Copper-steel composite element, electrical contact assembly and miniature circuit breaker for miniature circuit breaker

Abstract

This application provides a copper-steel composite element for miniature circuit breakers, an electrical contact assembly, and a miniature circuit breaker. The copper-steel composite element includes: a magnetic conductor, one end of which has at least one through groove extending through the thickness direction of the magnetic conductor; and an arc-starting angle, one end of which has a fitting portion matching the shape of the through groove, the fitting portion being riveted and fitted into the through groove. This application connects the end of the arc-starting angle to the through groove of the magnetic conductor by riveting and fitting together, forming a laterally composite copper-steel composite element. This allows for the connection between the arc-starting angle and the magnetic conductor without relying on additional parts, enabling rapid arc extinguishing without reducing the conductivity of the arc-starting electrical contact assembly. This makes the electrical contacts of the miniature circuit breaker more resistant to arc erosion, thus extending the product's service life.

Description

Technical Field

[0001] This application relates to the field of low-voltage electrical appliances, specifically to copper-steel composite components for miniature circuit breakers, electrical contact assemblies, and miniature circuit breakers. Background Technology

[0002] In existing technologies, pure copper is often used as a material for arc-starting elements due to its excellent electrical conductivity; however, its insufficient magnetic permeability makes it difficult to effectively control the arc path. While magnetically permeable materials (such as electrical steel) can optimize the magnetic field distribution, their electrical conductivity is poor. Current solutions often employ layered composites, welding, or riveting to connect copper and steel, but these methods have the following problems:

[0003] Copper and steel are connected by a layered composite method, which has problems such as low yield, high cost, easy wrinkling and cracking at large-angle bends, easy rusting in high temperature and high humidity environments, and difficulty in preventing rusting through electroplating.

[0004] Welding to connect copper and steel can easily lead to material oxidation, softening and deformation when heated, or poor welding at the joint can cause local temperature rise, thereby weakening the arc-starting and conductivity functions of the arc-starting element.

[0005] Riveting copper and steel together relies on additional parts, such as rivets or protrusions, which increases costs. After long-term use, it is prone to loosening due to vibration or thermal cycling, affecting product reliability.

[0006] Therefore, there is an urgent need to develop a copper-steel composite element for miniature circuit breakers that requires no additional components, has a simple structure, and combines electrical and magnetic conductivity, in order to solve at least one of the above problems. Utility Model Content

[0007] In view of one of the defects in the prior art, the purpose of this application is to provide a copper-steel composite element for miniature circuit breakers, an electrical contact assembly, and a miniature circuit breaker.

[0008] A first aspect of this application provides a copper-steel composite element for miniature circuit breakers, comprising:

[0009] A magnetic conductive component, wherein one end of the magnetic conductive component is provided with at least one through groove, the through groove extending through the thickness direction of the magnetic conductive component;

[0010] An arc-starting angle is provided at one end, with a fitting part matching the shape of the through groove, and the fitting part is riveted and fitted into the through groove.

[0011] Optionally, the cross-section of the through groove can be any one of the following: dovetail, T-shaped, rhomboid, and inverted spindle shape.

[0012] Optionally, the magnetic conductive element is made of any one of iron, iron alloy, stainless steel, low carbon steel, silicon steel, structural steel, and alloy steel.

[0013] Optionally, the material of the arc-drawing angle is any one of pure copper, red copper, oxygen-free copper, copper alloy, and copper matrix composite material with reinforced phase dispersion.

[0014] Optionally, the thickness of the arc-drawing angle is greater than the thickness of the magnetic conductor.

[0015] Optionally, the surface of the magnetic conductor is provided with a coating for rust prevention.

[0016] Optionally, the coating is a nickel layer or a zinc layer.

[0017] A second aspect of this application provides an electrical contact assembly, including an electrical contact and the aforementioned copper-steel composite element for miniature circuit breakers; the electrical contact is connected to the arc-starting angle of the copper-steel composite element.

[0018] A third aspect of this application provides a miniature circuit breaker, including the aforementioned copper-steel composite element for miniature circuit breakers or the aforementioned electrical contact assembly.

