of a contactor for connecting a large current according to an embodiment of the present invention.

[0023] Figure 2 for Figure 1 The front view of

[0024] Figure 3 for Figure 1 The side view of

[0025] Figure 4 for Figure 1 The plane composition diagram,

[0026] Figure 5 1 is a perspective view of a battery durability test device as an example of a high-current battery charge and discharge test using a high-current connection contactor according to an embodiment of the present invention.

[0027] Figure 6 For loading the large current connection contactor of the present invention Figure 5 The exploded perspective view of the clamping fixture part,

[0028] Figure 7 for Figure 5 The operating state diagram of the high current connection contactor of the present invention used in the battery durability test device,

[0029] Figures 8 to 11 This is a front view and an enlarged structural diagram of a contactor for connecting a large current according to another embodiment of the present invention.

[0030] Figure 12 This is an example diagram of the manufacturing process of a high current contactor according to another embodiment of the present invention.

[0031] Figure 13 This is a schematic diagram of the structure of an electromagnetic contactor (MC) using a contactor for connecting a large current according to another embodiment of the present invention. DETAILED DESCRIPTION

[0032] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0033] The contact surfaces on both sides of the selective electrical connection at the connection point with large currents ranging from hundreds to thousands of amperes (for example, the switch terminals of an electrical connector such as a No Fuse Breaker (NFB)) or the electrode terminal surfaces of the battery pack being tested and the contact surface of the high-current connection contactor of the charge and discharge test device are not completely flat.

[0034] If you zoom in and examine the contact surface of a switch member carefully, you'll notice tiny irregularities. This indicates that, unlike the apparent contact area, the actual contact between the two conductors is very small and localized.

[0035] Therefore, when current flows through the contact interface between two conductors, the actual contact area through which the current can flow is much smaller than the apparent contact area, and the current flows only at the actual contact point.

[0036] For this reason, large currents flow concentratedly through limited actual contact points at the contact interface between the terminal surface of a connection point where large currents of hundreds to thousands of amperes are connected and the contactor for large current connection, or between the electrode terminal surface of a battery pack and the contact interface of a probe for large current connection, thereby generating contact resistance, which causes heat.

[0037] The following mathematical formula 1 shows the relationship between the applied current (i) and the amount of heat generated by the contact resistance (R), that is, the contact heat (Q).

[0038]

Mathematical formula 1

[0039] Q=i 2 R

[0040] Q: Contact heat [W], i: Applied current, R: Contact resistance

[0041] Contact resistance R is the resistance generated by the contact force, contact form, and contact surface characteristics. It is independent of the apparent contact area and depends on the constriction resistance of the actual contact area (effective contact area). Therefore, contact resistance R is also called constriction resistance. Contact resistance R is inversely proportional to the actual contact area (effective contact area) between the contact interfaces.

[0042] When contact surfaces come into contact, the increased heat generated by contact resistance makes the measurement results of test objects such as battery packs unreliable. Therefore, it is desirable to minimize the contact resistance value when making selective electrical connections at connections with large currents of hundreds to thousands of amperes.

[0043] If the contact resistance value R of the contact surface of the large current connection contactor that contacts the terminal at the large current connection point can be reduced, as shown in Mathematical Formula 1, the contact heat Q generated in the large current connection contactor can also be reduced, thereby obtaining a reliable measurement result value or a reliable performance value of the large current connection contactor.

[0044] In addition, the contact resistance R can vary by several times or even dozens of times depending on the contact configuration of the connection contactor. In the present invention, when implementing a high-current connection contactor, the contact resistance R is minimized while also minimizing the variation in the contact resistance value depending on the contact configuration.

[0045] In the present invention, when constructing a contactor for connecting a large current, first, a plurality of real contact conducting spots are formed in a matrix structure on the contact bottom side of the contactor constituting the contact interface, so that a large current can be connected in parallel through the plurality of real contact conducting spots arranged in the matrix. The conductive spots are dispersed and flowed to minimize contact resistance, and multiple conductive spots that actually contact each other form a matrix cluster.

[0046] Secondly, the contact bottom side of the contactor forming the contact interface has reliable spring tension, thereby ensuring low contact resistance, and multiple actual contact conductive spots are each composed of independent spring forces.

