Assembly for an overvoltage protection device, overvoltage protection device and method for producing an assembly

Abstract

The invention relates to an assembly for an overvoltage protection device (10), with a disconnecting means (18) which has a spring arm (20) with a contact point (24) on the end side, and a holding element (22). The holding element (22) and the contact point (24) lie opposite each other in a starting position of the assembly (11). A thermally meltable material (26) is provided between the holding element (22) and the contact point (24), the material connecting the spring arm (20) both mechanically and also electrically to the holding element (22). The assembly (11) has a remote signalling contact (50) with a mechanical separating point (48). The spring arm (20), the holding element (22) and the remote signalling contact (50) are produced from a common punched sheet (14). The punched sheet (14) is at least partially insert-moulded with a plastics material which forms a frame (16). The invention also relates to an overvoltage protection device.

Description

[0001] Assembly for a surge protection device, surge protection device and method for producing an assembly

[0002] The invention relates to an assembly for a surge protection device and a surge protection device. Furthermore, the invention relates to a method for producing an assembly.

[0003] It is known from the prior art that a surge protection device is used to protect electrical components from overload if they have to operate outside their rated operating range.

[0004] For this purpose, it is known, for example, to provide a thermal break point that triggers when contacts of the thermal break point heat up due to excessive stress, for example, due to a corresponding current. Due to the resulting thermal stress, a thermally softenable material that is part of the thermal break point softens, thereby interrupting an electrical connection. Such an arrangement is known, for example, from DE 102011 100437 B4, but it requires numerous components that must be coupled together to provide the required functionality. This makes manufacturing and assembly more complicated, which in turn results in higher costs.

[0005] In any case, the thermal separation point ensures that in the event of thermal overload, a component to be protected is separated within a correspondingly short time.

[0006] Furthermore, it is known from the prior art that a separate disconnection point for a telecommunications circuit is formed using two gold contacts, but this leads to correspondingly high costs due to the material used. The object of the invention is to enable a cost-effectively manufactured surge protection device with a corresponding disconnection device.

[0007] The object is achieved according to the invention by an assembly for a surge protection device with a disconnection device, which comprises a spring arm with a contact point at its end and a holding element. The holding element and the contact point are located opposite one another at an output point of the assembly, with a thermally softenable material being provided between the holding element and the contact point, which connects the spring arm both mechanically and electrically to the holding element. The assembly comprises a remote signaling contact with a mechanical disconnection point. The spring arm, the holding element, and the remote signaling contact are made from a common stamped sheet. The stamped sheet is at least partially overmolded with a plastic material that forms a frame.

[0008] The basic idea of ​​the invention is to provide a simply constructed disconnecting device that can be integrated into a surge protection device. At the same time, the remote signaling contact is formed with the mechanical disconnecting point. This is possible because the retaining element, the spring arm, and the remote signaling contact are made from a single piece of material, namely the common stamped sheet metal, so that at least these three components—the spring arm, the retaining element, and the remote signaling contact—are formed from a single piece.

[0009] It is therefore no longer necessary to provide multiple, separately manufactured components that must be assembled individually, resulting in correspondingly high assembly and manufacturing costs. Consequently, the assembly according to the invention can be manufactured more easily, quickly, and thus more cost-effectively.

[0010] In addition, the stamped sheet, i.e., the components formed from the stamped sheet, can be directly overmolded with plastic material, forming the frame on which the corresponding functional components necessary for the functioning of the separating device can be provided. This also results in cost advantages, as the frame made of plastic material can directly incorporate the required functional components, eliminating the need for these components to be manufactured and subsequently assembled separately. The number of required components can thus be reduced, which in turn reduces manufacturing and assembly costs.

[0011] The plastic material serves primarily to hold the various components made from the stamped sheet metal, i.e., the remote signaling contact with the mechanical separation point, the retaining element, and the spring arm with the contact point. This is achieved by at least partially embedding the components made from the common stamped sheet metal in the frame, i.e., by overmolding them with the plastic material from which the frame is formed.

[0012] In this respect, cost-efficient production can be achieved, especially for large quantities.

[0013] In particular, a lead frame is provided. The lead frame corresponds to a system of electrical conductors made from a metal strip, for example, a stamped sheet. In this respect, the lead frame resembles a printed circuit board.

[0014] The stamped sheet has therefore been pre-processed into a stamped grid, especially before the plastic material is overmolded. For this purpose, the stamped sheet may have been previously formed and / or punched to create a three-dimensional stamped grid.

[0015] In addition, the stamped sheet, in particular the electrical conductors, may have been at least partially galvanized, for example corresponding surfaces.

[0016] In addition to the three components of the assembly mentioned above, which are made from the stamped sheet metal, i.e. the spring arm, the holding element and the remote signaling contact, two contacts for the electrical connection of the separating device as well as electrodes for an electrical component can also be formed through the stamped sheet metal.

[0017] Consequently, the stamped sheet provides numerous components of the assembly, in particular up to seven different components. For example, the numerous components are formed by parts that are separately formed and obtained from the stamped sheet. A part can also comprise more than one component.

[0018] A first plug contact can be formed integrally with the spring arm. The holding element can be formed integrally with one of the electrodes for the electrical component. Furthermore, the second electrode for the electrical component can be electrically conductively coupled to a second plug contact in the assembled state.

[0019] The remote signaling contact can be designed separately from the other components, but can still be held by the frame made of plastic material.

[0020] In the initial state, current flows to the holding element via the first plug contact and the spring arm formed integrally therewith, since the connection between the contact point and the holding element is closed—i.e., the thermal separation point. The holding element is formed integrally with the first electrode for the electrical component, so that the current then flows from the first electrode through the electrical component to the second electrode, which can be formed by a contact plate. The second electrode is electrically conductively coupled to the second plug contact, allowing the current to flow via the second plug contact.

