High-voltage contactor or high-voltage relay
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- PIERBURG GMBH
- Filing Date
- 2023-08-10
- Publication Date
- 2026-06-17
Smart Images
Figure EP2023072251_13022025_PF_FP_ABST
Abstract
Description
[0001] DESCRIPTION
[0002] High-voltage protection or high-voltage relay
[0003] The invention relates to a high-voltage contactor or high-voltage relay with an electromagnetic actuator with a coil, a movable armature, and an iron circuit surrounding the coil with a return plate, a housing with a contact chamber, a contact bridge which can be moved by means of the actuator in the contact chamber at least into a first position in which a first contact element is electrically connected to a second contact element via the contact bridge, and can be moved into a second position in which electrical contact between the first contact element and the second contact element is interrupted, a magnetic field conductor which radially encloses the contact chamber and which magnetically connects at least two permanent magnets arranged diametrically opposite one another in the contact chamber, wherein the magnetic field conductor has a plurality of lugs.
[0004] Such high-voltage switching devices are required to be able to establish and disconnect electrical connections in no-load conditions and in load conditions, where voltages of over 1000 V and currents of over 1000 A can occur in load conditions, which can be present, for example, between the battery and the drive motor or between a charging station and the battery in electrically powered vehicles.
[0005] Such a switching device is known, for example, from CN 111091987 A. The magnetic field guide body of the disclosed switching device is constructed in two parts and has several axially extending lugs with which the magnetic field guide body rests against the return plate. During assembly, the magnetic field guide body must therefore be held and precisely aligned in several directions in order to be placed precisely on the return plate.
[0006] The present invention is therefore based on the object of creating a high-voltage contactor or high-voltage relay in which the magnetic field guide body can be positioned and aligned relatively easily during assembly, so that no additional holding devices are required when overmolding with plastic.
[0007] This object is achieved with a high-voltage contactor or high-voltage relay according to the invention having the features of main claim 1.
[0008] The high-voltage contactor or high-voltage relay according to the invention has an electromagnetic actuator via which the contactor can be switched. An electromagnetic actuator is understood to be all actuators that generate movement due to a force caused by electromagnetism. The electromagnetic actuator comprises a coil consisting of a coil carrier and a winding wound thereon, as well as an armature movable due to the electromagnetic force, which is arranged within the coil, and an iron circuit surrounding the coil, with a return plate forming part of the iron circuit.
[0009] For the sake of simplicity, only the term high-voltage contactor is used below, although this also includes the term high-voltage relay.
[0010] Furthermore, the terms radial, axial and diametrical refer to the central axis of the high-voltage contactor along which the armature of the actuator can be moved.
[0011] The high-voltage contactor further comprises a multi-part housing, preferably made of plastic, with an inner contact chamber arranged axially adjacent to the actuator. The housing is designed such that the contact chamber is almost completely sealed from the environment, allowing only a slow exchange of air and thus a slight pressure equalization with the environment. When an arc occurs, a relatively high pressure is suddenly generated in the contact chamber compared to the environment. This pressure cannot be immediately reduced due to the slow air exchange between the contact chamber and the environment. While this high pressure promotes the extinguishing of the arcs, it also places increased strength requirements on the housing.
[0012] The high-voltage contactor further comprises a first and second contact element fixedly arranged on the housing, which protrude into the contact chamber and are connected outside the high-voltage contactor to two busbars, one of which leads to the battery and the other, for example, to the drive motor or which are connected to a charging station and the vehicle's battery. An electrical connection between these two contact elements can be established via a contact bridge, which is moved along a movement axis in the contact chamber by means of the actuator. In this case, the contact bridge, at the ends of which two electrical contacts can be formed, is usually displaced axially against the two contact elements fastened to the housing by energizing the winding in order to establish an electrical connection between the first contact element and the second contact element via the contact bridge in a first position.For this purpose, the contact bridge is operatively connected to the armature, for example, via an actuating rod, and is pressed against the contact elements by the movement of the armature or rotor due to the electromagnetic force. To open this electrical connection, the contact bridge is loaded in the opposite direction, which is usually achieved by a spring force acting on the armature or contact bridge in the opposite direction to the electromagnetic force. This causes the contact bridge to move to a second position outside of the energized times, in which electrical contact between the first contact element and the second contact element is interrupted.