[0047] Figure 1 This is a three-dimensional diagram of a contactor 2 for connecting a large current according to an embodiment of the present invention. Figure 2 for Figure 1 The front view of Figure 3 for Figure 1 The side view of Figure 4 for Figure 1 Plane composition diagram.

[0048] It should be understood that Figure 1 The large current connection contactor 2 of the present invention is as shown in FIG. Figure 5 An exemplary embodiment of a high-current battery charge and discharge test device may be fabricated in a contactor shape suitable for the configuration when electrically connected to a high-current connection.

[0049] The high-current connection contactor 2 of the present invention includes a base member 4 made of copper, which has excellent electrical conductivity, and a spring support member 6, which is a base metal welded to one side of the base member 4 and is made of a beryllium copper (BeCu) alloy material that has electrical conductivity and elasticity.

[0050] The elastic support member 6 of the large current connection contactor 2 of the present invention forms the contact bottom side of the contactor forming the contact interface, and therefore needs to be capable of forming a reliable spring tension contact and also needs to be made of a material with excellent electrical conductivity.

[0051] The beryllium copper alloy used for the elastic support member 6 of the high-current connection contactor 2 according to the present invention is a copper alloy with excellent electrical conductivity, superior mechanical spring properties, and workability. Specifically, beryllium copper (BeCu) used as the material for the elastic support member 6 of the present invention has excellent properties, such as the high conductivity of copper and the high rigidity of steel, making it the most suitable metal for the contact bottom side of the contactor.

[0052] In the present invention, among beryllium copper alloys, beryllium copper having a composition ratio that has good electrical conductivity, excellent spring properties, and high stress relaxation resistance even at high temperatures is selected for use in the elastic support member 6 .

[0053] The elastic supporting member 6 in the present invention is most preferably made of beryllium copper alloy material. According to needs, it can also include chromium copper alloy, tungsten copper alloy, nickel copper alloy and other equivalent materials with conductivity and elasticity.

[0054] First, in the present invention, as an initial step in manufacturing the contactor 2 for connecting a large current, the elastic support member 6 made of beryllium copper is welded to the base member 4 made of copper to obtain a contactor base material.

[0055] The contactor base material obtained in this way can be used to make various contactor (test probe or contact plate) shapes suitable for the properties of the connection. Figure 1 In the case of, for example, it can be made into a form in which the front end of a cylindrical rod has a flat quadrangular main body, so that it can be used as a large current connection contactor 2 for a large current battery charge and discharge test device.

[0056] After the contactor base material is obtained, in the present invention, the contact bottom side of the elastic support member 6 of the beryllium copper (BeCu) material located at the front end side of the contactor base material is cut in a matrix form and then heat-treated to form the following Figure 1 The elastic connecting piece matrix assembly 14 shown in the example can minimize the contact resistance even at high currents of hundreds to thousands of amperes.

[0057] That is, the elastic connecting sheet matrix assembly 14 of the present invention forms a matrix cluster of actual contact conductive spots at the contact interface, in which a large current can be dispersed and flowed simultaneously in the form of parallel paths. At the same time, each actual contact conductive spot of the matrix cluster of actual contact conductive spots has reliable spring tension, thereby minimizing contact resistance.

[0058] More specifically, in the elastic connection piece matrix assembly 14 of the high current connection contactor 2 of the present invention, the connection bottom side of the elastic support member 6 made of beryllium copper (BeCu) material is subjected to matrix cutting as a whole, such as Figure 4 As shown in the example in FIG, a matrix assembly 14 of elastic connecting sheets 10 is formed by configuring dozens to hundreds of elastic connecting sheets 10 in a matrix. Figure 2 and Figure 3 As shown in FIG, the elastic connector 10 includes an elastic leg 10a integrally extending from the base 8 of the beryllium copper elastic support member 6, and an elastic contact foot 10b at the front end of the elastic leg 10a. Each elastic connector 10, arranged in a matrix within an elastic connector matrix assembly 14, exerts spring tension and corresponds to the actual contact conductive spots of the matrix group, forming separate parallel paths for dispersing large current.

[0059] like Figures 1 to 4 In the design structure of the elastic connection matrix assembly 14 having a plurality of elastic connection pieces 10 in a matrix structure as shown in the example, it is preferably obtained by X-axis and Y-axis cutting processing in the matrix X-axis and Y-axis processing.