[0021] The remote signaling contact can be located in a remote signaling circuit through which a current flows. As soon as the module is triggered, both the current flow via the thermal break point is interrupted and the mechanical break point of the remote signaling contact is mechanically separated, thus interrupting the current flow in the remote signaling circuit.

[0022] In principle, the thermally softenable material can ensure a material connection between the holding element and the contact point of the spring arm in the initial position of the assembly.

[0023] During assembly of the module, it may be provided that the thermally softenable material is first applied to the retaining element, so that the spring arm is later shaped, in particular bent, so that the contact point at the end of the spring arm comes into contact with the thermally softenable material. The mechanical and electrical connection can then be established using, for example, an inductive soldering process.

[0024] The thermally softenable material is applied in particular after the components formed from the stamped sheet have been embedded in the plastic material, i.e. embedded in the frame.

[0025] One aspect provides that a thermal separation point is formed between the holding element and the contact point using the thermally softenable material. The mechanical and electrical connection between the contact point of the spring arm and the holding element can thus be thermally severed if the thermally softenable material is heated. Consequently, the state of the thermally softenable material changes when it is heated, in particular above a defined temperature.

[0026] For example, the thermally softenable material is a solder. Accordingly, a solder connection is provided between the holding element and the contact point.

[0027] Alternatively, an electrically conductive adhesive can be provided which is temperature sensitive and softens when the adhesive is heated.

[0028] The spring arm can have a projection that extends into an opening provided in the retaining element, particularly in the region of the contact point. The projection can also be referred to as a tab. The projection can have a height that is greater than the material thickness of the retaining element. The projection thus penetrates the retaining element. A larger surface contact can be realized, for example, on at least two surfaces that are perpendicular to each other, namely the surface of the spring arm from which the projection protrudes, and sides of the projection that are associated with the edge of the opening in the retaining element.

[0029] A further aspect provides that the assembly has a lever that serves to mechanically separate the mechanical separation point of the remote signaling contact and / or to open the connection between the holding element and the contact point in a defined manner. The lever is therefore provided, among other things, to separate the electrical and mechanical connection between the holding element and the contact point in a defined manner. Due to its shape, the lever arm ensures that when the connection between the holding element and the contact point is opened, the spring arm moves far enough that no arc can occur between the contact point and the holding element. This is understood as the defined opening of the thermal separation point.

[0030] In addition, the lever can be provided to mechanically separate the mechanical separation point of the remote signaling contact, i.e. to mechanically interrupt it.

[0031] In particular, both the mechanical interruption of the mechanical separation point and the (defined) opening of the thermal separation point occur (essentially) simultaneously. The lever acts on both the thermal separation point (indirectly via the spring arm) and the mechanical separation point (directly).

[0032] The lever can have a first lever arm that interacts with a preload element. The preload element can be an elastically preloaded preload element, e.g. a spring element. Due to the shape of the lever, the preload force applied by the preload element to the first lever arm is converted into a lever force that acts on the spring arm, whereby a separating force acts on the connection between the holding element and the contact point. If the separating force is greater than the holding force generated by the thermally softenable material, the connection is separated accordingly. However, this is only possible if the holding force of the thermally softenable material provided between the holding element and the contact point decreases due to thermal influences (heating). The preload element and the design of the lever ensure that a defined lever force is present that acts on the spring arm.The spring arm, in turn, is designed in such a way that a defined separating force acts on the thermally softenable material. In other words, the separating force can be adjusted by the design of the preload element, the lever, and the spring arm. The design is such that the holding force generated by the thermally softenable material in its initial state is not initially exceeded by the separating force. The elastically preloaded preload element therefore presses on the first lever arm of the lever, causing the preload force to act on the first lever arm, which is transmitted, among other things, via the lever to the thermally softenable material.

[0033] The lever can have a second lever arm that is opposite to the first lever arm. In principle, a gap can be provided between the end of the second lever arm and the spring arm, ensuring that the thermal isolation point and the remote signaling contact are separated first.

[0034] The second lever arm can act on the spring arm over at least a portion of the spring arm to assist opening or to hold the spring arm in an open position. The lever design, in particular the two lever arms, could thus adjust the leverage generated by the preloading element by means of the lever.

[0035] In addition, the separating force acting on the thermally softenable material can be adjusted by the design of the spring arm on which the second lever arm acts.

[0036] The lever can have reinforcing ribs or a truss structure, ensuring that the lever does not twist. Thanks to the reinforcing ribs or truss structure, the lever can be lightweight for the achieved stiffness, especially compared to a lever made of solid material with the same stiffness.

[0037] A further aspect provides for a pin to be provided on the lever which interacts with the mechanical separation point of the remote signaling contact. The pin can protrude laterally from a base body of the lever. In this respect, the pin extends in a direction that is (essentially) perpendicular to the extension directions of the two lever arms of the lever. If the lever moves from its initial position to the triggered position, which can also be referred to as the end position or end position, the pin arranged on the lever moves with the lever, whereby the lever severs or interrupts the mechanical separation point of the remote signaling contact. The pin can therefore be referred to as a pivot pin, since the pin performs a pivoting movement when the lever moves from the initial position to the triggered position.In its end position, which corresponds to the tripped position, the pin ensures, among other things, that the separated section of the remote signaling contact cannot return to its original position. This ensures the required clearance and creepage distances.

[0038] The lever itself can also be an injection-molded part.

[0039] The frame formed from the plastic material can include a bearing for the lever. The bearing defines the lever's axis of rotation, around which the lever can rotate when the assembly is triggered and enters the triggered state. Since the bearing for the lever is formed by the plastic material itself, it is not necessary to provide a separate bearing that would first have to be attached to a support. This simplifies assembly and manufacturing. In particular, the lever is simply placed on the bearing formed by the plastic material during assembly.