[0013] Furthermore, the high-voltage contactor has a magnetic field conductor which magnetically connects at least two permanent magnets arranged diametrically opposite one another in the contact chamber. For this purpose, the magnetic field conductor is in direct contact with the at least two permanent magnets, which are preferably each arranged radially adjacent to the contact point between the first contact element and the first contact plate of the contact bridge or to the contact point between the second contact element and the second contact plate of the contact bridge. When the contact bridge is separated from the contact elements, arcs can occur which can damage the high-voltage contactor and in particular the contact chamber and its adjacent components. By means of the magnetic fields of the permanent magnets, which are often also referred to as blowout magnets, orBy means of the Lorentz force exerted by the magnetic fields, the arc created when the contact plates and contact elements are separated can be deformed into an arc, thereby elongating it and thus extinguishing it. The permanent magnets are aligned in such a way that the Lorentz force deforms the arcs into an arc. The magnetic field conductor represents a magnetic short circuit between the permanent magnets, which, on the one hand, leads to relatively good magnetic field concentration and, on the other hand, is particularly beneficial for both the local field strength and the field homogeneity of the magnetic fields generated by the permanent magnets, which ultimately has a beneficial effect on the extinguishing of the arcs.
[0014] The magnetic field guide lies axially against the return plate and is therefore in direct magnetically conductive contact with the return plate and thus also with the actuator's iron circuit. The magnetic field guide also has several lugs. These are projections that extend axially from an end wall of the magnetic field guide toward the return plate and that extend circumferentially along the side wall of the magnetic field guide. The lugs are thus part of the side wall of the magnetic field guide and are preferably rectangular, forming two lug side surfaces arranged parallel to one another and aligned parallel to the movement axis.
[0015] According to the invention, the return plate has recesses corresponding to the lugs, into which the lugs engage. The recesses are, for example, openings in the return plate that extend axially either partially into the return plate or completely through the return plate. The recesses are preferably rectangular with respect to a cross-sectional plane oriented orthogonal to the axis of movement of the actuator, but can also have any other suitable shape, for example a circle or an oval. The inner distance between the two walls of the respective recesses facing each other in the circumferential direction is only slightly greater than the width of the lug in the circumferential direction, so that each lug rests with at least one of its nose side surfaces against the corresponding inner wall of the recess assigned to it.Slightly larger here means that the recess is preferably a few tenths of a millimeter larger, so that the magnetic field guide can be inserted into the recess relatively easily using the tabs, but the magnetic field guide can only be moved to a relatively small extent. This creates a positive connection between the magnetic field guide and the return plate, which prevents both a translational movement of the magnetic field guide transverse to the axis of movement and a rotational movement about the axis of movement. In addition, the one-sided axial contact of the magnetic field guide prevents translational movement in one of the two axial directions, so that in the assembled state only a single degree of freedom exists in the axial direction opposite to the return plate.This plug-in connection allows the magnetic field guide to be pre-assembled during the manufacturing process without the use of additional guide or fastening devices. During subsequent manufacturing steps, gravity acts against the last remaining degree of freedom, securely holding it in its final position on the return plate. If necessary, an additional securing device, such as a hold-down clamp, a locking hook connection, or a sling, can be provided, which also blocks the last degree of freedom and completely fixes the magnetic field guide in its final position.In this way, a particularly simple and cost-effective plug connection is created, which considerably simplifies the further manufacturing process compared to the switching device according to the prior art, which still requires additional devices for positioning and fixing the magnetic field guide body.