[0060] In the matrix X-axis and Y-axis cutting process according to the present invention, a wire cutting process using wires is preferred. The wire cutting process may include wire-cutting electrical discharge machining and diamond wire cutting. In a specific embodiment of the present invention, wire-cutting electrical discharge machining is more preferred.

[0061] Wire-cut EDM (Electro-Discharge Machining) is a machining method that uses the sparks generated by the discharge between a traveling wire electrode and the contacting bottom side of the elastic support member 6 as a saw blade to cut the workpiece. Using a thin wire of 0.05 to 0.3 mm, it enables more precise machining than laser or water jet machining. Furthermore, the matrix-arranged elastic connectors 10 can be machined to the desired precise dimensions and shape using numerical control (NC).

[0062] Diamond wire cutting is a machining method that uses a diamond wire cutting machine with a diamond wire coated with diamond powder to cut the workpiece with ultra-precision.

[0063] Refer again Figure 2 The contact bottom side of the elastic support component 6 in the contactor base material is processed as a whole by X-axis (row) and Y-axis (column) cutting by CNC, preferably by X-axis (row) and Y-axis (column) cutting by wire cutting discharge machining, so that at the base 8, there is an elastic leg 10a extending integrally in the inclined direction and an elastic contact foot 10b at the front end of the elastic leg 10a, thereby forming an elastic connecting piece 10 of an elastic connecting piece matrix assembly 14.

[0064] like Figure 2 As shown, in order to widen the actual contact area (effective contact area) of the contactor 2 for connecting large current, the left and right widths of the elastic contact foot 10b (in Figure 2 As a reference) is processed to be larger than the left and right width of the elastic leg 10a that plays the role of a spring (based on Figure 2 As a benchmark), the results, such as Figure 2 As shown in FIG, there may be residual pins left between the spring legs 10a that were removed during the wire-cut electrical discharge machining.

[0065] In the constitution of the elastic connecting piece matrix assembly 14 provided by matrix X-axis (row) and Y-axis (column) cutting according to the present invention, as shown in FIG. Figure 1 Example or Figure 9 As shown in the example, left and right elastic connecting piece matrix parts can be formed on the left and right sides of the left and right center line planes so that the inclination directions of the elastic legs 10a of the elastic connecting piece 10 are arranged symmetrically with each other.

[0066] Figure 1 In one example, the left and right center line planes are symmetrical axes, and the elastic legs 10a of the elastic connecting piece 10 are formed in a tilted manner relative to each other on the left and right sides. Figure 9 In another example, the left and right center lines are symmetric axes, and the elastic legs 10a of the elastic connecting piece 10 are formed to be inclined in a manner facing away from each other on the left and right sides.

[0067] In addition, in the configuration of the elastic connecting piece matrix assembly 14 provided by X-axis (row) and Y-axis (column) cutting according to the embodiment of the present invention, as shown in FIG. Figure 8 As shown in another example, the elastic leg portions 10a of the elastic connecting piece 10 may be all inclined toward one side.

[0068] In addition, in the structure of the elastic connecting piece matrix assembly 14 provided by X-axis (row) and Y-axis (column) cutting according to the embodiment of the present invention, the elastic leg portion 10a of the elastic connecting piece 10 is not simply tilted. Figure 10 or Figure 11 As shown in another example, it can also be constructed into a compound bending shape.

[0069] That is, Figure 10 and Figure 11 As shown in another example, the elastic support member 6 is integrally extended from the base portion 8 by X-axis and Y-axis cutting on the contact bottom side. The elastic leg portion 10a and the elastic contact foot portion 10b at the front end of the elastic leg portion 10a are arranged in a matrix on the entire contact bottom side. The elastic connecting pieces 10 that have been heat-treated to have elastic durability are formed into an elastic connecting piece matrix assembly 14.

[0070] Figure 10 Shown in The elastic leg portion 10a is formed into a one-stage structure. Figure 11 Shown in The elastic leg portion 10a is extended into two stages.

[0071] On the other hand, the elastic connecting piece matrix assembly 14 of the large current connection contactor 2 of the present invention can be obtained by cutting such as X-axis and Y-axis cutting, but can also be obtained by Figure 12 Another modified example of the precision wheel shown in FIG is achieved by cutting and bending.

