Temperature sensor for a high-voltage conductor and manufacturing method of such a temperature sensor

Abstract

The present invention relates to a temperature sensor (10) for a high-voltage conductor. The temperature sensor (10) comprises a sensor housing for forming a chamber, wherein the sensor housing has a base plate (100) with a measuring window (110) for attachment to the high-voltage conductor and a lid (200) for covering the chamber. Furthermore, the temperature sensor (10) comprises 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.The temperature sensor (10) further comprises a preformed elastomer mat (300) enclosed in the chamber between the base plate (100) and the lid (200), wherein the elastomer mat (300) has an insulating section (310) extending around the measuring window (110) to electrically insulate the temperature sensor from the high-voltage conductor, and wherein the elastomer mat (300) further comprises a heat exchange section (330) surrounded by the insulating section (310), wherein the heat exchange section (330) extends through the measuring window (110) to the high-voltage conductor in a heat transport direction (W) to conduct heat energy in the heat transport direction (W) between the high-voltage conductor and the temperature sensor element (410) adjacent to the heat exchange section.

Description

[0001] The invention relates to a temperature sensor for a high-voltage conductor and a manufacturing method of such a temperature sensor.

[0002] High-voltage conductors are used in high-voltage applications. High-voltage applications refer to the use of electrical voltage in the high-voltage range, typically above a few hundred volts. These applications span various industries and technologies. In the automotive sector, 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 more than 600 V. These high-voltage batteries are crucial for the performance and range of the vehicles.

[0003] In the electronics industry, high-voltage applications play a role in supplying power to electrical devices, particularly in high-voltage power supplies and transformers. High-voltage applications are also used in energy technology to transport electrical energy over long distances and distribute it at different voltage levels.

[0004] Safe handling of high voltage is crucial because high-voltage applications can be potentially dangerous. The development of protective measures, insulation materials, and safety standards is therefore essential 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 designed sensors used in environments with high electrical voltages. Typically, temperature sensors provide signals in the low-voltage range. For example, temperature sensors in vehicles are connected to the on-board electrical system, which, in passenger cars, has a supply voltage of 12 V.

[0006] The above circumstances require that temperature sensors for high-voltage conductors be designed to take into account the increased risk of electrical discharges in high-voltage applications. Furthermore, special material selection may be necessary, as these sensors must be not only electrically insulating but also heat-resistant to withstand the extreme conditions that can occur in high-voltage applications. Furthermore, in high-voltage applications, accurate temperature measurement can be critical for safety and reliable operation. These sensors must therefore exhibit high accuracy and stability to ensure accurate measurements over a wide temperature range. Due to the often demanding operating conditions, temperature sensors for high-voltage applications must be long-term stable and reliable to ensure consistent performance over time.

[0007] For all these reasons, temperature sensors for high-voltage conductors are typically very expensive. Therefore, a primary goal is to reduce manufacturing costs.

[0008] Following a market trend, high-voltage connectors in particular are becoming significantly more compact. As a result, thermal monitoring of the 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, realized, for example, by encapsulation or a double-walled heat-shrink tube. Such double or reinforced insulation can protect against flashovers. However, such insulation makes the sensor expensive and slow.

[0010] Alternatively, the sensor can incorporate a ceramic or metallic sensor plate to improve response time. However, this increases cost.

[0011] The invention is based on the object of creating a temperature sensor which meets at least one of the above-mentioned requirements better, more cost-effectively or more simply.

[0012] The above objects are solved by the subject matter of the independent patent claims. Advantageous further developments are the subject matter of the dependent patent claims.

[0013] In general, the above objects are achieved by an insulating sensor housing in conjunction with a preformed, one-piece insulating elastomer mat housed therein and supporting a temperature sensor element. In particular, the preformed insulating elastomer mat includes a heat exchange section surrounded by an insulating section.

[0014] The preformed insulating elastomer mat thus fulfills two functions. The insulating section contributes to enhanced insulation. Furthermore, the heat exchange section enables a fast sensor response time. Combined with the two-part design of the sensor housing, cost-effective linear integration of the elastomer mat is possible.

[0015] In other words, the task is solved by using two insulating plastic half-shells that form the housing for a molded elastomer mat that holds the sensor. The molded elastomer mat transfers the thermal energy to the sensing element. The elastomer mat enables tolerance compensation and secure contact between the sensing element and the current-carrying metal part whose temperature is to be monitored. This ensures good thermal energy transfer throughout the product's lifetime.

[0016] This configuration enables a mounted sensor that requires no potting or shrink tubing, allowing the sensor to be manufactured cost-effectively in large quantities, for example, in line production. Double or reinforced insulation is achieved by using a molded elastomer mat around the sensor. This results in a sensor with lower costs compared to existing sensor solutions.

[0017] Ribs can be added to extend the creepage and visibility distances. In particular, a creepage distance of 10.6 mm can be achieved. This allows the temperature sensor to be manufactured particularly compactly.