[0016] In a particularly preferred embodiment of the invention, the magnetic field conductor completely surrounds the contact chamber, i.e. the magnetic field conductor completely encloses the contact chamber radially. For this purpose, the magnetic field conductor can, for example, have a tubular shape with a rectangular or circular cross-section. The magnetic field conductor is preferably made of a ferromagnetic metal and is therefore relatively strong compared to the housing, which is usually made of plastic. The occurrence of arcs in the contact chamber is accompanied by a sudden, relatively high pressure increase in the contact chamber, which particularly stresses the housing sections radially surrounding the contact chamber and, in the worst case, can cause the housing to burst.The magnetic field conductor surrounding the contact chamber creates a metallic reinforcement for the housing section radially surrounding the contact chamber, which withstands the high pressures in the contact chamber caused by arcs and thus protects the housing from damage. Nevertheless, the contact chamber walls can be designed relatively thin, which is particularly advantageous for the compactness of the high-voltage contactor.
[0017] In a further particularly preferred embodiment of the invention, the magnetic field guide has a particularly substantially flat contact surface, with which the magnetic field guide bears axially against the return plate, wherein the lugs extend from the contact surface in the axial direction into the recesses. The contact surface, which is flat with the exception of the lugs, is preferably an end face of the magnetic field guide facing in an axial direction, the normal of which is aligned parallel to the axis of movement. The contact surface enables relatively large-area contact between the magnetic field guide and the return plate, which, for example, makes it more difficult for the magnetic field guide to tilt during the manufacturing process.
[0018] In a further particularly preferred embodiment of the invention, the magnetic field guide body has a total of two lugs which are arranged diametrically opposite one another. The diametrically opposed arrangement of the lugs makes it possible to create the necessary form fit, which is required to block the translational movement transverse to the axis of movement and the rotational movement about the axis of movement, with just two lugs. This results in a relatively good cost-benefit ratio with regard to the structural design and manufacture of the high-voltage contactor. In a further advantageous embodiment of the invention, the return plate is arranged axially between the contact chamber and the actuator. The return plate thus forms a metallic partition ora metallic reinforcement of a partition wall between the actuator chamber and the contact chamber, which makes the contact chamber relatively robust against mechanical stresses that can occur, for example, due to an increase in pressure in the contact chamber, which can occur as a result of arcing when the contact bridge is separated from the contact elements.
[0019] In a further preferred embodiment of the invention, the recesses are arranged at the edge of the return plate and are open radially outward. The recesses are therefore preferably designed as rectangular pockets that form part of the outer contour of the return plate. This allows the return plate to be designed and manufactured relatively simply, since the recesses, as part of the outer contour, can be produced in a single step during the manufacturing process. Furthermore, the return plate can be designed to be relatively compact in the radial direction, which ultimately also leads to a compact design of the high-voltage contactor.
[0020] In a further embodiment of the invention, each recess is formed by two projections of the return plate, which are arranged adjacent to each other in the circumferential direction and spaced apart from each other and extend radially outward. The projections preferably extend parallel to each other from the radial surface of the return plate outward, whereby only the two inner walls of the projections facing each other in the circumferential direction, against which the lugs rest, need to be arranged parallel to each other. By designing the return plate with the projections, the return plate can be designed to be particularly compact, resulting in a relatively compact high-voltage contactor from a structural perspective.
[0021] In another particularly preferred embodiment of the invention, the return plate and the magnetic field conductor are overmolded with plastic when plugged together. The housing of the high-voltage contactor, or at least parts thereof, are manufactured using an injection molding process. In order to create a particularly sealed contact chamber, it can be advantageous to overmold the return plate and the magnetic field conductor with plastic in a single injection molding process, thus creating a smooth and seamless border around the contact chamber. The plug connection, created by the lugs engaging in the recesses, serves to position the magnetic field conductor on the return plate and to hold it in position during the injection molding process.If the injection point through which the injection mold is filled is placed on the axial side of the magnetic field guide, towards which the magnetic field guide can be moved, the injection pressure can press the magnetic field guide against the return plate and thus securely hold it in position. Alternatively, a hold-down device can be provided in the injection mold to do this. The overmolding creates a metal (reinforced) wall around the contact chamber, with the magnetic field guide reinforcing the contact chamber wall that radially encloses the contact chamber, whereas the return plate reinforces the contact chamber wall that axially limits the contact chamber in the direction of the actuator. The plug-in connection can simplify the injection molding process considerably, as no additional holding devices need to be provided for the magnetic field guide.This allows the production cycle rate to be increased compared to a high-voltage contactor with a non-pluggable magnetic field conductor, thereby reducing manufacturing costs. In another particularly advantageous embodiment of the invention, the magnetic field conductor is made of sheet metal. The magnetic field conductor is thus relatively thin-walled, with a sheet thickness of less than 3 mm. This allows the magnetic field conductor to be manufactured relatively easily in large quantities, for example, by bending or deep drawing, and is therefore particularly well suited for a series-produced high-voltage contactor.