[0072] Figure 12 Another embodiment of the elastic connecting sheet matrix assembly 14 of the present invention is an example of being realized by wheel cutting and bending.

[0073] Reference Figure 12 In order to set the elastic connecting piece 10 of the overall matrix configuration on the bottom side of the contactor, at least one of the X-axis and Y-axis of the matrix of the elastic supporting component 6 of the contactor base material is processed by wheel cutting, such as Figure 12 As shown in (a), a plurality of cutting grooves 31 are provided on the base portion 8. At this time, a limiting embankment 16 for limiting the elastic depth of the elastic connection sheet matrix assembly 14 is also provided in advance.

[0074] As a result, a matrix of standing support pieces 30 is left, which extend upright from the base portion 8 with the cutout grooves 31 provided on the base portion 8 interposed therebetween.

[0075] Then, if Figure 12 As shown in (b), the iron core 32 is placed in the cutting groove 31, as shown in FIG. Figure 12 As shown in (c), the matrix-arranged standing support pieces 30 are bent obliquely to form elastic connecting pieces 10 having elastic legs 10a and elastic contact feet 10b at the front ends of the elastic legs 10a. Thus, the elastic connecting pieces 10 arranged in this manner are arranged in a matrix on the entire bottom side of the elastic support member 6, forming the elastic connecting piece matrix assembly 14 of the present invention. The elastic connecting piece matrix assembly 14 also includes a limiting embankment 16 on one side for limiting the elastic depth of the elastic connecting piece matrix assembly 14.

[0076] In the arrangement of the elastic connecting sheet matrix assembly 14 of the present invention, the arrangement of the X-axis and Y-axis cutting processing methods such as wire cutting discharge machining is good, and according to needs, it can also be arranged as follows Figure 12 The precision wheel cutting and bending processing methods shown in the example are set.

[0077] Furthermore, when the elastic connection piece matrix assembly 14 of the large current connection contactor 2 of the present invention is formed by cutting, as shown in FIG. Figure 2 As shown, preferably, a limiting embankment 16 for limiting the elastic depth of the elastic connecting piece 10 of the elastic connecting piece matrix assembly 14 is provided at a portion of the contact bottom side of the elastic supporting member 6, more preferably formed at the deep side of the contact bottom side.

[0078] Figures 8 to 11 Although the settings are not shown in Figure 2 The state of the limiting embankment 16 shown in FIG. 1 is preferably provided on the deep side of the contact bottom side of the elastic support member 6. Figure 2 The limiting embankment 16 is shown.

[0079] After cutting and setting the elastic connecting pieces 10 constituting the elastic connecting piece matrix assembly 14 of the present invention, the elastic contact feet 10b of the elastic connecting pieces 10 constituting the elastic connecting piece matrix assembly 14 are subjected to flatness alignment processing such as wire cutting discharge machining, thereby forming a flat processing surface of the same level on the elastic contact feet 10b of the elastic connecting pieces 10.

[0080] By making the flat surface of all elastic contact foot portions 10b formed in the elastic connecting piece matrix assembly 14 nearly perfectly flat, the effective contact area for reducing contact resistance is increased. In other words, the elastic connecting pieces 10 of the elastic connecting piece matrix assembly 14 are made into a matrix of actual contact conductive spots, with the actual contact conductive spots being maximized.

[0081] In the present invention, after the elastic connecting piece matrix aggregate 14 is formed in the elastic supporting component 6 through the aforementioned cutting process, in order to restore the elastic durability of the elastic connecting piece 10 damaged by the heat generated during the cutting process, improve fatigue resistance, and increase conductivity, the elastic supporting component 6 including the elastic connecting piece matrix aggregate 14 is heat treated.

[0082] The heat treatment method according to the present invention is age hardening treatment.

[0083] As the aging hardening treatment for the elastic connecting piece matrix assembly 14 of the beryllium copper material, the annealing temperature is melted. During the aging process, the strong and fine beryllium component in the beryllium copper structure generates many particles and distributes them in the structure, which plays a role in increasing the strength through heat treatment.