[0040] In addition, the frame made from the plastic material can have a stop for the first lever arm, against which the first lever arm strikes in a triggered position, i.e. the end position. This ensures that the lever performs a defined movement when the thermally softenable material loses its mechanical strength, i.e. the holding force decreases, causing the lever to rotate due to the preload force of the preload element. The stop then ensures that the lever only performs a defined rotation, e.g. through an angle of 40°. Since the stop is formed by the plastic material itself, the assembly can be designed accordingly simply, as a separately formed stop is not necessary. This ensures that the spring arm assumes a defined end position when the separating device is in the triggered position or the end position.

[0041] Another aspect provides that the frame forms a base plate that is substantially parallel to a main section of the stamped sheet. The main section of the stamped sheet is, in particular, a section of the stamped sheet that is mechanically unprocessed, i.e., has not been formed, in particular, has not been bent. For example, the main section of the stamped sheet corresponds to the first electrode for the electrical component.

[0042] The base plate thus represents the basis of the frame made of the plastic material, from which structures protrude to form functional components of the separation device, e.g. the bearing for the lever, the stop for the first lever arm or other functional components.

[0043] In particular, the base plate has a recess in which the lever's pin is movably accommodated. The recess can therefore define the lever's maximum possible range of motion, since the lever can only move in the same way as the pin can move within the recess.

[0044] In particular, at least one edge of the recess forms a stop point for the pin, against which the pin can strike in a released position. This creates a further stop point for the lever, in particular its pin, which limits the movement of the lever in the released state, for example, to a rotation angle of 40°. This position corresponds to the technical end position of the lever.

[0045] Furthermore, the assembly can include an electrical component. The electrical component can be electrically coupled to the holding element, so that an electrical connection to the electrical component exists via the holding element. For this purpose, a soldered connection, for example in the form of a solder paste, can be provided between the stamped sheet, in particular the first electrode formed by the stamped sheet, and the electrical component. The soldered connection is advantageous with regard to the thermal function of the separation device.

[0046] In principle, the electrical component can be in thermal contact with the stamped sheet, for example via the holding element or generally the main section of the stamped sheet, which forms the first electrode for the electrical component. Heating of the electrical component leads to heating of the stamped sheet, in particular of the first electrode, which in turn leads to the holding element, which can be made integrally with the first electrode from the shared stamped sheet and contacts the thermally softenable material, being heated accordingly, whereby the thermally softenable material softens. The separation device therefore reacts to heating of the electrical component, causing it to trigger and the thermal separation point to separate. In this case, the lever presses the spring arm into the technical end position, i.e. the triggered position, due to the pretensioning force of the pretensioning element.

[0047] Simultaneously or (directly) sequentially, the pin on the lever interrupts the mechanical separation point of the remote signaling contact, signaling the activation of the module. Preferably, the pin interrupts the mechanical separation point of the remote signaling contact shortly after the thermal separation point has been opened. This means that the lever or pin has traveled a certain distance before the pin interrupts the mechanical separation point of the remote signaling contact.

[0048] The electrical component can be arranged on a side of the stamped sheet, in particular the first electrode for the electrical component formed therefrom, which faces away from the spring arm. This results in a compact design, since the mechanically moving parts are arranged on one side of the stamped sheet, in particular on one side of the first electrode, whereas the electrical component is arranged on an opposite side of the stamped sheet or the first electrode. In particular, the moving components are separated from the electrical component by the base plate of the frame.

[0049] A further aspect provides that a contact plate is arranged on the electrical component, from which a contacting section extends through an opening in the frame formed by the plastic material. The contact plate represents the second electrode for the electrical component. The electrical component can be electrically contacted via the contact plate and the contacting section, so that a current can flow through the electrical component. The contacting section protrudes in particular perpendicularly from the contact plate. The opening provided in the frame formed by the plastic material also ensures that a defined arrangement of the contact plate in relation to the assembly is possible. The second plug contact is partially arranged in the opening, so that it can be contacted.The contacting section establishes an electrical contact in the area of ​​the opening in the frame with a second plug contact of the assembly, which is also formed from the stamped sheet metal.

[0050] The contact plate can be electrically and mechanically attached to the electrical component by means of a soldered connection, in particular a solder paste. In principle, the soldered connection can also be realized using solder plates. Alternatively, a welded connection or a mechanical connection, such as a riveted connection, can also be provided.

[0051] The electrical component is, for example, a varistor, in particular a metal oxide varistor.

[0052] A gas discharge tube (GDT) may also be provided.

[0053] In addition, the frame can form a receptacle for the electrical component. This receptacle ensures that the electrical component is securely held within the frame, thereby maintaining a defined position within the frame. The receptacle can also provide a mechanical positive fit for the electrical component.

[0054] In particular, the mount can have a snap connection for mechanically fastening the electrical component to the frame. This provides mechanical security for the electrical component, eliminating the need for additional connecting elements, which further simplifies the installation of the surge protection device.

[0055] The corresponding snap connection may have been formed when the stamped sheet was overmolded with the plastic material.

[0056] According to a further aspect, the spring arm, at its end opposite the contact point, transitions via a tapered pivot point into a connecting section made from the common stamped sheet metal, wherein the spring arm can pivot about the tapered pivot point. The tapered pivot point ensures that the force applied by the lever does not have to be too great to pivot the spring arm about the pivot point. At the same time, this allows the preload element to be designed with a reduced preload force, thereby reducing the load on the electrical and mechanical connection established via the thermally softenable material. For example, the tapered pivot point has an opening, resulting in the material taper.

[0057] The connecting section may have been created by partially forming the stamped sheet metal.