[0022] In a further embodiment of the invention, the magnetic field guide body is designed in the shape of a rectangular tube and has two long side walls and two short side walls. Accordingly, the contact chamber also has a rectangular shape. This shape is particularly suitable because the contact bridge also has an elongated, usually rectangular shape, so that the shape of the contact chamber is adapted to the shape of the contact bridge and the distance between the contact bridge and the radial side walls of the contact chamber is approximately the same on all sides. Thus, the contact chamber does not require more space than necessary, which leads to a relatively compact design of the high-voltage contactor.
[0023] In a further embodiment of the invention, the magnetic field guide is manufactured by bending a flat sheet metal strip. The flat sheet metal strip is bent by 90° at at least three points forming the corners, creating a rectangular tube, with the two ends of the sheet metal strip meeting in the fourth corner when bent. However, the sheet metal strip particularly preferably has four bending points with 90° bends, so that the two ends of the sheet metal strip meet in the area of a side wall between the two corners, enabling a clean connection of the joints. Manufacturing by bending is particularly cost-effective and therefore particularly suitable for series production. In addition, a bent magnetic field guide has a constant sheet thickness, which would not be possible with a deep-drawn magnetic field guide due to manufacturing difficulties.
[0024] In a further embodiment of the invention, the magnetic field guide body has a connecting structure by means of which the ends of the magnetic field guide body that abut in the bent state are connected to one another. The connecting structure is designed such that the two abutting ends cannot move away from one another in the circumferential direction, thereby preventing the rectangular tube forming the magnetic field guide body from expanding during the manufacturing process, for example, during an injection molding process. This is achieved by a connecting structure that creates a positive connection in the circumferential direction, whereas in the orthogonal direction, which is perpendicular to the sheet plane, the connection can be easily released.The two ends of the magnetic field conductor are designed like puzzle pieces that, when plugged together, are securely connected to prevent relative movement in the plane of the sheet metal. For this purpose, one end has a recess undercut in the circumferential direction and the other end has a correspondingly shaped extension that sits in the recess. In addition, after being inserted into the recesses, the extension can be widened within the plane of the sheet metal during the manufacturing process using a suitable tool so that the extension fits precisely and without play in the recess. This can be achieved, for example, by inserting a mandrel that is pressed into the center of the extension and thereby displaces the material outwards, pressing it against the inner walls of the recess and forming a form-fitting fit against the inner walls.This ensures that the noses of the magnetic field guide sit securely in the recesses of the return plate and that the magnetic field guide is thus fixed in its position.
[0025] Advantageously, the connecting structure has at least one dovetail joint. The dovetail joint is one of the possible puzzle-like configurations of the connecting structure and is characterized by its excellent dimensional stability in all directions of the sheet plane. For further improvement, multiple dovetail joints can be arranged along the abutting ends, which additionally reinforce and stabilize the connecting structure.
[0026] The lugs are preferably formed on the short side walls, since the short side walls are more stable and less susceptible to deformation than the long side walls, so that an arrangement of the lugs on the short side can achieve a more secure connection between the magnetic field guide body and the return plate than an arrangement of the lugs on the long side.
[0027] In a further advantageous embodiment of the invention, the magnetic field conductor has a plurality of openings that radially penetrate the magnetic field conductor. The openings fill with plastic during the overmolding of the magnetic field conductor during an injection molding process for producing the contact chamber walls, thereby creating an additional positive connection between the magnetic field conductor and the contact chamber wall enclosing the magnetic field conductor, which securely holds the magnetic field conductor in its position.
