Contactor for high-current connection and method for manufacturing the same.

Abstract

The present invention relates to a high-current contactor 2, which is composed of an elastic support member 6 made of a conductive and elastic alloy material such as beryllium copper. The elastic support member 6 has elastic legs 10a that extend integrally from the base 8 in an inclined direction or in a "self" shape by machining the X and Y axes of the matrix on the entire contact bottom surface side, and elastic contact feet 10b at the tips of the elastic legs 10a. Elastic connecting pieces 10 that have been heat-treated to have elastic durability are arranged in a matrix on the entire contact bottom surface side, thereby forming an elastic connecting piece matrix assembly 14.

Description

Technical Field

[0001] The present invention relates to a high-current connection device, and particularly to an improvement of a high-current contactor for minimizing contact resistance during selective electrical connection to a high-current connection point that is used for charging and discharging tests of high-current batteries or ranges from several hundred to several thousand amperes.

Background Art

[0002] Generally, when the electrical contact state at connection points such as between an electric wire and a switching device, between an electric wire and a connection terminal, and between a connection terminal and an electrode becomes incomplete, the contact resistance of the connection portion increases, and heat generation occurs in that portion. Usually, a heat generation pattern corresponding to the increase in contact resistance and the magnitude of the load current appears. However, the larger the load current and the larger the contact resistance, the higher the heating temperature.

[0003] In recent years, in order to improve the quality reliability of high-capacity batteries used in electric vehicles, not only the extraction inspection of batteries but also the introduction of a full-inspection system for batteries may be carried out. In the full-inspection system for batteries, in addition to the optimization inspection of charge and discharge, inspections of voltage, current, etc. are also performed on all the batteries produced. Electric vehicle batteries of various sizes and materials are manufactured. During the inspection, the current applied from the test device to the battery may reach a high current of, for example, 300 A to 500 A, and the peak current may reach 1800 A. If the electrical contact state at the connection points that come into contact during the test is unstable or lacks consistency, the reliability of the battery test will be impaired.

[0004] For example, when repeatedly performing charge and discharge tests on a high-capacity battery pack using a charge and discharge test device for secondary batteries, when using the charge and discharge test device for secondary batteries, when a load current of several hundred to several thousand amperes [A] flows with the charge and discharge of the battery, if an incomplete electrical contact state is caused at the connection points that come into contact during the test, the increase in contact resistance and the accompanying heat generation will deteriorate the battery and act as a factor that makes the measurement results of the battery pack unreliable.

[0005] If an imperfect electrical contact exists, the initial heat generation temperature will be low and may not cause problems. However, over time, due to factors such as increased load current and inadequate heat dissipation conditions, the heat generation temperature will rise rapidly. This increase in heat generation temperature will further increase the contact resistance, and the resulting increase in heat generation will have many adverse effects on the mechanical durability of the electrical connector.

[0006] Therefore, when implementing high-current contactors, there is a need for contactors that can minimize contact resistance when used for charging and discharging tests of high-current batteries, or when making selective electrical connections (switchable electrical connections) to connection points with high currents of several hundred to several thousand amperes. [Overview of the project] [Problems that the invention aims to solve]

[0007] Therefore, the object of the present invention is to provide a high-current contactor and a method for manufacturing the same that can be used for charging and discharging tests of high-current batteries or for selective electrical connection to connection points with high currents ranging from several hundred to several thousand amperes, while minimizing contact resistance. [Means for solving the problem]

[0008] The present invention, for the above-mentioned purpose, is a contactor for high-current connection, comprising an elastic support member made of a conductive and elastic alloy material, wherein the elastic support member is characterized in that the entire contact bottom surface is machined along the X and Y axes, and elastic legs extending integrally from the base in an inclined direction, and elastic contact feet at the tips of the elastic legs, and elastic connecting pieces that have been heat-treated to have elastic durability are arranged in a matrix across the entire contact bottom surface, thereby forming an assembly of elastic connecting pieces.

[0009] In the contactor for high-current connection of the present invention, the elastic connection piece matrix assembly can form left and right elastic connection piece matrix parts arranged on the left and right sides of the left-right center line plane such that the inclination directions of the elastic legs of the elastic connection pieces are symmetric with each other.

[0010] Also, the elastic connection piece matrix assembly can be configured such that all the elastic legs of the elastic connection pieces face one side inclination direction.