[0058] The spring arm can have a first and a second section extending at an angle to each other that differs from 0° and 180°, respectively, with the second section comprising the contact point. The correspondingly designed spring arm ensures a compact design while still providing the largest possible contact surface for the lever, allowing the spring arm to be easily pivoted.

[0059] The two sections of the spring arm can be aligned in such a way that a kink is formed in the spring arm. The corresponding kink is created by the two sections.

[0060] The contact point of the spring arm may have a window into which an angled web is inserted, which is soldered to the edge of the window.

[0061] In addition, an outer housing can be provided, which at least accommodates the frame. The outer housing surrounds all components of the separating device, thus protecting them from the outside. Furthermore, the outer housing ensures that the clearance and creepage distances are maintained.

[0062] In particular, the outer housing is designed like a hood. The outer housing is mounted on the frame, which has two (essentially) parallel contact surfaces for the outer housing and a contact surface perpendicular to the two (essentially) parallel contact surfaces. This ensures that the outer housing is guided during installation, resulting in a defined position. This simplifies the installation of the surge protection device.

[0063] In particular, the snap connection is formed on the edge portion of the frame, which simultaneously provides the support surface. The corresponding edge portion can be spring-loaded to ensure the snap connection.

[0064] Alternatively or additionally, it may be provided that resilient edge sections are formed on sides that are perpendicular to the support surface.

[0065] In principle, the stamped sheet, in particular the stamped grid, can have contacts for electrical connection, for example, contact pins, contact plugs, or the like. These can be used to connect the assembly to another assembly, in particular by soldering or plugging it in.

[0066] In addition, the invention provides a surge protection device which has an assembly of the type mentioned above.

[0067] The surge protection device can be a surge arrester, i.e. a device or component for limiting dangerous overvoltages in electrical cables and devices.

[0068] The invention further relates to methods for producing an assembly for a surge protection device. The method comprises the following steps:

[0069] Providing a punching sheet,

[0070] - Forming a remote signaling contact from the stamped sheet, whereby the remote signaling contact has a mechanical separation point,

[0071] - Forming a spring arm with an end contact point from the stamped sheet,

[0072] - Forming a holding element from the stamped sheet, so that the holding element and the contact point are opposite each other in an initial position of the assembly,

[0073] - Applying a thermally softenable material between the holding element and the contact point, which connects the spring arm both mechanically and electrically to the holding element, and

[0074] The stamped sheet is at least partially overmolded with a plastic material to form a frame. The remote signaling contact, the spring arm, and the retaining element are thus manufactured from a single stamped sheet, which reduces manufacturing costs accordingly. The remote signaling contact is therefore designed to be made from the same material as the spring arm and the retaining element.

[0075] In particular, the remote signaling contact, the spring arm and / or the holding element are manufactured by forming the stamped sheet metal, for example by bending the stamped sheet metal.

[0076] When forming the remote signaling contact, its mechanical separation point can be created by tapering the material, for example, by a web that has at least one constriction. It can also be provided that the mechanical separation point is provided with a notch during the formation of the remote signaling contact.

[0077] Furthermore, the spring arm can be manufactured in the desired manner during the formation of the spring arm, i.e. the forming of the stamped sheet, so that the spring arm, for example, has a pivot point with a tapered material.

[0078] In addition, a lever, in particular with a first lever arm and a second lever arm, can be provided, which is arranged on a bearing, in particular a bearing formed by the frame.

[0079] An assembly of the type mentioned above can therefore be manufactured using the process.

[0080] The previously mentioned advantages and properties with regard to the assembly result in an analogous manner for the process.

[0081] Further advantages and features of the invention will become apparent from the following description and the drawings, to which reference is made. In the drawings:

[0082] Figure 1 is a perspective view of an overvoltage protection device according to the invention with an assembly according to the invention in the initial position, Figure 2 is the overvoltage protection device from Figure 1 in the triggered position,

[0083] Figure 3 shows the surge protection device from Figure 1 in a different perspective view,

[0084] Figure 4 shows the surge protection device from Figure 1 in a front view,

[0085] Figure 5 shows the surge protection device from Figure 1 in an exploded view in a perspective view,

[0086] Figure 6 shows the exploded view from Figure 5 in a different perspective,

[0087] Figure 7 is a front view of the remote signaling contact according to a first embodiment in the initial position,

[0088] Figure 8 is a detailed view of Figure 7,

[0089] Figure 9 shows the remote signal contact of Figure 7 in the triggered position,

[0090] Figure 10 is a detailed view of Figure 9,

[0091] Figure 11 is a front view of the remote signaling contact according to a second embodiment in the initial position,

[0092] Figure 12 is a detailed view of Figure 11,

[0093] Figure 13 shows the remote signal contact of Figure 11 in the triggered position,

[0094] Figure 14 is a detailed view of Figure 13,

[0095] Figure 15 is a front view of the remote signaling contact according to a third embodiment in the initial position,

[0096] Figure 16 is a detailed view of Figure 15,

[0097] Figure 17 shows the remote signal contact of Figure 15 in the triggered position,

[0098] Figure 18 is a front view of the remote signaling contact according to a fourth embodiment in the initial position,

[0099] Figure 19 is a detailed view of Figure 18,

[0100] Figure 20 shows the remote signal contact of Figure 18 in the triggered position, Figure 21 shows a detailed view of Figure 20,

[0101] Figure 22 is a side perspective view of the remote signaling contact according to a variant embodiment,

[0102] Figure 23 is a partial view of Figure 22,

[0103] Figure 24 is a side perspective view of the remote signaling contact according to a further embodiment,

[0104] Figure 25 is a partial view of Figure 24,

[0105] Figure 26 is a partially sectioned view of the surge protection device from Figure 1,

[0106] Figure 27 is a detailed view of Figure 26,

[0107] Figure 28 is a side view of the representation of Figure 26,

[0108] Figure 29 is a detailed view of Figure 28, and

[0109] Figure 30 is a perspective view of the representation of Figure 26.