[0028] In a further embodiment, the openings are arranged on the long side wall of the magnetic field guide body. This allows multiple openings to be provided in the side wall of the magnetic field guide body without significantly weakening the side wall.
[0029] In a further advantageous embodiment of the invention, the permanent magnets are located on the short side wall of the magnetic field conductor. This allows the permanent magnets to be positioned particularly close to the contact points, resulting in a particularly high quenching effect.
[0030] An embodiment of a high-voltage contactor or high-voltage relay according to the invention is shown in the figures and is described below.
[0031] Figure 1 shows a side view of a high-voltage contactor according to the invention in a sectional view.
[0032] Figure 2 shows a perspective view of the return plate and the magnetic field guide body of the high-voltage contactor of Figure 1 in the pre-assembled state.
[0033] The high-voltage contactor 10 shown in Figure 1 comprises an electromagnetic actuator 12 having a coil 14 consisting of a coil carrier 16 and a winding 18 wound thereon, a ferromagnetic iron circuit 20, and an armature 22. The ferromagnetic iron circuit 20 has a U-shaped yoke 24, the legs 26 of which rest on a return plate 28 or are attached to the return plate 28, thus forming the closed iron circuit 20.
[0034] The yoke 24 has a central opening 32 at its base 30, the diameter of which essentially corresponds to the inner diameter of the coil carrier 16. A bushing 34 is secured in this opening 32, in which the armature 22 is slidably arranged and guided. When current is applied to the coil 14, the armature 22 is drawn in a known manner against the force of a spring 36 in the contact chamber 42 toward the return plate 28.
[0035] An actuating rod 38 rests axially on the armature 22 on the contact chamber side and projects through a further central opening 40 in the return plate 28 into a contact chamber 42. A contact bridge 44 is arranged at the end of the actuating rod 38 opposite the armature 22. This contact bridge 44 is preferably pressed by a spring element 46 against a stop 48 at the end of the actuating rod 38, which is supported on a shoulder 49 on the actuating rod 38 and is accordingly arranged on the actuating rod 38 so as to be slightly axially and tiltably movable. A contact plate 52, 53 made of a particularly highly conductive material is fastened to each end of the contact bridge 44. The first contact plate 52 is arranged axially opposite a first contact element 54, which can be connected in particular to a high-voltage battery via a busbar (not shown).The second contact plate 53 is arranged opposite a second contact element 56, which can be connected, for example, via a busbar to a drive motor of a motor vehicle.
[0036] The entire high-voltage contactor 10 is arranged in a housing 58, which is composed of a total of three parts, as can be seen particularly in Figure 1. For this purpose, the actuator 12 is overmolded with a plastic to form an actuator housing part 60. This plastic completely surrounds the coil 14 radially to form a radial boundary wall 66 and also fills a gap 68 radially between the coil 14 and the yoke 24. In addition, the yoke 24 itself is completely radially surrounded by this plastic and is thus shielded from the environment. Furthermore, the return plate 28, which rests against the coil carrier 16 on its side facing the coil carrier, is covered by this plastic axially in the direction of the contact chamber 42, whereby an axial contact chamber wall 45 is formed.The opening 40 of the return plate 28 is also covered radially inwards by the plastic and leaves only a central guide opening 70 free, in which the actuating rod 38 is guided.
[0037] On the axial outer side 72 of the actuator housing part 60 opposite the contact chamber 42, the plastic extends further radially inward along a radially outer region 74 of the base part 30 of the yoke 24 or of the actuator 12 and leaves an opening 78 free only in the central, radially inner region 76, which opening is designed symmetrically to the opening 32 but has a slightly larger diameter so that there is sufficient space for pressing in the bushing 34.
[0038] This opening 78 is closed by a plastic cover 80, which is firmly attached to the actuator housing part 60 in the opening 78, in particular by laser welding, ultrasonic welding or rotational vibration welding.