[0018] By using an elastomer mat with high thermal conductivity, heat is quickly transferred from the contact of the high-voltage conductor to the temperature sensor element. Heat can be transferred from the current-carrying metal part to the temperature sensor element without an air gap, as the heat transfer part of the elastomer mat compensates for tolerances and geometric deviations.

[0019] When assembled, the lower and upper housing shells form a protected product. Additionally, the sensor can be equipped with strain relief for the cables.

[0020] In particular, the molded elastomer can be a silicone with increased thermal conductivity, while the plastic half-shells have low thermal conductivity. This increases performance and, in particular, enables fast response times and high temperature measurement accuracy.

[0021] According to a first example, a temperature sensor for a high-voltage conductor comprises a sensor housing for forming a chamber, wherein the sensor housing has a base plate with a measuring window for attachment to the high-voltage conductor and a lid for covering the chamber.

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

[0023] A housing consisting of a base plate and a lid connected to each other allows electronic or mechanical components to be protected from external influences. The base plate forms the base on which the components are placed, while the lid seals the housing and provides comprehensive protection. The housing does not have to completely enclose the chamber, but has openings such as the measurement window and a connection port for connecting the temperature sensor element to a power supply.

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

[0025] The separation of the base plate and lid allows for easy assembly of the internal components. In particular, linear production is possible.

[0026] The base plate is mounted on the high-voltage conductor and thus has contact with the high-voltage conductor. Thermal energy can be conducted into the chamber through the measuring window.

[0027] According to the first example, 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 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 consist of various types of sensors, such as thermocouples, resistance thermometers (RTDs), or thermistors.

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

[0030] In the first example, the temperature sensor also includes a preformed elastomer mat. A preformed elastomer mat is a sheet or mat made of elastomeric materials that has already been molded into a specific shape and / or with specific properties. Elastomers are polymeric materials with rubber-like properties that can deform under stretching and then return to their original shape. Rubber is an example of an elastomer material. A preformed elastomer mat enables particularly simple assembly of the temperature sensor, as injection molding is eliminated during final assembly.

[0031] Furthermore, the elastomer mat is enclosed in the chamber between the base plate and the lid. In other words, the elastomer mat, which consists of a single piece, is held within a confines of the sensor housing, e.g., clamped. Such a stacked construction contributes to the ease of assembly of the temperature sensor, as line production can be used and only one part needs to be positioned.

[0032] Furthermore, the elastomer mat has an insulating section extending around the measuring window to electrically insulate the temperature sensor from the high-voltage conductor. The insulating section extends around the measuring window on the base plate, thus increasing the creepage and line-of-sight distances between the high-voltage conductor and the temperature sensor. In other words, the distance between an edge of the measuring window open to the high-voltage conductor and the temperature sensor element arranged in the chamber is increased. As described further below, the temperature sensor element is preferably arranged in the elastomer mat, but can also be arranged on a side of the elastomer mat facing the cover.

[0033] The terms creepage distance and line of sight are used in electrical engineering, particularly in connection with insulation coordination and safety standards.

[0034] The creepage distance is the longest electrically conductive path across the surface of an insulator between two conductive parts. In other words, it is the distance an arc can travel along a surface. Increasing this distance ensures that in the event of foreign material, such as contamination or condensation, there is still enough insulation on the surface of an insulator to protect the conductors from a short circuit.

[0035] The line-of-sight distance is the shortest air path between two conductive parts or electrical components separated by insulating materials or air. This term is particularly important when assessing the insulation strength between different parts in electrical circuits or devices. An increase in the line-of-sight distance indicates that the air resistance or insulating material between the parts provides sufficient protection to prevent a breakdown or arc flash.

[0036] The elastomer mat further comprises a heat exchange section surrounded by the insulation section, the heat exchange section extending through the measuring window to the high-voltage conductor in a heat transport direction to conduct heat energy in the heat transport direction between the high-voltage conductor and the temperature sensor element adjacent to the heat exchange section.

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

[0038] By arranging the high-voltage conductor and the temperature sensor element in the heat exchange section, the contact area between the three elements is increased. This allows for efficient heat energy transfer and rapid measurement feedback.

[0039] Furthermore, this arrangement enables heat transport by conduction, which is generally more efficient than other types of heat transport, such as thermal radiation. This allows for efficient heat energy transport and rapid measurement feedback.

[0040] The heat transfer direction is defined here as the direction between the temperature sensor element and the contact surface between the heat exchange section and the high-voltage conductor. The contact surface is laterally limited by the contact window and is ideally aligned centrally with the contact window. The temperature sensor element is ideally positioned perpendicular to the contact surface. This allows for a short distance between the high-voltage conductor and the temperature sensor element. This allows for efficient heat transfer and rapid measurement feedback.

[0041] Further aspects to improve the first example above are described in the following examples.