[0084] By subjecting the elastic connecting piece matrix assembly 14 of the elastic support member 6 to a heat treatment such as aging hardening, the elastic connecting pieces 10 of the elastic connecting piece matrix assembly 14 of the high-current connection contactor 2 of the present invention are endowed with excellent mechanical spring properties. Specifically, the elastic connecting pieces 10 of the elastic connecting piece matrix assembly 14 of the high-current connection contactor 2 of the present invention exhibit elastic durability and fatigue resistance, possess reliable spring tension, and also have improved electrical conductivity.

[0085] In addition, in the present invention, after the heat treatment such as aging hardening treatment, the elastic connecting piece assembly 14 of the elastic supporting member 6 subjected to aging hardening treatment is electroplated with an electrical contact material to form a Figure 2 、 Figures 8 to 11 The electrical contacts in the apparatus are plated with a layer 12.

[0086] Figure 12 Although not shown in the figure, the flat surface processing and heat treatment are similarly performed to form the electroplating layer 12 for electric contacts. Figure 12 (d)].

[0087] The electric contact plating layer 12 formed on the elastic connecting piece 10 is preferably made of a material having good conductivity and durability, including hard gold plating or hard silver plating.

[0088] As previously described, the elastic connecting piece matrix assembly 14 of the high-current connection contactor 2 of the present invention is machined to include elastic connecting pieces 10 integrally extending from the base portion 8 of the elastic support member 6 made of beryllium copper. After being machined to form a matrix arrangement of tens to hundreds of elastic connecting pieces 10, the matrix assembly 14 is heat-treated. This increases the actual contact area (effective contact area) of the elastic connecting piece matrix assembly 14 to as close as possible to the entire bottom surface of the elastic support member 6 by the multiple elastic connecting pieces 10 arranged in the matrix. Specifically, multiple conductive spots of actual contact are formed on the contact bottom side of the high-current connection contactor 2, which forms the contact interface, by the matrix-arranged elastic connecting pieces 10.

[0089] As a result, in the contactor 2 for high current connection of the present invention, high current is dispersed and flows through the actual contact conductive spots of the plurality of elastic connecting pieces 10 arranged in a matrix, and each elastic connecting piece 10 forms a reliable spring tension, thereby minimizing the contact resistance at the contact interface.

[0090] The inventors of the present application have confirmed that the contact resistance can be minimized to a level of approximately 1 / 10 of the contact resistance when the large current connecting contactor 2 of the present invention is not used.

[0091] Figures 5 to 7 shown in the Figures 1 to 4 The illustrated example is an example in which the high-current connection contactor 2 of the present invention is used in a high-current battery charge and discharge test device.

[0092] Figure 5 For use according to an embodiment of the present invention Figure 1 A perspective view of a battery durability test device 100 as an example of a high-current battery charge and discharge test device with a high-current connection contactor 2, Figure 6 For loading the large current connection contactor 2 of the present invention Figure 5 Exploded perspective view of the clamping fixture part. Figure 7 for Figure 5 FIG. 1 is an operating state diagram of the high-current connection contactor 2 of the present invention used in the battery durability test device 100.

[0093] The high-current connection contactor 2 used in the battery endurance test device 100 is mainly called a probe, which is connected to a high-current power supply line 26 and mounted in a holding fixture 20 . It is raised and lowered by the tester's operation of a knob 24 .

[0094] Place the battery pack 22 in Figure 5 After the battery durability test device 100 is used, the clamping fixture 20 loaded with the large current connection contactor 2 of the present invention is used to hold the large current connection contactor 2 from the battery. Figure 7 (a) state is reduced to Figure 7 In position (b), the elastic connecting piece matrix assembly 14 of the contactor 2 is in elastic contact with the electrode terminal 22a of the battery pack 22. Even if the high-current connection contactor 2 is lowered further, the elastic connecting pieces 10 arranged in the matrix of the elastic connecting piece matrix assembly 14 will not lose their elasticity and will be protected by the retaining embankment 16 formed deep in the elastic support member 6.

[0095] In the present invention, the structure of the elastic connecting piece matrix assembly 14 of the high-current connection contactor 2 forms a matrix cluster of actual contact conductive spots. This maximizes the actual contact area (effective contact area) with the electrode terminals 22a of the battery pack 22 through these multiple actual contact conductive spots. Furthermore, by ensuring reliable spring tension in the actual contact conductive spots of each elastic connecting piece 10, the present invention minimizes contact resistance at the contact interface.