[0039] Furthermore, the actuator housing part 60 produced by overmolding the actuator 12 forms a molding 82 in the form of a plug housing 82, through which the connecting lines 84 to the winding 18 of the coil 14 are led outwards, so that the electrical connection of the coil 14 to a voltage source can be established via a plug counterpart.
[0040] In addition, a circumferential radial contact chamber wall 47 extends from the return plate 28 in extension of the plastic surrounding the actuator 12, which radially delimits the contact chamber 42 and is also manufactured in one piece during the overmolding of the actuator 12 and thus forms four side walls of the contact chamber 42 in the present exemplary embodiment.
[0041] The radial contact chamber wall 47 is designed in a so-called sandwich construction. The radial contact chamber wall 47 is formed by a contact chamber inner wall 474 and a contact chamber outer wall 476, which are spaced apart and arranged parallel to one another. Between the contact chamber inner wall 474 and the contact chamber outer wall 476, a magnetic field guide body 50 formed by a ferromagnetic magnetic field guide plate 51 is arranged, which completely radially surrounds the contact chamber 42. The radial contact chamber wall 47, the contact chamber inner wall 474, and the contact chamber outer wall 476 are manufactured by overmolding the magnetic field guide plate 51 with plastic on the inside and outside, respectively.The overmolding takes place in the same work step in which the actuator 12 is overmolding, whereby the contact chamber outer wall 476 is formed integrally with the actuator housing part 60 and the contact chamber inner wall 474 is formed integrally with the axial contact chamber wall 45. Nevertheless, the contact chamber inner wall 474 and the contact chamber outer wall 476 are integrally connected to one another at several points, for example, by openings 512 in the long side walls 506 of the magnetic field guide plate 51.
[0042] The contact chamber 42 is cuboid-shaped and therefore has a rectangular cross-section, which is radially delimited by four side walls, each formed by the radial contact chamber wall 47. On the two opposing short sides, the side walls of the contact chamber wall 47 each have a cuboid-shaped, inwardly projecting pocket 471, 472, which is open to the axial side opposite the actuator 12, with a permanent magnet 55, 57 arranged in each pocket 471, 472. Each pocket 471, 472 or each permanent magnet 55, 57 arranged in the pocket 471, 472 is arranged adjacent to one of the contact plates 52, 53 of the contact bridge 44.Each permanent magnet 55, 57 is aligned with respect to its magnetic poles in such a way that the Lorentz force exerted by the magnetic fields of the permanent magnets 55, 57 deforms the arc occurring between the contact plates 52, 53 and the contact elements 54, 56 into an arc and thus extinguishes the arcs due to the resulting elongation and faster cooling.
[0043] The magnetic field guide plate 51 is not completely overmolded on the inside in the area of the pockets 471, 472. Instead, each permanent magnet 55, 57 contacts the magnetic field guide plate 51 on its respective short inner side, thereby magnetically connecting the permanent magnets 55, 57 to one another. Arranged within each pocket 471, 472 is a stop structure 475, each formed by two parallel and spaced-apart ribs 477 and a wall projection 478. The wall projection 478 projects radially inward from the inside of the magnetic field guide plate 51. The ribs 477 each extend radially from the contact chamber inner wall 474 to the wall projection 478. The permanent magnets 55, 57 rest axially against the respective stop structure 475, whereby each permanent magnet 55, 57 is arranged at the level of one of the contact points in the contact chamber 42 with respect to the axial direction.
[0044] In addition, the magnetic field guide plate 51 extends axially in the actuator direction up to the return plate 28 and rests axially against the return plate 28 with a flat contact surface 504, so that the magnetic field guide plate 51 is in direct, magnetically conductive contact with the return plate 28 and thus with the iron circuit 20. This leads to both an increased local field strength and improved homogeneity of the magnetic field, thereby achieving a relatively strong deformation of the arcs and thus a relatively rapid extinguishing of the arcs.