[0042] According to a second example, the insulation portion of the temperature sensor according to Example 1 further comprises a heat insulation constriction, wherein a thickness of the heat insulation constriction in the heat transport direction is smaller than a thickness of the heat exchange portion in the heat transport direction in order to reduce heat conduction between the heat exchange portion and the insulation portion.

[0043] In other words, the one-piece elastomer mat is preformed, with the cross-section in the heat transfer direction being larger at the heat transfer section than at the thermal insulation constriction of the insulation section. Advantageously, the thermal insulation constriction is arranged adjacent to the heat transfer section.

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

[0045] The thermal insulation constriction reduces the cross-section of the one-piece elastomer mat at the thermal insulation constriction of the insulation section. This allows more thermal energy to be retained in the heat exchange section and enables rapid measurement feedback.

[0046] According to a third example, the insulation portion of the temperature sensor according to any of the above examples further comprises an electrical insulation rib, wherein the electrical insulation rib protrudes from the elastomer mat and at least partially surrounds the temperature sensor element to increase a creepage distance between the temperature sensor element and the measuring window.

[0047] A rib is an elongated, raised structural element that protrudes from the surface of the elastomer mat. In particular, the insulation rib protrudes from a surface of the elastomer mat facing the cover.

[0048] The insulating rib surrounds the temperature sensor element, thus being arranged circumferentially relative to the heat transfer direction. This at least increases the creepage distance between the temperature sensor element and the edge of the measuring window.

[0049] The insulation rib can completely or partially surround the temperature sensor element, e.g., in a U-shape. A partially surrounding insulation rib can facilitate contact with the temperature sensor element.

[0050] According to a fourth example, the heat exchange section of the temperature sensor according to each of the above examples has a contact surface, wherein the contact surface protrudes from the elastomer mat in the heat transport direction from the measuring window of the sensor housing and / or the contact surface has a convex shape.

[0051] Contact between the heat exchanger section and the high-voltage conductor occurs at the contact surface. A contact surface that extends beyond the edge of the measurement window on the base plate contributes to air bubble-free contact between the high-voltage conductor and the heat exchanger section. This enables, as described above, more efficient heat energy transfer and rapid measurement feedback.

[0052] A convex shape refers to a geometric section where, when two points within the shape are connected, the connection remains entirely within the shape. A convex-shaped contact surface prevents air bubbles from remaining between the high-voltage conductor and the heat exchange section when the temperature sensor is attached to the high-voltage conductor, as these air bubbles are pushed outward. This enables, as described above, more efficient heat energy transport and rapid measurement feedback.

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

[0054] As described above, the temperature sensor element can be housed in the heat exchange section. Since the elastomer mat is preformed, a corresponding cavity, i.e., an empty space within the heat exchange section, can be preformed for the temperature sensor element. A sensor cavity contributes to a larger contact area between the temperature sensor element and the heat exchange section. This enables, as described above, more efficient heat energy transfer and rapid measurement feedback.

[0055] According to a sixth example, the heat exchange portion of the temperature sensor according to any of the above examples comprises a mounting surface, the mounting surface being opposite the cover, and the mounting surface having an access for receiving the temperature sensor element through the access into the heat exchange portion, the access preferably having a beveled edge, in particular wherein the heat exchange portion comprises the sensor cavity according to the fifth example.

[0056] The temperature sensor element can be partially housed within the heat exchange section, i.e., within an access that opens the mounting surface into the heat exchange section. The mounting surface is located opposite the cover of the sensor housing. This increases the creepage and line-of-sight distance between the temperature sensor element and the high-voltage conductor. At the same time, the distance between the temperature sensor element and the high-voltage conductor for heat conduction is reduced.

[0057] Beveled edges of the access facilitate linear integration.

[0058] It is particularly advantageous if the access leads to a sensor cavity according to the fifth example, since the advantages described above then accumulate.

[0059] According to a modification of the sixth example, the insulating portion of the temperature sensor according to each of the above examples has a mounting surface, the mounting surface being opposite the cover, and the mounting surface having a cable duct open toward the cover, in which a connection terminal of the temperature sensor element is exposed for connection to a supply line of the low-voltage network.

[0060] A cable duct is a device or structure used to organize, protect, and guide electrical cables or wires. A cable duct positioned on the mounting surface facilitates linear integration, as the terminal block can be easily connected to the low-voltage supply line. At the same time, the arrangement on the mounting surface can increase creepage and visibility distances. Advantageously, the insulating rib described above also surrounds the cable duct.

[0061] According to a seventh example, the heat exchange portion of the temperature sensor according to each of the above examples has a mounting surface, the mounting surface facing the lid, and the mounting surface having a clamping rib, the clamping rib protruding toward the lid and contacting the lid.

[0062] The contact between the cover and the clamping rib elastically deforms the elastomer mat in the heat exchange section. Specifically, the heat exchange section is pushed toward the measurement window. This creates air bubble-free contact between the high-voltage conductor and the heat exchange part. As described above, this enables more efficient heat energy transfer and rapid measurement feedback.