[0110] Figures 1 to 10 show a surge protection device 10 which is intended to protect electronic components and has an assembly 11.

[0111] The assembly 11 has an outer housing 12 that (completely) surrounds internal components of the surge protection device 10 or the assembly 11.

[0112] In particular, the outer housing 12 is designed like a hood, as can be seen from Figures 5 and 6, since the outer housing 12 has only one open side 13.

[0113] In addition, the assembly 11 has a stamped sheet 14 from which several components of the surge protection device 10 or the assembly 11 are formed, as will be explained below.

[0114] The stamped sheet 14, or the components formed therefrom, are at least partially overmolded with a plastic material that forms a frame 16. The stamped sheet 14 has been mechanically processed, for example, by forming sections and contacts, in particular by bending them. Consequently, it is a stamped grid that has a three-dimensional shape, as can be seen from the figures.

[0115] Furthermore, the assembly 11 comprises a separating device 18 composed of several components. The separating device 18 includes, among other things, a spring arm 20 having a first section 20a and a second section 20b extending at an angle to each other, thereby forming a bend 21 between the two sections 20a, 20b.

[0116] In addition, the separating device 18 comprises a holding element 22 which interacts with the spring arm 20, as will be explained below.

[0117] The spring arm 20 and the retaining element 22 were both manufactured from the common stamped sheet metal 14 by punching out and / or forming corresponding areas of the stamped sheet metal 14 to form the components. The spring arm 20 and the retaining element 22 were thus produced by punching and / or forming the stamped sheet metal 14.

[0118] Furthermore, further components are formed from the stamped sheet 14, in particular the stamped grid, which serve for the electrical connection of the separating device 18, namely a first contact 23a and a second contact 23b. The two contacts 23a, 23b are designed, for example, as contact pins, contact plugs, or the like. The contacts 23a, 23b can also have been produced by stamping and / or forming the stamped sheet 14.

[0119] For example, the first contact 23a is formed integrally with the spring arm 20, so that the two components have been punched out together and formed accordingly by forming.

[0120] The second contact 23b, however, may have been punched out of the stamped sheet 14 as a separate component.

[0121] The spring arm 20 has a contact point 24 formed at a free end of the spring arm 20. In the initial position of the assembly 11, which is shown in Figures 1, 3, and 4, the contact point 24 lies opposite the holding element 22, wherein a thermally softenable material 26, for example, a solder, is provided between the holding element 22 and the contact point 24.

[0122] The thermally softenable material 26 ensures both a mechanical and an electrical connection between the contact point 24 and the holding element 22, which, however, is separable. In this respect, the thermally softenable material 26 forms a thermal separation point 27.

[0123] The spring arm 20 passes into the first contact 23a via a material-tapered pivot point 28.

[0124] The tapered pivot point 28 is provided at an end of the spring arm 20 opposite the contact point 24, whereby the spring arm 20 can pivot about the corresponding tapered pivot point 28 when the assembly 11 enters a triggered state, as explained below. For example, the tapered pivot point 28 is provided with an opening 29, which accordingly improves the pivoting behavior of the spring arm 20 about the pivot point 28.

[0125] Furthermore, the spring arm 20 has an embossing 30.

[0126] The embossing 30 can be provided on the first section 20a to stiffen the spring arm 20. In this respect, the embossing 30 forms a stiffening rib in the first section 20a.

[0127] In the second section 20b, at least one embossed portion 30, in particular two embossed portions 30, can (likewise) be provided in the region of the contact point 24 to form spacers. This ensures a defined distance between the contact point 24 and the holding element 22 in order to adjust the thickness of the thermally softenable material 26 provided between the contact point 24 and the holding element 22.

[0128] Basically, the assembly 11 also has a lever 32, which in the embodiment shown comprises a first lever arm 34 and a second lever arm 36, via which the lever 32 interacts with a preloading element 38, in particular an elastic preloading element such as a spring, or the spring arm 20. The preloading element 38 generates a preload force acting on the first lever arm 34, causing the lever 32 to rotate about a rotation axis D. Due to the preload force, the second lever arm 36 presses against the spring arm 20, which is mechanically fastened to the holding element 22 via the contact point 24 by means of the thermally softenable material 26.

[0129] The lever 32, in particular the two lever arms 34, 36, the spring arm 20, the thermally softenable material 26 and the prestressing element 38 are coordinated with one another in such a way that the mechanical connection of the thermally softenable material 26 generates a sufficiently high holding force so that the lever 32 initially remains in the initial position shown in Figures 1, 3 and 4.

[0130] In the event of thermal heating of the thermally softenable material 26, which occurs, for example, due to an increased current flow through the electrically conductive connection created by the thermally softenable material 26 and / or due to thermal coupling of a warm component, the thermally softenable material 26 can become softer, whereby the mechanical connection generates a lower holding force, so that the preloading element 38 adjusts the lever 32. The lever 32 is rotated about the rotation axis D, which runs through a bearing 40 for the lever 32, which is provided by the plastic material of the frame 16.

[0131] During assembly of the assembly 11, the lever 32 may have been placed on the bearing 40, whereby the lever 32 can be easily mounted on the frame 16.

[0132] When the lever 32 rotates, the second lever arm 36 engages the spring arm 20, causing it to pivot about the tapered pivot point 28, so that there is no longer any mechanical or electrical connection between the contact point 24 and the holding element 22, as shown in Figure 2.