[0045] The magnetic field guide plate 51 is shaped like a rectangular tube and manufactured from a flat sheet metal strip by bending. The magnetic field guide plate 51 has four bending points 507 that form the corners of the magnetic field guide plate 51. At its two ends, which abut one another in the bent state, the magnetic field guide plate 51 has a puzzle-like connecting structure 510 formed by two axially adjacent and spaced-apart dovetail joints 511. These dovetail joints prevent the abutting ends of the magnetic field guide plate 51 from moving away from one another in the circumferential direction, thus preventing the magnetic field guide plate 51 from expanding radially.
[0046] On its two short side walls 508, the magnetic field guide plate 51 has two diametrically opposed lugs 502 that extend axially from the contact surface 504 in the direction of the return plate 28, as shown in Figure 2. At the edge of the return plate 28, two recesses 282 are arranged, into which the lugs 502 extend and into which the lugs 502 engage. Each recess 282 is formed by two projections 284 that are spaced apart from one another along the circumference of the return plate 28 and extend radially outwardly parallel to one another. The distance between the two facing inner walls of the adjacent projections 284 is 0.5 mm greater than the width of the lugs 502 in the circumferential direction, so that the lugs 502 are received in the recesses 282 with relatively little play. The recesses 282 are open radially outwards, whereby the return plate 28 is relatively compact.The lugs 502 prevent translational movement of the magnetic field guide plate 51 in all directions transverse to the movement axis of the actuator 12 and in the rotational direction around the movement axis of the actuator 12. Furthermore, the contact surface 504 axially abutting the return plate 28 prevents axial displacement of the magnetic field guide plate 51 in the direction of the actuator 12. This holds the magnetic field guide plate 51 and the actuator 52 in their position during joint overmolding without additional holding devices.
[0047] The contact chamber 42 in Figure 1 is axially closed on the axial side opposite the axial contact chamber wall 45 by a contact chamber cover 88, which also axially closes the pockets 471, 472. Two axial openings 90 are formed on the contact chamber cover 88, in which the two contact elements 54, 56 are received and secured, for example, by ultrasonic welding or overmolding. Extending circumferentially in the axial direction from this contact chamber cover 88 is a collar 92 that radially encloses the circumferential contact chamber outer wall 476, so that these two walls 92, 476 can be joined together circumferentially in a materially bonded manner, for example, by laser welding, ultrasonic welding, or rotational vibration welding, thereby creating a high-strength housing 58.Immediately inside the collar 92, a circumferential axial groove 94 is formed, which is thus delimited to the outside by the collar 92 of the contact chamber cover 88 and into which the end of the housing wall 86 of the actuator housing part 60 projects, whereby this is protected from laser welding, ultrasonic welding or.
[0048] Rotational vibration welding is precisely fixed in its position relative to the contact chamber cover 88.
[0049] If the flow of current between the electric motor or the charging station and the battery is to be enabled, the coil 14 is energized, whereby the armature 22 is pulled towards the return plate 28 due to the acting electromagnetic forces. As a result, the actuating rod 38 with the contact bridge 44 and the contact plates 52, 53 is pushed against the contact elements 54, 56 so that a current can flow via the contact bridge 44 from the first contact element 54 to the second contact element 56 and thus from the battery to the electric motor or from the charging station to the battery. If the coil 14 is not energized, the actuating rod 38 and the armature 22 are loaded in the opposite direction by the spring 36 so that the contact bridge 44 is lifted off the contact elements 54, 56 and the circuit is interrupted. This creates an arc due to the high currents, which also results in an increase in pressure in the contact chamber 42.
[0050] This pressure increase can be well absorbed by the housing 58 due to the metal-reinforced walls 45, 47 surrounding the contact chamber 42, and the actuator 12 is also reliably protected, particularly by the molded-on axial contact chamber wall 45. The tight welding of the only three housing parts also ensures complete sealing to the outside, so that no gas can escape from the contact chamber 42, the arc is extinguished reliably and quickly, and no gases or liquids can penetrate from the outside. The required installation space and assembly costs are very low.
[0051] It should be clear that various modifications are possible compared to the described embodiment. In particular, the design of the contact unit as well as the arrangement of the springs and the actuating rod guide and mounting may differ from the form shown.