[0063] The use in connection with the fifth example above, the temperature sensor element arranged in the sensor cavity, is particularly advantageous, since the heat exchange section is pressed toward the temperature sensor element. Two clamping ribs aligned in the same direction, e.g., parallel clamping ribs, which press from two sides against a temperature sensor element arranged in the sensor cavity, are particularly advantageous.

[0064] The clamping rib on the mounting surface reduces the thermal coupling between the cover and the elastomer mat, as it is positioned away from the measurement window. It is particularly advantageous if the clamping rib is only provided in the heat exchange section to reduce the thermal coupling between the cover and the elastomer mat.

[0065] According to an eighth example, the heat exchange section of the temperature sensor according to each of the above examples comprises a first material and the insulation section comprises a second material, wherein the thermal conductivity of the first material is greater than the thermal conductivity of the second material, in particular wherein fillers are admixed in the region of the heat exchange section.

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

[0067] The thermal conductivity of an elastomer mat can be increased, for example, by adding fillers with high thermal conductivity such as graphite, aluminum oxide or boronitride.

[0068] According to a ninth example, the thermal conductivity of the elastomer mat of the temperature sensor according to each of the above examples is higher than the thermal conductivity of the base plate, preferably wherein the thermal conductivity of the elastomer mat is higher than the thermal conductivity of the cover.

[0069] This increases the thermal insulation of the housing parts compared to the elastomer mat.

[0070] According to a tenth example, the cover of the temperature sensor according to each of the above examples comprises a ceiling rib, wherein the ceiling rib projects from the cover into the chamber and at least partially surrounds the heat exchange section, wherein a beveled flank of the ceiling rib contacts the heat exchange section in order to align the elastomer mat perpendicular to the heat transport direction

[0071] The ceiling rib reduces the thermal coupling between the cover and the elastomer mat, as the contact surface is located away from the measurement window. It is particularly advantageous if the ceiling rib touches an edge of the heat exchange section, for example, an edge of the mounting surface, to reduce the thermal coupling between the cover and the elastomer mat.

[0072] According to an eleventh example, the cover of the temperature sensor according to any of the above examples comprises a ceiling rib, wherein a tip of the ceiling rib projects from the cover into the chamber and at least partially surrounds the heat exchange section, in particular, wherein an air pocket is provided between the tip of the ceiling rib and the insulation section to prevent heat conduction between the air pocket and the insulation section.

[0073] The ceiling rib thus increases the visible distance between the heat exchange section and an edge of the insulation section.

[0074] To prevent heat conduction between the cover and the elastomer mat, an air pocket can be provided between the insulation section and the ceiling rib. This also has the advantage of increasing assembly tolerances.

[0075] According to a modification of the eleventh example, in addition to the second and third examples, the cover of the temperature sensor comprises the cover rib that protrudes into a thermal insulation trench formed by the thermal insulation constriction and at least partially surrounds the heat exchange section. This creates a labyrinth that increases the creepage and visibility distances.

[0076] According to a twelfth example, the cover of the temperature sensor according to each of the above examples has a connecting element and the base plate of the temperature sensor according to each of the above examples has a counter-connecting element in order to hold the cover and the base plate together in the connecting direction, wherein the connecting direction preferably runs in the heat transport direction.

[0077] This simplifies assembly. In particular, the connection direction can be selected to coincide with the heat transfer direction, enabling cost-effective linear manufacturing.

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

[0079] This enables a secure connection to the supply line on the sensor housing side. This is particularly advantageous when the temperature sensor is part of a high-voltage connector.

[0080] According to a thirteenth example, the base plate of the temperature sensor according to each of the above examples has a positioning element and the insulating portion of the elastomer mat of the temperature sensor according to each of the above examples has a counter-positioning element for aligning the elastomer mat perpendicular to the heat transport direction.

[0081] A counter-positioning element on the insulation section reduces the thermal coupling between the base plate and the elastomer mat, as the contact surface is positioned away from the measurement window. It is particularly advantageous if the positioning element touches an edge of the insulation section to reduce the thermal coupling between the base plate and the elastomer mat.

[0082] According to a modification of the thirteenth example, an air pocket is provided between an edge of the measuring window and the heat exchange portion to prevent heat conduction between the heat exchange portion and the edge of the measuring window.

[0083] For example, one flank of the heat exchanger section that protrudes through the measuring window is chamfered. This creates an insulating air pocket. This also has the advantage of increasing assembly tolerances.

[0084] A fourteenth example relates to the manufacturing method of a temperature sensor for a high-voltage conductor, the method comprising: Providing a base plate with a measuring window for attachment to the high-voltage conductor and a lid for covering the chamber; Providing a preformed elastomeric mat having an insulation portion and a heat exchange portion, the elastomeric mat being enclosed in the chamber between the base plate and the lid; Arranging a temperature sensor element on the elastomer mat to measure the temperature of the high-voltage conductor and output an electrical temperature signal to a low-voltage network; Forming a chamber in a sensor housing by connecting the base plate to the lid; wherein the heat exchange section is surrounded by the insulation section to electrically insulate the temperature sensor from the high-voltage conductor, and wherein the heat exchange section extends through the measuring window to the high-voltage conductor in a heat transport direction to conduct heat energy between the high-voltage conductor and the temperature sensor element adjacent to the heat exchange section.