[0019] The copper-steel composite element for miniature circuit breakers provided in this application connects the end of the arc-starting angle to the through slot of the magnetic conductor by riveting and fitting together to form a laterally composite copper-steel composite element. It can achieve the connection between the arc-starting angle and the magnetic conductor without relying on additional parts. It can promote the rapid extinguishing of the arc without reducing the conductivity of the arc-starting contact assembly, thereby making the contacts of the miniature circuit breaker more resistant to arc erosion and helping to extend the service life of the product.

[0020] Other technical effects resulting from the additional features will be further illustrated in the corresponding embodiments. Attached Figure Description

[0021] Other features, objects, and advantages of this application will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0022] Figure 1 This is a schematic diagram of the structure of a copper-steel composite element for a miniature circuit breaker according to an exemplary embodiment;

[0023] Figure 2 This is an exploded view of a copper-steel composite element for a miniature circuit breaker according to an exemplary embodiment.

[0024] Figure 3 This is a schematic diagram of the structure of an electrical contact assembly supported by a copper-steel composite element (with a dovetail groove) according to an exemplary embodiment.

[0025] Figure 4 This is a schematic diagram of the structure of an electrical contact assembly supported by a copper-steel composite element (with a T-shaped through slot) according to an exemplary embodiment.

[0026] In the diagram: 1 is the magnetic conductor, 2 is the arc-leading angle, 3 is the copper-steel composite component, 4 is the electrical contact, 5 is the through slot, and 6 is the fitting part. Detailed Implementation

[0027] The present application will now be described in detail with reference to specific embodiments. These embodiments will help those skilled in the art to further understand the present application, but do not limit the present application in any way. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the present application, and these all fall within the protection scope of the present application. Parts not described in detail in the following embodiments can be implemented using existing technology.

[0028] Existing copper-steel composite components require additional parts for connection, resulting in complex connection processes and low product reliability. To address these issues, this application provides a copper-steel composite component for miniature circuit breakers.

[0029] Reference Figure 1 and Figure 2 As shown in one embodiment of this application, a copper-steel composite element for a miniature circuit breaker includes a magnetic conductor 1 and an arc-starting angle 2. One end of the magnetic conductor 1 is provided with at least one through groove 5, which penetrates the thickness direction of the magnetic conductor 1. One end of the arc-starting angle 2 is provided with a fitting part 6 that matches the shape of the through groove 5, and the fitting part 6 is riveted and fitted into the through groove 5.

[0030] Specifically, the cross-sectional shape of the fitting part 6 at the end of the arc-starting angle 2 is consistent with the cross-sectional shape of the through groove 5. The fitting part 6 is fitted into the through groove 5 by lateral riveting. The fitting method has the advantages of simple process, high yield, and cold working at the joint. It can achieve a firm connection between the arc-starting angle 2 and the magnetic conductive part 1 without adding extra parts. It avoids the problems of low yield, high cost, and easy wrinkling and cracking at large angle bends caused by the layered composite connection method, the problems of affecting the arc-starting and conductive functions of the arc-starting element caused by the welding method, and the problems of high cost and low product reliability caused by the riveting method. It has the advantages of high yield, low manufacturing cost, and high reliability.

[0031] For example, the material of the magnetic conductive component 1 is any one of iron, iron alloy, stainless steel, low carbon steel, silicon steel, structural steel, and alloy steel, so that the copper-steel composite component has the function of magnetic conduction and guides the electric arc to move towards the arc extinguishing grid.

[0032] For example, the material of the arc-starting angle 2 is any one of pure copper, red copper, oxygen-free copper, copper alloy, or copper matrix composite material with reinforced phase dispersion, which makes the copper-steel composite element have good conductivity and heat dissipation capacity, which helps the miniature circuit breaker reduce the temperature rise of the electrical contacts when interrupting the arc, helps to quickly reduce the arc temperature, and thus extends the service life of the electrical contacts.

[0033] It should be noted that the number of through slots 5 is determined based on factors such as the properties of the materials to be fitted (e.g., hardness), the area of ​​the fitting interface, and the current rating of the circuit breaker. Selecting an appropriate number of through slots helps to improve the bonding strength and torsional resistance at the joint.