[0133] The spring arm 20 is thus pivoted due to the preload force of the preload element 38 if the thermally softenable material 26 forming the thermal separation point 27 no longer generates a sufficiently high holding force. The preload element 38 is designed such that the spring arm 20 reliably reaches its end position in the event of a triggering event, thereby ensuring that no arc forms between the contact point 24 and the holding element 22. For this purpose, it can also be provided that the lever 32 partially covers the holding element 22 when it is in the end position.

[0134] The frame 16 formed from the plastic material also forms a stop 41 for the first lever arm 34 of the lever 32, as can be seen from Figure 2, so that the maximum movement or rotation of the lever 32 is limited by the frame 16.

[0135] The corresponding stop 41 is thus formed integrally with a base plate 42 of the frame 16, which is substantially parallel to a main portion 43 of the punching sheet 14, which has not been mechanically deformed.

[0136] The base plate 42 also includes a recess 44 into which a pin 46 of the lever 32 extends, the pin 46 being movably received in the recess 44. An edge of the recess 44 can form a stop point for the pin 46, thereby again limiting the freedom of movement of the lever 32.

[0137] The pin 46 essentially serves to open a mechanical isolating point 48 of a remote signaling contact 50 when the module 11 moves from the initial position to the triggered position, i.e., the end position. The remote signaling contact 50 is part of a remote signaling circuit 52, via which the status of the module 11 or the surge protection device 10 is reported.

[0138] The lever 32 moves, as already described above, due to the softening of the thermally softenable material 26 and the preload force emanating from the preload element 38, so that the pin 46 performs a pivoting movement and in the process interrupts the mechanical separation point 48 of the remote signaling contact 50, thereby interrupting the remote signaling circuit 52.

[0139] The mechanical separation point 48 is formed by a web 54, which in the first embodiment (Figures 4 and 7 to 10) has two narrow points 56. The two narrow points 56 are each formed by cutting into the web 54 on both sides, i.e., the material thickness of the web 54 tapers from both sides.

[0140] Furthermore, it can be provided that only one of the two constrictions 56, in this case the constriction 56 shown below in the figures, has at least one embossing, thereby ensuring that the first constriction 56 functions as the axis of rotation, while the second constriction 56 is separated. The embossing reduces the cross-section and is thus the weakened point. This ensures that the clearance and creepage distances are sufficient and that a safe end position is also achieved.

[0141] Figures 7 to 10 show that when the lever 32 is pivoted, the pin 46 is moved against the web 54, thereby separating the mechanical separation point 48 in the region of at least one of the two constrictions 56. The remaining part of the web 54 can then be pivoted around the other of the two constrictions 56 when the lever 32 moves further toward the end position with the pin 46, as illustrated in Figures 9 and 10. However, when the mechanical separation point 48 is separated, separation can also occur at both constrictions 56. In either case, the web 54 is destroyed by the pin 46.

[0142] Figures 7 and 9 show the back of the stamped sheet 14, in particular the main section 43, which forms a first electrode 58 for an electrical component 60.

[0143] The punched sheet 14, in particular the main section 43, is embedded in the frame 16, as can be seen from Figures 26 to 30, in which the frame 16 is shown partially in section.

[0144] Further components made from the stamped sheet 14 may also be at least partially embedded in the frame 16, in particular the section comprising the first contact 23a, the second contact 23b and / or the remote signaling contact 50.

[0145] Figures 5 and 6 show the electrical component 60, which is designed, for example, as a varistor. The electrical component 60 is arranged on a side of the stamped sheet 14 that faces away from the lever 32, as illustrated in Figures 5 and 6.

[0146] This ensures that the mechanically moved components of the separating device 18 are arranged on one side of the punched sheet 14, in particular the main section 43, whereas the electrical component 60 is located on an opposite side of the punched sheet 14.

[0147] The electrical component 60 is electrically connected to the holding element 22 via the first electrode 58. The electrical component 60 is also thermally coupled to the first electrode 58 and thus to the holding element 22.

[0148] The thermal and electrical coupling of the electrical component 60 to the first electrode 58, which is formed from the stamped sheet 14, is ensured, for example, by a solder connection, in particular by means of a solder paste or a preformed solder part such as a solder plate. Alternatively, an electrically conductive adhesive can be provided. A welded connection or a mechanical connection, for example, a riveted connection, can also be provided.

[0149] This ensures, among other things, that heating of the electrical component 60 leads to heating of the holding element 22, which is made from the stamped sheet metal 14. The heat is thus introduced into the thermal separation point 27, which heats the thermally softenable material 26. Heating of the electrical component 60 during operation of the surge protection device 10 thus leads to heating of the thermally softenable material 26, which can trigger the thermal separation point 27.

[0150] In addition, a second electrode 62 formed by a contact plate is provided on the electrical component 60. A contacting section 64 protrudes from the contact plate or the second electrode 62 and extends through an opening in the frame 16 formed by the plastic material. The contact plate or the second electrode 62 can also be attached to the electrical component 60 by means of a soldered connection, for example a solder paste or a preformed solder part such as a solder plate, to ensure an electrical connection. Alternatively, an electrically conductive adhesive can be provided. A welded connection or a mechanical connection, for example a riveted connection, can also be provided.

[0151] The second electrode 62 is electrically connected to the second contact 23b by means of the contacting section 64.

[0152] In this respect, in the initial state, which is shown in Figures 1, 3 and 4, a continuous electrical line results from the first contact 23a to the second contact 23b, wherein a current flows from the first contact 23a and the spring arm 20 formed integrally therewith via the electrically conductive and thermal separation point 27 to the holding element 22, which is integrally connected to the first electrode 58. Via the first electrode 58, the current flows via the electrical component 60 to the second electrode 62, in particular to the contacting section 64, which is electrically conductively connected to the second contact 23b.