[0085] To avoid repetition, reference is made to the above examples of temperature sensors for the manufacturing process. In particular, the manufacturing process serves to manufacture a temperature sensor according to one of the above examples.

[0086] According to a fifteenth example, in the manufacturing method according to the fourteenth example, the preformed elastomer mat is provided as an injection-molded part before the base plate and the lid are joined.

[0087] This means that the elastomer mat can be preformed particularly cost-effectively.

[0088] For a better understanding of the present invention, it will be explained in more detail with reference to the exemplary embodiments illustrated in the following figures. Identical parts are provided with the same reference numerals and component designations. Furthermore, individual features or combinations of features of the various examples shown and described may also represent independent, inventive, or inventive solutions in their own right.

[0089] The present invention will now be described with the aid of the figures.

[0090] They show: Fig. 1 is an exploded view of an example of the temperature sensor; Fig. 2 is a second view of the Fig. 1; Fig. 3 is a sectional view of the Fig. 1, the temperature sensor being assembled; Fig. 4 is a second sectional view of the Fig. 1, wherein the temperature sensor is assembled; and Fig. Figure 5 shows a high-voltage connector with a temperature sensor of the above figures.

[0091] As in the Fig. 1 and Fig. 2, the temperature sensor 10 for a high-voltage conductor (not shown) comprises a sensor housing for forming a chamber, the sensor housing comprising a base plate 100 with a measuring window 110 for attachment to the high-voltage conductor and a cover 200 for covering the chamber.

[0092] The sensor housing extends in a longitudinal direction L from a measuring end, at which the measuring window 110 is arranged, to an opposite connector housing end, at which an opening is provided for electrical connection to a strain relief 120 for a supply line of the low-voltage network.

[0093] The stacking direction of the Fig. 1 to 4 extends along an axis W which is perpendicular to the longitudinal direction L. As shown in the figures, the heat is transported along the stacking direction W by a high-voltage conductor (not shown) through the measuring window 110 to the sensor unit. In particular Fig. 3 shows the direction of heat propagation by the thick lines 333.

[0094] Perpendicular to the heat transport direction W and longitudinal direction L, the sensor housing extends in a transverse direction Q.

[0095] As in Fig. 1, the base plate 100 has positioning elements 116, 117, the strain relief 120, a side wall 130 surrounding the measuring end, and a counter-connecting element 140. The base plate 100 with the components described above can be manufactured in one piece, e.g. as an injection-molded part.

[0096] The positioning elements 116, 117 are rib-shaped projections that can be integrally connected to the base plate 100. They protrude from the base plate 100 in the direction of the axis W and can be connected to the side wall 130.

[0097] The strain relief 120 comprises protrusions that protrude from the base plate toward the axis W and can be integrally connected to it. They form cable ducts for the supply line that extend in the longitudinal direction L and transverse direction Q.

[0098] The side wall 130 encloses the base plate 100 and protrudes from it in the direction of the axis W. In the example shown, it encloses three of the four edges of the rectangular base plate 100. The side walls 130 and the base plate 100 form a cup-shaped receptacle, with the strain relief 120 arranged on the fourth edge.

[0099] Furthermore, the counter-connecting element 140 is provided in the side wall 130 in the form of a through opening.

[0100] As in Fig. As shown in Figure 2, the cover 200 comprises a cover rib 210, positioning elements 216, 217, a side wall 230, and a connecting element 240. The cover 200 with the components described above can be manufactured in one piece, e.g., as an injection-molded part.

[0101] As in Fig. As shown in Figure 3, the ceiling rib 210 extends from the lid 200 into the chamber and at least partially surrounds a heat exchange section 330 of an elastomer mat 300, described later. Furthermore, the ceiling rib 210 has a beveled flank 212 and a tip 214.

[0102] The beveled flank 212 contacts the heat exchange section 330. As in Fig. 3 and Fig. As shown in Figure 4, only the parts of the ceiling rib 210 extending in the longitudinal direction L have the beveled flank 212. This allows the heat exchange section 330 to be aligned, particularly in the transverse direction, while minimizing the contact area.

[0103] As in Fig. 3 to 4, in the assembled state, an air pocket 614 is provided between a tip 214 of the ceiling rib 210 and an insulation section 310 of the elastomer mat 300, described later.

[0104] The positioning elements 216, 217 are rib-shaped projections 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.

[0105] The side wall 230 encloses the lid 200 and protrudes from it in the direction of the axis W. It encloses three of the four edges of the rectangular lid 200. The side walls 230 and the lid 200 form a pot-shaped receptacle, with the fourth wall being partially open.

[0106] Furthermore, the connecting element 240 in the form of a locking hook is provided in the side wall 230.