[0034] In the above embodiments of this application, the end of the arc-starting angle 2 is riveted and fitted together with the through groove 5 of the magnetic conductor 1 to form a laterally composite copper-steel composite element. The connection between the arc-starting angle 2 and the magnetic conductor 1 can be achieved without relying on additional parts. This can promote the rapid extinguishing of the arc without reducing the conductivity of the arc-starting electrical contact assembly, thereby making the core component of the miniature circuit breaker, the electrical contact, more resistant to arc erosion and helping to extend the product's service life.

[0035] In order to fit the fitting part 6 of the arc-leading angle 2 into the through groove 5 of the magnetic conductor 1 by riveting, in some specific embodiments of this application, the cross-section of the through groove 5 is dovetail-shaped.

[0036] In the above embodiments of this application, one end of the copper arc-drawing angle 2 is machined into a dovetail shape, and a dovetail-shaped through groove 5 is opened on one side end of the steel magnetic conductive component 1. The dovetail end of the arc-drawing angle 2 is placed in the through groove 5 of the magnetic conductive component 1, and riveting pressure is applied to the upper and lower surfaces of the dovetail end of the arc-drawing angle 2, so that the two are fitted together. Figure 3 The novel copper-steel composite component shown possesses both excellent electrical conductivity and the arc-initiating effect of the steel magnetic component 1. The mating position utilizes a dovetail-shaped mating and riveting process, effectively constraining the joint in the horizontal, longitudinal, and vertical directions. The shapes of the through groove 5 and the mating part 6 prevent in-plane movement of the joint in the thickness direction perpendicular to the arc-initiating angle 2, ensuring a firm connection. This significantly improves the problem of loosening of existing riveted connections during long-term use, enhances the performance of the arc-initiating component, improves the reliability of the copper-steel composite component, and significantly reduces production costs, resulting in substantial economic benefits.

[0037] In order to fit the fitting part 6 of the arc-inducing angle 2 into the through groove 5 of the magnetic conductor 1 by riveting, in some optional embodiments of this application, the cross-section of the through groove 5 can also be any one of the shapes such as T-shaped, rhomboid, or inverted spindle. A schematic diagram of the T-shaped through groove is shown below. Figure 4 As shown.

[0038] In the above embodiments of this application, the through groove 5 and the fitting part 6 are configured with T-shape, rhombus shape, or inverted spindle shape, which can achieve the same technical effect as the dovetail-shaped through groove 5 and fitting part 6, and will not be described in detail here.

[0039] In order to improve the stability and reliability of the connection between the arc-starting angle 2 and the magnetic conductor 1, in some specific embodiments of this application, the thickness of the arc-starting angle 2 is greater than the thickness of the magnetic conductor 1.

[0040] In the above embodiments of this application, the thickness of the arc-leading angle 2 is greater than the thickness of the magnetic conductor 1, so that when the arc-leading angle 2 and the magnetic conductor 1 are riveted together, the material of the arc-leading angle 2 is deformed by riveting and fills the gap at the connection between the two, thereby achieving a good bond.

[0041] To prevent the copper-steel composite components from rusting, in some specific embodiments of this application, the surface of the magnetic conductive component 1 is provided with a rust-proof coating.

[0042] For example, the coating is a nickel layer or a zinc layer.

[0043] In the embodiments described above, the use of an interlocking connection method allows for pre-plating of the magnetic conductive component 1 for rust prevention before interlocking. Before riveting the magnetic conductive component 1, a rust-preventive plating material, such as nickel or zinc, is pre-plated onto its surface, thereby improving the problem of difficulty in electroplating existing copper-steel composite components produced by rolling composite methods.

[0044] Another embodiment of this application provides an electrical contact assembly, such as... Figure 3 As shown, the electrical contact assembly includes an electrical contact 4 and the aforementioned copper-steel composite element 3 for miniature circuit breakers; the copper-steel composite element 3 serves as a support, and the electrical contact 4 is connected to the arc-leading angle 2 of the copper-steel composite element 3.