[0096] Furthermore, in the present invention, when the contact configuration 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 of the high-current connection contactor 2 to precisely rise and fall linearly, the contact resistance value hardly fluctuates because a matrix cluster of actual contact conductive spots with reliable spring tension is formed, which is adaptive in characteristics.

[0097] Figure 13 Shown in Figure 12 The schematic structure of an electromagnetic contactor (MC) 200 using the large current connecting contactor 2 according to another embodiment of the present invention is shown, and is an example in which the large current connecting contactor 2 acts on a moving tip 48 .

[0098] Figure 13 The electromagnetic contactor 200 of the example has a movable end 48 and a fixed end 50 as opening and closing contacts for opening and closing a large current flow path, and according to another embodiment of the present invention, Figure 12 A large current connection contactor 2 of the same configuration is mounted on the movable end 48 .

[0099] Figure 13 The electromagnetic contactor 200 is primarily used for remotely controlling the power supply of high-power loads. Power is applied to a coil 40 wound around an iron core. As current flows through coil 40, the fixed core 42 attached to the coil becomes an electromagnet, attracting the moving core 46 of the upper armature 44. This causes the movable end 48 of the high-current contactor 2 to contact the lower fixed end 50, creating a current flow that causes a high current to flow. This current causes a load, such as a motor, connected to the circuit section to operate.

[0100] According to the present invention, the structure of the matrix assembly 14 of elastic connecting pieces 10 in the high-current connection contactor 2 at the movable end 48 forms a matrix cluster of actual contact conductive spots. Consequently, the actual contact area (effective contact area) with the fixed end 50 is maximized by the multiple actual contact conductive spots of the matrix-structured elastic connecting pieces 10. Furthermore, by ensuring reliable spring tension in the actual contact conductive spots of each elastic connecting piece 10, the contact resistance at the interface between the movable end 48 and the fixed end 50 is minimized.

[0101] While current is flowing due to contact between the movable end 48 and the fixed end 50, if the power is turned off by remote control, the magnetism of the electromagnet formed in the fixed core 42 disappears, and the armature 44 retreats due to the force of the spring 54 mounted in the housing 52, thereby separating the contact points between the fixed end 50 and the movable end 48. This disconnects the circuit of the electromagnetic contactor 200, preventing the flow of high current to the load.

[0102] It should be understood that as an example of the present invention using a high current connection contactor 2 for selectively electrically connecting to a connection point with a high current of several hundred to several thousand amperes, there is Figure 13 The invention can be applied to electromagnetic contactors (MC: MagneticContactor), and can also be applied to no-fuse switches (NFB), vacuum circuit breakers (VCB: Vacuum CircuitBreaker), power breakers, switches, voice converters, etc. or their equivalents.

[0103] In the above description of the preferred embodiment of the present invention, a specific embodiment in which both the X-axis and Y-axis of the matrix assembly 14 are machined is described. However, either the X-axis or Y-axis can also be extruded. Furthermore, various variations, such as first extrusion or other molding to form a basic shape and then fine-cutting as a second process, are possible without departing from the scope of the present invention. Therefore, the scope of the present invention is not limited by the described embodiment but rather by the claims and their equivalents.

[0104] Industrial application possibilities

[0105] The present invention can be used to minimize contact resistance when used for selective electrical connection in electrical contact devices such as NFBs (No Fuse Breakers) that cut off current during large current charge and discharge tests or in abnormal conditions such as overload and short circuit.

Claims

1. A contactor for high current connection, characterized in that: An elastic supporting member comprising an alloy material having electrical conductivity and elasticity, The elastic supporting member includes an elastic connecting piece matrix assembly formed by configuring an elastic connecting piece matrix on the entire contact bottom side. Among them, the elastic connecting piece has elastic durability after heat treatment, including: an elastic leg portion that extends integrally from the base toward the inclined direction through X-axis and Y-axis processing on the contact bottom side; and an elastic contact foot portion at the front end of the elastic leg portion.

2. The contactor for connecting a large current according to claim 1, characterized in that: The elastic connecting piece matrix assembly forms left and right elastic connecting piece matrix parts on the left and right sides of the left and right center line planes, in which the inclination directions of the elastic legs of the elastic connecting pieces are arranged symmetrically.

3. The contactor for connecting a large current according to claim 1, characterized in that: The elastic connecting piece matrix assembly is constructed such that the elastic legs of the elastic connecting pieces are all inclined toward one side.