[0107] As in Fig. 4, the cover 200 and the base plate 100 are held together in the connection direction W by the connecting element 240 and the counter-connecting element 140. Here, the connection direction corresponds to the heat transport direction W. In particular, the side wall 230 of the cover 200 lies within the side wall 130 of the base plate, thus increasing the creepage distance and the line of sight between the high-voltage conductor and the temperature sensor element 410.

[0108] As in Fig. 3 to 4, in the assembled state, an air pocket 614 is provided between the side wall 230 of the lid and the insulation section 310 described later.

[0109] Furthermore, the temperature sensor 10 comprises a sensor unit with a temperature sensor element 410 for measuring the temperature of the high-voltage conductor and for outputting an electrical temperature signal via two connection terminals 420, 422 to mating terminals 520, 522 of a low-voltage network. The mating terminals 520, 522 are routed through the strain relief 120.

[0110] The temperature sensor element 410 is arranged in the chamber. Specifically, the temperature sensor element 410 is housed in a preformed elastomer mat 300. For this purpose, the preformed elastomer mat 300 is enclosed in the chamber between the base plate 100 and the cover 200. This enables simple and cost-effective production, since the temperature sensor element 410 is not cast in the elastomer mat but rather placed within it.

[0111] The Fig. 3 and Fig. The elastomer mat 300 shown in Figure 4 comprises an insulation section 310 extending around the measuring window and a heat exchange section 330. A theoretical boundary between the insulation section 310 and the heat exchange section 330 of the integrally formed elastomer mat 300 is indicated by the dashed line extending in extension of the measuring window edge 112.

[0112] Advantageously, the thermal conductivity of the elastomer mat 300 is higher than the thermal conductivity of the base plate 100. It is particularly preferred if the thermal conductivity of the elastomer mat 300 is also higher than the thermal conductivity of the cover 200.

[0113] The insulation section 310 of the elastomer mat 300 extends along the base plate 100, i.e., in the longitudinal direction L and the transverse direction Q, thereby electrically insulating the temperature sensor, the temperature sensor element 410, and / or the connection terminals 420, 422 from the high-voltage conductor. The above-described air pockets 612 and 614 allow the insulation section 310 and the base plates to rest loosely on one another rather than being pressed together. This reduces thermal coupling. Furthermore, installation tolerances can be increased.

[0114] The isolation section, as particularly in Fig. 3, the heat exchange section 330 has a thermal insulation constriction 312, an electrical insulation rib 314, and a counter-positioning element 316 perpendicular to the axis W. Furthermore, the insulation section 310 has a cable duct 315 open toward the cover in the insertion direction W.

[0115] As in the Fig. As shown in Figures 1 to 4, the thermal insulation constriction 312 surrounds and adjoins the heat exchange section 330. This reduces the heat conduction in the longitudinal direction L and transverse direction Q in the elastomer mat 300 from the heat exchange section 330 to the insulation section 310.

[0116] In particular, the Fig. 3 and Fig. 4 shows that the electrical insulation rib 314 protrudes from the elastomer mat 300 in the heat transfer direction, i.e., along the W axis, 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 measuring window.

[0117] As in the Fig. As shown in Figures 1 to 4, the counter-positioning element 316 rests against two opposite longitudinal sides of the electrical insulation rib 314. Together with the positioning element 116 of the base plate 100, it enables low-stress and simple positioning of the elastomer mat 300 in the longitudinal direction L. The counter-positioning element 316 also increases the creepage distance and the line of sight between the temperature sensor element 410 and the edge 112 of the measuring window.

[0118] The cable duct 315 is arranged on a mounting surface, with the mounting surface facing the cover 200 and the mounting surface facing the cover 200. The cable duct 315 is open to the cover 200. Thus, the connecting terminals 420, 422 of the temperature sensor element 410 are exposed to the mating terminals 520, 522 of the supply line of the low-voltage network before the cover 200 is attached and can be connected easily and cost-effectively during production.

[0119] The heat exchange section 330, as it is particularly shown in Fig. 3, has a contact surface 332 of the high-voltage conductor (not shown) in the heat transport direction W, a sensor cavity 334 in which the temperature sensor element 410 is received and a mounting surface.

[0120] The heat exchange section 330 may comprise a first material, and the insulation section 310 may comprise a second material, wherein the thermal conductivity of the first material is advantageously greater than the thermal conductivity of the second material. Thus, heat can be conducted more efficiently to the temperature sensor element 410.

[0121] The mounting surface of the heat exchange section 330, as shown in Fig. 1 to 4, faces the cover 200. An access is provided on the mounting surface, which has a beveled edge 342. Furthermore, a clamping rib 344 is provided on the mounting surface.

[0122] The contact surface 334 contacts the high-voltage conductor (not shown). As in Fig. 1, Fig. 2 and Fig. As shown in Figure 4, the contact surface 334 is convex in at least one direction. This reduces the formation of air pockets between the heat exchange section 330 and the high-voltage conductor and thus increases the thermal coupling between the high-voltage conductor and the temperature sensor element 410.