[0045] Specifically, the electrical contact 4 is connected to one surface of the arc-starting angle 2 of the copper-steel composite element 3 by welding.

[0046] Another embodiment of this application provides a miniature circuit breaker, including the copper-steel composite element for miniature circuit breakers described above or the electrical contact assembly described above.

[0047] Due to the aforementioned technical effects of copper-steel composite components, the electrical contact assembly and miniature circuit breaker in the above embodiments of this application also have the same technical effects, which will not be elaborated here.

[0048] In the above embodiments of this application, a cold working method of riveting and fitting is used to laterally fit the end of the copper arc-leading angle 2 with the through groove 5 of the steel magnetic component 1, forming a copper-steel composite component with a lateral composite and a non-planar shape such as a dovetail-shaped composite contact interface. This ensures that the functional areas of the copper-steel composite component are entirely made of copper or copper alloy materials, while the non-functional areas at the tail are entirely made of magnetically conductive materials such as steel. When current enters the circuit breaker and flows through the contact assembly, the current mainly flows through the functional areas of the copper-steel composite component. This allows the copper-steel composite component to possess both the excellent electrical and thermal conductivity of copper and the magnetic conductivity of steel, effectively solving the problems of difficulty in separately electroplating copper and steel, low yield, and easy wrinkling and cracking during bending in existing rolled composite copper-steel composite components. Furthermore, since the connection between the components in the copper-steel composite element in the above embodiments of this application is cold-worked, the problem of temperature rise caused by heat deformation and poor contact at the connection is effectively prevented; and the above embodiments of this application do not require additional riveting parts, resulting in lower cost, thereby effectively improving the yield and performance of copper-steel composite elements for miniature circuit breakers.

[0049] The preferred features in the above embodiments can be used individually in any embodiment, or in any combination thereof, provided they do not conflict with each other. Furthermore, parts not described in detail in the embodiments can be implemented using existing technologies.

[0050] The following examples and comparative examples will be used to further illustrate this application in order to better understand the above-mentioned technical solutions. It should be understood that the following are only some examples and are not intended to limit this application.

[0051] Application Example 1:

[0052] refer to Figures 1-3 The copper-steel composite component provided in this application example includes: a 1008 steel magnetic conductor and a pure copper arc-starting angle; one end of the 1008 steel magnetic conductor has a through groove with a dovetail cross-section, and a layer of nickel is pre-plated on the surface of the 1008 steel magnetic conductor; the pure copper arc-starting angle has a dovetail-shaped end, i.e., an interlocking part. The dovetail-shaped end of the pure copper arc-starting angle is first inserted into the dovetail-shaped through groove of the 1008 steel magnetic conductor, at which point the arc-starting angles are laterally connected. Then, an impact pressure is applied to the upper and lower surfaces of the end of the pure copper arc-starting angle, so that the material of the dovetail-shaped end of the arc-starting angle fills the through groove of the magnetic conductor, so that the end material is tightly attached to the inner wall of the through groove of the magnetic conductor, thereby increasing the interlocking effect.

[0053] Application Example 2:

[0054] refer to Figure 4The copper-steel composite component provided in this application example includes: a silicon steel magnetic conductor and a QFe2.5 iron bronze arc-starting angle; one end of the silicon steel magnetic conductor has a T-shaped cross-section through slot, and the QFe2.5 iron bronze arc-starting angle has a T-shaped end, i.e., an interlocking part. The T-shaped end of the QFe2.5 iron bronze arc-starting angle is first inserted into the T-shaped through slot of the silicon steel magnetic conductor, at which point the arc-starting angles are laterally connected. Then, an impact pressure is applied to the upper and lower surfaces of the end of the QFe2.5 iron bronze arc-starting angle, so that the material of the T-shaped end of the arc-starting angle fills the through slot of the magnetic conductor, making its end material tightly adhere to the inner wall of the through slot of the magnetic conductor, thereby increasing the interlocking effect.