[0153] In addition, a current can flow through the remote signaling contact 50, thereby closing the remote signaling circuit 52.

[0154] If the assembly 11 or the surge protection device 10 moves from the initial position to the triggered position, i.e., from the start position to the end position, the thermal separation point 27 is opened due to the heating, whereby the lever 32 moves the spring arm 20 to the end position. At the same time, the pin 46 provided on the lever 32 opens the mechanical separation point 48 of the remote signaling contact 50 by destroying the web 54. Thus, the current flow through the separation device 18 is interrupted, and simultaneously, a message is transmitted via the remote signaling circuit 52.

[0155] The frame 16 generally has a receptacle 66 for the electrical component 60, so that the electrical component 60 can be inserted into the frame 16 formed by the plastic material and coupled thereto. The frame 16 thus serves as an insertion aid to ensure the clearance and creepage distances.

[0156] In addition, the receptacle 66 can have a snap connection via which the electrical component 60 can be mechanically fastened to the frame 16. For this purpose, the electrical component 60 is inserted into the receptacle 66 of the frame 16, wherein the snap connection creates a corresponding positive fit in order to fasten the electrical component 60 to the frame 16.

[0157] Furthermore, the plastic material forming the frame 16 ensures that the frame 16 has two (essentially) parallel contact surfaces 68 and a support surface 70 perpendicular thereto, which serve to guide and support the outer housing 12.

[0158] The hood-like outer housing 12 can thus be placed on the frame 16, wherein inner sides of the outer housing 12 slide along the contact surfaces 68 and are guided until an inner side of the outer housing 12 opposite the open side 13 of the outer housing 12 rests against the support surface 70.

[0159] Figures 11 to 14 show a second embodiment of the telecommunication contact 50, in which the web 54 has two narrow points 56, which are formed by the web 54 being cut in the region of the narrow points 56 only on one side, but starting from opposite sides.

[0160] In this embodiment, there is again a defined constriction 56 which acts as a rotation axis, whereas the other constriction 56 is weakened, for example by at least one embossing, in such a way that it is separated.

[0161] Figures 15 to 17 show a third embodiment of the telecommunication contact 50, in which the web 54 has two narrow points 56 which are formed by the web 54 being cut in the region of the narrow points 56 only on one side, but starting from the same side, in particular the side of the web 54 which points away from the pin 46 in the initial position.

[0162] In this embodiment, there is again a defined constriction 56 which acts as a rotation axis, whereas the other constriction 56 is weakened, for example by at least one embossing, in such a way that it is separated.

[0163] Figures 18 to 21 show a third embodiment of the telecommunications contact 50, in which the web 54 is tapered relative to the contact points, so that the web 54 can be severed upon pivoting the pin 46. For example, the web 54 can be formed by an applied wire with a constriction, which has been bonded, soldered, or welded on.

[0164] Figures 22 and 23 show a further embodiment in which the web 54 additionally has notches 72.

[0165] In particular, the notches 72 are provided on two opposite sides of the web 54, which are perpendicular to the side from which the at least one cut per constriction 56 is formed in the web 54. In this respect, the notches 72 can be provided in addition to the at least one cut.

[0166] Figures 24 and 25 show a further embodiment in which the web 54 additionally has a notch 72 which is larger than a single one of the two notches 72 according to the embodiment of Figures 22 and 23.

[0167] Due to the stamped sheet 14 overmolded with the plastic material, it is ensured that the surge protection device 10 or the assembly 11, in particular the separating device 18, has fewer individual parts that must be laboriously assembled in order to form the separating device 18, since the thermal separation point 27 is formed by the thermally softenable material 26 as well as the holding element 22 and the contact point 24 of the spring arm 20.

[0168] Since the spring arm 20, the holding element 22, the remote signaling contact 50, the contacts 23a, 23b, and the electrodes 58, 62 are manufactured from the stamped sheet metal 14 by punching out and / or forming corresponding areas of the stamped sheet metal 14, the simple structure results. It is not necessary to provide separate components and couple them together to form the thermal separation point 27.

[0169] The plastic material, which has been molded around the stamped sheet 14, also provides other components required for the functioning of the separating device 18, for example, the bearing 40 for the lever 32, the receptacle 66 for the electrical component 60, and the stop 41 for the lever arm 34 of the lever 32. Furthermore, the remote signaling contact 50 is provided with the mechanical separation point 48, which is destroyed via the lever 32, in particular the pin 46 provided on the lever 32. The mechanical separation point 48 has a web 54, which is severed by the pin 46. For this purpose, the web 54 can have a taper, for example, a constriction 56 and / or a notch 72.

[0170] Lever 32, particularly its movement, ensures that the thermal separation point 27 and the mechanical separation point 48 are opened or separated in a defined temporal sequence. This preferably occurs in quick succession, i.e., sequentially.

[0171] This makes the assembly of the individual components much easier, so that manufacturing and assembly costs can be reduced.

[0172] In principle, the assembly 11 shown can be formed by carrying out a method for manufacturing the assembly.

[0173] This process includes the following steps:

[0174] Providing a punching sheet 14,

[0175] - forming a remote signaling contact 50 from the stamped sheet 14, wherein the remote signaling contact 50 has a mechanical separation point 48,

[0176] - Forming a spring arm 20 with an end contact point 24 from the stamped sheet 14,

[0177] - Forming a holding element 22 from the stamped sheet 14, so that the holding element 22 and the contact point 24 are opposite each other in an initial position of the assembly 11,

[0178] - Applying a thermally softenable material 26 between the holding element 22 and the contact point 24, which connects the spring arm 20 both mechanically and electrically to the holding element 22, and

[0179] The stamped sheet 14 is at least partially overmolded with a plastic material to form a frame 16. The remote signaling contact 50, the spring arm 20, and the retaining element 22 are thus produced from a common stamped sheet 14. In particular, the remote signaling contact 50, the spring arm 20, and / or the retaining element 22 are produced by forming the individual stamped sheet 14, for example, by bending the stamped sheet 14.