[0123] Furthermore, the sensor cavity 334 is arranged in the heat exchange section 330. The sensor cavity is partially open to provide access to the mounting surface. In particular, the temperature sensor element 410 can be easily inserted into the preformed heat exchange section 330 via the beveled edge 342 and is at least partially enclosed by the heat exchange section 330. The arrangement in the sensor cavity enlarges the contact area and thus increases the thermal coupling between the high-voltage conductor and the temperature sensor element 410.

[0124] The clamping rib 344 extends along the axis W from the mounting surface 340 toward the cover 200. In particular, the clamping rib 344 serves to deform the heat exchange section 330 when the cover 200 is mounted to the base plate 100. In particular, the sensor cavity 334 is then compressed, resulting in a larger contact area between the heat exchange section 330 and the temperature sensor 410. Furthermore, the clamping rib 344 allows the heat exchange section to be pressed toward the high-voltage conductor through the measurement window 110, thus improving the contact between the contact surface 332 of the heat exchange section 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.

[0125] A further measure to increase the thermal coupling between the high-voltage conductor and the temperature sensor element 410 and the thermal insulation between the heat exchange section 330 and the base element is the air pocket 616 between an edge 112 of the measuring window and the heat exchange section 330. This also serves to increase the installation tolerances.

[0126] The above measures promote heat conduction along the thick lines 333 in the heat exchange area 330. This is essentially along the direction of the W axis.

[0127] The sensor can be assembled cost-effectively by stacking the parts. First, the base plate 100 is provided with a measuring window 110 for attachment to the high-voltage conductor.

[0128] In a next step, the preformed elastomer mat 300 with the insulation section 310 and the heat exchange section 330 is then incorporated into this base plate.

[0129] The temperature sensor element can already be arranged in the elastomer mat or can be arranged after the elastomer mat has been attached to the base plate.

[0130] Subsequently, the lid 200 is mounted to cover the chamber so that the elastomer mat 300 is enclosed in the chamber between the base plate 100 and the lid 200.

[0131] As described above, a heat exchange portion surrounded by the insulation portion is formed so that the insulation portion electrically insulates the temperature sensor 410 from the high-voltage conductor, and the heat exchange portion extends through the measuring window to the high-voltage conductor in a heat transport direction to conduct heat energy between the high-voltage conductor and the temperature sensor element adjacent to the heat exchange portion.

[0132] Fig. Finally, Figure 5 shows the connection of the temperature sensor to a high-voltage header.

[0133] For example, the preformed elastomer mat can be provided as an injection-molded part before connecting the base plate and the lid.

[0134] Although not shown in the figures, the sensor housing can have a different shape and does not necessarily have to be rectangular. The same applies to the measurement window. List of reference symbols: 10 Temperature sensor 100 base plate 110 measuring windows 112 Edge of the measuring window 116, 117, 216, 217 Positioning element 120 strain relief 130, 230 side wall 140 Counter connecting element 200 lids 210 Ceiling rib 212 bevelled flank 214 lace 230 side wall 240 connecting element 300 elastomer mat 310 Isolation section 312 Thermal insulation constriction 314 electrical insulation rib 314 cable duct 316 Counter-positioning element 330 Heat exchange section 332 contact surface 333 Heat Ouch 334 Sensor cavity 410 Temperature sensor element 420, 422 connection terminals 520, 522 Counter connections 612, 614, 616 air pocket W Heat transport direction and stacking direction L longitudinal direction Q transverse direction