[0055] The finished electrical contact assembly, which is made by welding AgNi15 electrical contacts and copper-steel composite component support in this application example, is compared with the electrical contact assembly product made by welding AgNi15 electrical contacts and copper-steel composite component support in Comparative Example (CN118287580A) in terms of corrosion resistance, electrical life and yield. The detailed results are shown in Table 1 below.

[0056] Table 1. Test results of corrosion resistance, electrical life, and yield.

[0057] Electrical life test (times) Corrosion resistance test yield Application Example 1 9100 No pitting observed in 24 hours 88％ Application Example 2 8500 No pitting observed in 24 hours 91％ Comparative Example 7800 Pitting began on the cut surface after 8 hours of punching. 73％

[0058] According to the test results in Table 1, the electrical contact assembly product in the application example of this application is significantly better than the comparative example in terms of corrosion resistance, electrical life, and yield.

[0059] In the embodiments described above, the copper-steel composite component combines electrical conductivity and magnetic permeability. While ensuring the stability and functionality of electrical appliances, it effectively reduces the amount of precious copper used, eliminates the need for additional parts, simplifies the production process, and utilizes cold working throughout, resulting in high yield and easy mass production. The electrical contact assembly using this copper-steel composite component as a support can achieve a dual improvement in conductivity and ablation resistance. The electrical contact assembly is more resistant to arc erosion, has a longer electrical life, and is suitable for mass production. Due to the fewer parts, the corresponding dimensional tolerance fluctuations are smaller, which can improve the consistency of product quality.

[0060] In the description of the embodiments of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0061] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature.

[0062] In the description of the embodiments in this application, "multiple" means two or more, unless otherwise explicitly specified. In this application, unless otherwise explicitly specified and limited, the terms "installed," "connected," "linked," "fixed," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0063] The terms "comprising" and "having," and any variations thereof, in the embodiments of this application are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or device that includes a series of steps or units is not limited to the steps or units listed, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to such processes, methods, products, or devices.

[0064] The foregoing has described some specific embodiments of this application. It should be understood that this application is not limited to the specific embodiments described above, and those skilled in the art can make various modifications or variations within the scope of the claims, which do not affect the substantive content of this application. The above-described preferred features can be used in any combination without conflict.

Claims

1. A copper-steel composite element for a miniature circuit breaker, characterized by, include: A magnetic conductive component, wherein one end of the magnetic conductive component is provided with at least one through groove, the through groove extending through the thickness direction of the magnetic conductive component; An arc-starting angle is provided at one end, with a fitting part matching the shape of the through groove, and the fitting part is riveted and fitted into the through groove.

2. The copper-steel composite element for a miniature circuit breaker according to claim 1, characterized by The cross-section of the through groove can be any one of the following: dovetail, T-shaped, rhomboid, and inverted spindle shape.

3. The copper-steel composite element for miniature circuit breakers according to claim 1, characterized in that, The magnetic conductive component is made of any one of the following materials: iron, ferroalloy, stainless steel, low carbon steel, silicon steel, structural steel, and alloy steel.

4. The copper-steel composite element for miniature circuit breakers according to claim 1, characterized in that, The material of the arc-drawing angle is any one of pure copper, red copper, oxygen-free copper, copper alloy, and copper matrix composite material with dispersed reinforcing phase.

5. The copper-steel composite element for miniature circuit breakers according to claim 1, characterized in that, The thickness of the arc-starting angle is greater than the thickness of the magnetic conductive element.

6. The copper-steel composite element for miniature circuit breakers according to claim 1, characterized in that, The surface of the magnetic conductive component is provided with a rust-proof coating.

7. The copper-steel composite element for miniature circuit breakers according to claim 6, characterized in that, The coating is a nickel layer or a zinc layer.

8. An electrical contact assembly, characterized in that, It includes an electrical contact and a copper-steel composite element for a miniature circuit breaker as described in any one of claims 1-7, wherein the electrical contact is connected to the arc-starting angle of the copper-steel composite element.

9. A miniature circuit breaker, characterized in that, Includes the copper-steel composite element for miniature circuit breakers as described in any one of claims 1-7 or the electrical contact assembly as described in claim 8.

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