Claims
P A T E N T A N S P R Ü C H E 1. High-voltage contactor (10) or high-voltage relay with an electromagnetic actuator (12) with a coil (14), a movable armature (22), and an iron circuit (20) surrounding the coil (14) with a return plate (28), a housing (58) with a contact chamber (42), a contact bridge (44) which is displaceable by means of the actuator (12) in the contact chamber (42) at least into a first position in which a first contact element (54) is electrically connected to a second contact element (56) via the contact bridge (44), and is displaceable into a second position in which an electrical contact between the first contact element (54) and the second contact element (56) is interrupted, and a magnetic field conducting body (50) which magnetically conductively connects at least two permanent magnets (55, 57) arranged diametrically opposite one another in the contact chamber (42), wherein the magnetic field conducting body (50) is axially connected to the return plate (28) and has several lugs (502),characterized in that the return plate (28) has recesses (282) corresponding to the lugs (502) into which the lugs (502) engage.
2. High-voltage contactor (10) or high-voltage relay according to claim 1, characterized in that the magnetic field conducting body (50) radially completely encloses the contact chamber (42).
3. High-voltage contactor (10) or high-voltage relay according to claim 1 or 2, characterized in that the magnetic field guide body (50) has a contact surface (504) with which the magnetic field guide body (50) bears axially against the return plate (28), wherein the lugs (502) extend from the contact surface (504) in the axial direction into the recesses (282).
4. High-voltage contactor (10) or high-voltage relay according to one of the preceding claims, characterized in that the magnetic field conducting body (50) has a total of two lugs (502) which are arranged diametrically opposite one another.
5. High-voltage contactor (10) or high-voltage relay according to one of the preceding claims, characterized in that the return plate (28) is arranged axially between the contact chamber (42) and the actuator (12).
6. High-voltage contactor (10) or high-voltage relay according to one of the preceding claims, characterized in that the recesses (282) are arranged at the edge of the return plate (28) and are open radially outwards.
7. High-voltage contactor (10) or high-voltage relay according to claim 6, characterized in that each recess (282) is formed between two projections (284) of the return plate (28) which are arranged adjacent to and spaced from one another in the circumferential direction and extend radially outwards.
8. High-voltage contactor (10) or high-voltage relay according to one of the preceding claims, characterized in that the return plate (28) and the magnetic field guide body (50) are overmolded with plastic when plugged together.
9. High-voltage contactor (10) or high-voltage relay according to one of the preceding claims, characterized in that the magnetic field conducting body (50) is made of a sheet material.
10. High-voltage contactor (10) or high-voltage relay according to claim 9, characterized in that the magnetic field conducting body (50) is designed in the form of a rectangular tube and has two long side walls (506) and two short side walls (508).
11. High-voltage contactor (10) or high-voltage relay according to claim 9 or 10, characterized in that the magnetic field guide body (50) is made from a flat sheet metal strip by bending.
12. High-voltage contactor (10) or high-voltage relay according to claim 10, characterized in that the magnetic field conducting body (50) has a connecting structure (510) by means of which the ends of the magnetic field conducting body (50) which abut one another in the bent state are connected to one another.
13. High-voltage contactor (10) or high-voltage relay according to claim 12, characterized in that the connecting structure (510) has at least one dovetail connection (511).
14. High-voltage contactor (10) or high-voltage relay according to one of claims 10-13, characterized in that the lugs (502) are formed on the short side walls (508).
15. High-voltage contactor (10) or high-voltage relay according to one of the preceding claims, characterized in that the magnetic field conducting body (50) has a plurality of openings (512) which radially penetrate the magnetic field conducting body (50).
16. High-voltage contactor (10) or high-voltage relay according to claim 15, characterized in that the openings (512) are arranged on the long side wall (506) of the magnetic field conducting body (50).
17. High-voltage contactor (10) or high-voltage relay according to one of claims 10-16, characterized in that the permanent magnets (55, 57) rest on the short side wall (508) of the magnetic field conducting body (50).