Claims

[1] 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 base plate (100) with a measuring window (110) for attachment to the high-voltage conductor and a lid (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 elastomer mat (300) enclosed in the chamber between the base plate (100) and the lid (200), wherein the elastomer mat (300) has an insulating section (310) extending around the measuring window (110) to electrically insulate the temperature sensor from the high-voltage conductor, and wherein the elastomer mat (300) further comprises a heat exchange section (330) surrounded by the insulation section (310), the heat exchange section (330) extending through the measuring window (110) to the high-voltage conductor in a heat transport direction (W) to conduct heat energy in the heat transport direction (W) between the high-voltage conductor and the temperature sensor element (410) adjacent to the heat exchange section. [2] The temperature sensor (10) according to claim 1, wherein the insulation portion (310) further comprises a heat insulation constriction (312), wherein a thickness of the heat insulation constriction (312) in the heat transport direction (W) is smaller than a thickness of the heat exchange portion (330) in the heat transport direction (W) in order to reduce heat conduction between the heat exchange portion (330) and the insulation portion (310). [3] Temperature sensor (10) according to one of the preceding claims, wherein the insulation section (310) further comprises an electrical insulation rib (314), wherein the electrical insulation rib (314) protrudes from the elastomer mat (300) and at least partially surrounds the temperature sensor element (410) in order to increase a creepage distance between the temperature sensor element (410) and the measuring window (110). [4] Temperature sensor (10) according to one of the preceding claims, wherein the heat exchange section (330) has a contact surface (332), wherein the contact surface (332) protrudes from the elastomer mat (300) counter to the heat transport direction (W) from the measuring window (110) of the sensor housing, in particular wherein the contact surface (332) has a convex shape. [5] Temperature sensor (10) according to one of the preceding claims, wherein the heat exchange section (330) has a sensor cavity (334) in which the temperature sensor element (410) is received. [6] Temperature sensor (10) according to one of the preceding claims, wherein the heat exchange section (330) has a mounting surface, wherein the mounting surface is opposite the cover (200) and wherein the mounting surface (340) has an access to receive the temperature sensor element (410) through the access into the heat exchange section (330), wherein the access preferably has a beveled edge (342), in particular wherein the heat exchange section (330) has the sensor cavity (334) according to claim 5; and / or wherein the insulation section (310) has a mounting surface, wherein the mounting surface is opposite the cover (200) and wherein the mounting surface has a cable duct (315) open towards the cover (200), in which a connection terminal (420, 422) of the temperature sensor element (410) is exposed for connection to a supply line of the low-voltage network. [7] Temperature sensor (10) according to one of the preceding claims, wherein the heat exchange section (330) has a mounting surface, the mounting surface facing the cover (200) and the mounting surface (340) has a clamping rib (344), the clamping rib (344) protruding towards the cover (200) and contacting the cover (200). [8] Temperature sensor (10) according to one of the preceding claims, wherein the heat exchange section (330) comprises a first material and the insulation section (310) comprises a second material, wherein the thermal conductivity of the first material is greater than the thermal conductivity of the second material, in particular wherein fillers are admixed in the region of the heat exchange section (330). [9] Temperature sensor (10) according to one of the preceding claims, wherein the thermal conductivity of the elastomer mat (300) is higher than the thermal conductivity of the base plate (100), preferably wherein the thermal conductivity of the elastomer mat (300) is higher than the thermal conductivity of the cover (200). [10] Temperature sensor (10) according to one of the preceding claims, wherein the cover (200) comprises a ceiling rib (210), wherein the ceiling rib (210) projects from the cover (200) into the chamber and at least partially surrounds the heat exchange section (330), wherein a beveled flank (212) of the ceiling rib (210) contacts the heat exchange section (330) in order to align the elastomer mat perpendicular to the heat transport direction. [11] Temperature sensor (10) according to one of the preceding claims, wherein the cover comprises a ceiling rib, wherein a tip (214) of the ceiling rib (210) projects from the cover (200) into the chamber and at least partially surrounds the heat exchange section (330), in particular wherein an air pocket (612) is provided between the tip (214) of the ceiling rib (210) and the insulation section (310) to prevent heat conduction between the tip (214) and the insulation section (310). [12] Temperature sensor (10) according to one of the preceding claims, wherein the cover (200) has one or more connecting elements (240) and the base plate (100) has one or more counter-connecting elements (140) in order to hold the cover (200) and the base plate (100) together in the connecting direction (W), wherein the connecting direction (W) preferably runs in the heat transport direction (W), and / or wherein the temperature sensor element (410) is arranged at a measuring end of the sensor housing and the sensor housing has a strain relief (120) for a supply line of the low-voltage network at a plug housing end opposite the measuring end. [13] Temperature sensor (10) according to one of the preceding claims, wherein the base plate (100) has a positioning element (116, 117) and the insulation section (310) of the elastomer mat (300) has a counter-positioning element (316) for aligning the elastomer mat (300) perpendicular to the heat transport direction, and / or wherein an air pocket (616) is provided between an edge (112) of the measuring window (110) and the heat exchange section (330) in order to prevent heat conduction between the heat exchange section (330) and the edge (112) of the measuring window (110). [14] Manufacturing method of a temperature sensor (10) for a high-voltage conductor, the method comprising: Providing a base plate (100) with a measuring window (110) for attachment to the high-voltage conductor and a lid (200) for covering the chamber; Providing a preformed elastomer mat (300) having an insulation section (310) and a heat exchange section (330), the elastomer mat (300) being enclosed in the chamber between the base plate (100) and the lid (200); Arranging a temperature sensor element (410) on the elastomer mat (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 a sensor housing by connecting the base plate (100) to the cover (200); wherein the heat exchange section (330) is surrounded by the insulation section (310) so that the insulation section (310) electrically insulates the temperature sensor from the high-voltage conductor, and wherein the heat exchange section (330) extends through the measuring window (110) to the high-voltage conductor in a heat transport direction (W) to conduct heat energy between the high-voltage conductor and the temperature sensor element (410) adjacent to the heat exchange section (330). [15] Manufacturing method of a temperature sensor (10) for a high-voltage conductor according to claim 14, wherein the preformed elastomer mat (300) is provided as an injection-molded part before connecting the base plate (100) and to the cover (200).

Images