[0011] As another aspect of the present invention, in the contactor for high-current connection, it is composed of an elastic support member made of an alloy material having conductivity and elasticity. The elastic support member has an "S" - shaped elastic leg integrally extended from the base by machining in the X - axis and Y - axis directions on the entire contact bottom surface side, and an elastic contact leg at the tip of the elastic leg. Elastic connection pieces heat - treated to have elastic durability are arranged in a matrix on the entire contact bottom surface side, thereby forming an elastic connection piece matrix assembly.

[0012] As still another aspect of the present invention, in the contactor for high - current connection, it is composed of an elastic support member made of an alloy material having conductivity and elasticity. The elastic support member forms a matrix - shaped upright support piece integrally rising and extending from the base by machining in the X - axis and Y - axis directions in order to provide elastic connection pieces arranged in a matrix on the entire contact bottom surface side. Each of the upright support pieces has an elastic leg obtained by bending it obliquely and an elastic contact leg at the tip of the elastic leg. Elastic connection pieces heat - treated to have elastic durability are arranged in a matrix on the entire contact bottom surface side, thereby forming an elastic connection piece matrix assembly.

[0013] Also, in the present invention, the elastic contact leg of the elastic connection piece is configured such that a flat processing surface of the same level is formed by flatness adjustment processing.

[0014] Also, the elastic connection piece assembly of the elastic support member is plated with a material for electrical contact, and further includes an electrical contact plating layer formed on the elastic contact leg of the elastic connection piece.

[0015] Furthermore, the present invention is characterized in that a stopper projection is further provided on a part of the contact bottom surface side of the elastic support member for limiting the elastic depth of the elastic connection piece matrix assembly.

[0016] Furthermore, in another aspect of the present invention, a method for manufacturing a high-current contactor is characterized by comprising: a step of obtaining a contactor base material from an elastic support member made of a conductive and elastic alloy material; a step of machining the entire contact bottom surface side of the elastic support member of the contactor base material along the X and Y axes to obtain an elastic connection piece matrix assembly in which elastic connection pieces, formed to have elastic legs integrally extended in an inclined direction from the base and elastic contact feet at the tips of the elastic legs, are arranged in a matrix across the entire contact bottom surface side; and a step of performing an age hardening treatment as a heat treatment to increase the elastic durability, fatigue resistance, and conductivity of the elastic connection piece matrix assembly constituting the elastic support member.

[0017] Furthermore, in yet another aspect of the present invention, a method for manufacturing a high-current contactor comprises: a step of obtaining a contactor base material from an elastic support member made of a conductive and elastic alloy material; a step of forming an upright support piece in the shape of a matrix, integrally extended upright from the base of the elastic support member of the contactor base material by processing the X and Y axes of the matrix in order to provide elastic connecting pieces arranged in a matrix across the entire contact bottom surface; a step of obtaining an elastic connecting piece matrix assembly in which elastic legs obtained by bending each of the upright support pieces to be inclined and elastic connecting pieces formed to have elastic contact feet at the tips of the elastic legs are arranged in a matrix across the entire contact bottom surface; and a step of performing an age hardening treatment as a heat treatment in order to increase the elastic durability, fatigue resistance and conductivity of the elastic connecting piece matrix assembly constituting the elastic support member. [Effects of the Invention]

[0018] This invention improves the structure of high-current contactors, offering the advantage of minimizing contact resistance when used for charging and discharging tests of high-current batteries or when making selective electrical connections to high-current points ranging from several hundred to several thousand amperes. [Brief explanation of the drawing]