4. A contactor for high current connection, characterized in that: An elastic supporting member comprising an alloy material having electrical conductivity and elasticity, The elastic supporting member includes an elastic connecting piece matrix assembly formed by configuring an elastic connecting piece matrix on the entire contact bottom side. The elastic connecting piece has elastic durability after heat treatment, including: the contact bottom side is processed by X axis and Y axis, from the base to An elastic leg portion extending in an integral manner; and an elastic contact point foot portion at the front end of the elastic leg portion.

5. A contactor for high current connection, characterized in that: An elastic supporting member comprising an alloy material having electrical conductivity and elasticity, The elastic supporting member includes an elastic connecting piece matrix assembly formed by configuring an elastic connecting piece matrix on the entire contact bottom side. Among them, the elastic connecting piece has elastic durability after heat treatment, including: in order to set the elastic connecting piece of matrix configuration, the contact bottom side is processed as a whole through the X-axis and Y-axis to form a matrix-shaped standing support piece extending from the base as a whole, and each standing support piece is bent obliquely to obtain an elastic leg; and an elastic contact foot at the front end of the elastic leg.

6. The contactor for connecting a large current according to any one of claims 1, 4 and 5, characterized in that: The elastic contact foot portions of the elastic connecting piece are configured to form flat processed surfaces at the same level through a flatness alignment process.

7. The contactor for connecting a large current according to any one of claims 1, 4 and 5, characterized in that: The elastic contact foot portions in the elastic connection pieces of the elastic connection piece matrix assembly of the elastic support member are configured to form a plating layer for plating points formed by electroplating with an electrical contact material.

8. The contactor for connecting a large current according to any one of claims 1, 4 and 5, characterized in that: The portion of the elastic supporting component that contacts the bottom further includes a limiting embankment for limiting the elastic depth of the elastic connecting piece matrix assembly.

9. The contactor for connecting a large current according to claim 1 or 4, characterized in that: X-axis and Y-axis machining is one of wire-cut electrical discharge machining and diamond wire-cut machining.

10. A method for manufacturing a contactor for high current connection, characterized in that: include: The step of obtaining a contactor base material by using an elastic supporting member made of an alloy material having conductivity and elasticity; The step of disposing a matrix of elastic connecting pieces on the entire contact bottom side to obtain an elastic connecting piece matrix assembly, wherein the entire contact bottom side of the elastic supporting component of the contactor base material is subjected to X-axis and Y-axis machining to form an elastic connecting piece including an elastic leg extending integrally from the base along an inclined direction and an elastic contact foot at the front end of the elastic leg; and A step of performing an age hardening treatment as a heat treatment for increasing elastic durability, fatigue resistance, and electrical conductivity of an elastic connection piece matrix assembly constituting the elastic supporting member.

11. A method for manufacturing a contactor for high current connection, characterized in that: include: The step of obtaining a contactor base material by using an elastic supporting member made of an alloy material having conductivity and elasticity; In order to provide the elastic connecting pieces arranged in a matrix on the bottom side of the contact, the elastic supporting component of the contactor base material is processed through the matrix X-axis and Y-axis to form a matrix-shaped standing supporting piece extending integrally from the base; The step of obtaining an elastic connecting piece matrix assembly in which an elastic connecting piece matrix is arranged on the entire contact bottom side, wherein the elastic connecting piece includes: elastic legs obtained by obliquely bending the standing support pieces, and elastic contact feet at the front ends of the elastic legs; and A step of performing an age hardening treatment as a heat treatment for increasing elastic durability, fatigue resistance, and electrical conductivity of an elastic connection piece matrix assembly constituting the elastic supporting member.

12. The method for manufacturing a contactor for connecting a large current according to claim 10 or 11, characterized in that: The step of obtaining the elastic connecting piece matrix assembly further includes: performing flatness alignment processing on the elastic contact foot portions of the elastic connecting pieces to form a flat processing surface at the same level on the elastic connecting piece matrix assembly.

13. The method for manufacturing a contactor for connecting a large current according to claim 10 or 11, characterized in that: Also includes: The step of plating the elastic connection piece assembly of the elastic supporting member subjected to age hardening with an electric contact material to form an electric contact plating layer on the elastic connection piece.

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