[0180] When forming the remote signaling contact 50, its mechanical separation point 48 can be created by tapering the material, for example, by the web 54, which has at least one constriction 56 and / or notch 72, as already explained above. Furthermore, the lever 54 is arranged on the bearing 40, which is formed in particular by the frame 16.

[0181] In particular, an assembly 11 according to one of the previously discussed embodiments can be produced using the method.

Claims

Patent claims 1. Assembly for a surge protection device (10), comprising a disconnecting device (18) which has a spring arm (20) with an end contact point (24) and a retaining element (22), wherein the retaining element (22) and the contact point (24) are opposite each other in a starting position of the assembly (11) and a thermally softenable material (26) is provided between the retaining element (22) and the contact point (24), which connects the spring arm (20) both mechanically and electrically to the retaining element (22), wherein the assembly (11) has a remote signaling contact (50) with a mechanical disconnecting point (48), wherein the spring arm (20), the retaining element (22) and the remote signaling contact (50) are made from a common stamped sheet (14), and wherein the stamped sheet (14) is at least partially overmolded with a plastic material which forms a frame (16).

2. Assembly according to claim 1, characterized in that a thermal separation point (27) is formed between the retaining element (22) and the contact point (24) by means of the thermally softenable material (26).

3. Assembly according to claim 1 or 2, characterized in that the thermally softenable material (26) is a solder.

4. Assembly according to one of the preceding claims, characterized in that the assembly (11) has a lever (32) which serves to mechanically separate the mechanical separation point (48) of the telecommunication contact (50) and / or to open the connection between the retaining element (22) and the contact point (24) in a defined manner.

5. Assembly according to claim 4, characterized in that the lever (32) has a first lever arm (34) which interacts with a preloading element (38), in particular wherein the preloading element (38) is an elastically preloaded preloading element, in particular wherein the lever (32) has a second lever arm (36) which is opposite to the first lever arm (34), wherein the second lever arm (36) acts on the spring arm (20).

6. Assembly according to one of claims 4 to 5, characterized in that a pin (46) is provided on the lever (32) which interacts with the mechanical separation point (48) of the telecommunications contact (50).

7. Assembly according to one of claims 4 to 6, characterized in that the frame (16) formed from the plastic material has a bearing (40) for the lever (32) and / or that the frame (16) formed from the plastic material has a stop (41) for the first lever arm (34) of the lever (32) against which the first lever arm (34) can strike in a released position.

8. Assembly according to one of the preceding claims, characterized in that the frame (16) forms a base plate (42) which is substantially parallel to a main section of the stamped sheet (14).

9. Assembly according to claim 8 insofar as it relates back to claim 7, characterized in that the base plate (42) has a recess (44) in which the pin (46) of the lever (32) is movably received, in particular wherein at least one edge of the recess (44) forms a stop point for the pin (46) at which the pin (46) can strike in a released position.

10. Assembly according to one of the preceding claims, characterized in that the assembly (11) has an electrical component (60), in particular wherein the electrical component (60) is arranged on a side of the stamped sheet (14) that points away from the spring arm (20).

11. Assembly according to claim 10, characterized in that a contact plate is arranged on the electrical component (60), from which a contacting section (64) extends through an opening in the frame (16) formed by the plastic material.

12. Assembly according to one of claims 10 to 11, characterized in that the electrical component (60) is a varistor.

13. Assembly according to one of claims 10 to 12, characterized in that the frame (16) forms a receptacle (66) for the electrical component (60), in particular wherein the receptacle (66) is a has a snap connection for the mechanical fastening of the electrical component (60) to the frame (16).

14. Assembly according to one of the preceding claims, characterized in that the spring arm (20) transitions at its end opposite the contact point (24) via a material-tapered pivot point (28) into a connecting section which is made from the common stamped sheet (14), wherein the spring arm (20) is pivotable about the material-tapered pivot point (28).

15. Assembly according to one of the preceding claims, characterized in that the spring arm (20) has a first section (20a) and a second section (20b) which extend at an angle to each other which is different from 0° and 180° respectively, wherein the second section (20b) has the contact point (24), in particular wherein the two sections (20a, 20b) of the spring arm (20) are aligned to each other such that a kink (21) is formed in the spring arm (20).

16. Assembly according to one of the preceding claims, characterized in that an outer housing (12) is provided which at least accommodates the frame (16).

17. Assembly according to claim 16, characterized in that the outer housing (12) is designed in a hood-like manner and is placed on the frame (16), which has two substantially parallel contact surfaces (68) for the outer housing (12) and a support surface (70) perpendicular to the two substantially parallel contact surfaces (68).

18. Surge protection device comprising an assembly (11) according to one of the preceding claims.

19. Surge protection device according to claim 18, characterized in that the surge protection device (10) is a surge arrester.

20. Method for manufacturing an assembly (11) for a surge protection device (10), comprising the following steps: Providing a die (14), - Forming a telecommunications contact (50) from the stamped sheet (14), wherein the telecommunications contact (50) has a mechanical separation point (48), - Forming a spring arm (20) with an end contact point (24) from the stamped sheet (14), - Forming a retaining element (22) from the stamped sheet (14) such that the retaining element (22) and the contact point (24) are opposite each other in a starting position of the assembly (11), - Applying a thermally softenable material (26) between the retaining element (22) and the contact point (24), which connects the spring arm (20) to the retaining element (22) both mechanically and electrically, and Overmolding the stamped sheet (14) with a plastic material at least partially, so that a frame (16) is formed.

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