[0019] [Figure 1] Perspective configuration diagram of a contactor for high-current connection according to an embodiment of the present invention [Figure 2] Front configuration diagram of FIG. 1 [Figure 3] Side configuration diagram of FIG. 1 [Figure 4] Plan configuration diagram of FIG. 1 [Figure 5] Perspective view of a battery durability test device as an example of a charge and discharge test of a high-current battery in which a contactor for high-current connection according to an embodiment of the present invention is adopted [Figure 6] Exploded perspective view of the clamp jig portion of FIG. 5 in which the contactor for high-current connection of the present invention is installed [[ID=I19]] [Figure 7] Operation state diagram of the contactor for high-current connection of the present invention adopted in the battery durability test device of FIG. 5 [Figure 8] Front and enlarged configuration diagram of a contactor for high-current connection according to another embodiment of the present invention [Figure 9] Front and enlarged configuration diagram of a contactor for high-current connection according to another embodiment of the present invention [Figure 10] Front and enlarged configuration diagram of a contactor for high-current connection according to another embodiment of the present invention [Figure 11] Front and enlarged configuration diagram of a contactor for high-current connection according to another embodiment of the present invention [Figure 12] Diagram showing the manufacturing procedure of a contactor for high-current connection according to yet another embodiment of the present invention [Figure 13] Schematic configuration diagram of an electronic contactor (MC: Magnetic Contactor) in which a contactor for high-current connection according to another embodiment of the present invention is adopted

Mode for Carrying Out the Invention

[0020] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0021] The contact surfaces on both sides of a high-current connection point (e.g., the switch terminals of electrical connectors such as circuit breakers (NFB: No Fuse Breaker)) when making a selective electrical connection to a point where the current can reach several hundred to several thousand amperes, as well as the electrode terminal surfaces of the battery pack under test and the contact surfaces of the high-current connection contacts of the charge / discharge test equipment, are not perfectly flat.

[0022] When the surface of the contact surface of the switching mechanism is magnified and examined closely, it is found to be finely uneven. Therefore, the actual contact area between the contact surfaces of the two conductors is much smaller than the apparent contact area, and is formed locally at the same time.

[0023] Therefore, when current flows through the contact interface between two conductors, the actual contact area through which the current can pass is much smaller than the apparent contact area, and the current concentrates and flows only at the actual contact point.

[0024] In this relationship, large currents, ranging from hundreds to thousands of amperes, concentrate and flow through limited actual contact points at the contact interface between the terminal surface of a connection point and a high-current contactor, or between the electrode terminal surface of a battery pack and the contact interface of a high-current probe. This creates contact resistance, which in turn causes heat generation.

[0025] Equation 1 below shows the relationship between the applied current i and the amount of heat generated by the contact resistance R, i.e., the contact heat quantity Q.

[0026]

number

[0027] Q: Contact heat amount [W], i: Applied current, R: Contact resistance

[0028] Contact resistance R is the electrical resistance arising from the contact force, contact type, and characteristics of the contact surface, and is determined by the constriction resistance of the actual contact area (effective contact area), regardless of the apparent contact area. Therefore, contact resistance R is also known as constriction resistance. Contact resistance R is inversely proportional to the actual contact area (effective contact area) between the contact interfaces.

[0029] When contact surfaces are made, the increase in heat generated due to contact resistance makes the measurement results for test subjects such as battery packs unreliable. Therefore, it is necessary to minimize the contact resistance value when making selective electrical connections to high-current points, such as those involving hundreds or thousands of amperes.

[0030] If the contact resistance R of the contact surface of the high-current contactor that contacts the terminals of the high-current connection point can be reduced, then, as shown in Equation 1, the contact heat Q generated by the high-current contactor can also be reduced, and reliable measurement results or reliable performance values ​​of the high-current contactor can be obtained.

[0031] Furthermore, while the contact resistance R can vary by several to more than ten times depending on the contact configuration of the connecting contactor, the present invention aims to minimize the contact resistance R and minimize fluctuations in the contact resistance value according to the contact configuration in order to realize a high-current connecting contactor.

[0032] In the present invention, when constructing a contactor for high-current connection, firstly, a large number of real contact conductive spots are formed in a matrix structure on the contact bottom surface side of the contactor that forms the contact interface. This allows the large current to be distributed and flow through parallel paths via the large number of matrix-arranged real contact conductive spots, minimizing contact resistance. The large number of real contact conductive spots are configured to form a matrix cluster.

[0033] Secondly, the design aims to ensure low contact resistance by providing a reliable spring tension on the contact bottom side of the contactor that forms the contact interface, and each of the numerous actual contact conductive spots has an independent spring force.

[0034] Figure 1 is a perspective view of a high-current contactor 2 according to an embodiment of the present invention, Figure 2 is a front view of Figure 1, and Figure 3 is a side view of Figure 1. Figure 4 is a plan view of Figure 1.

[0035] It should be understood that the high-current connection contactor 2 of the present invention shown in Figure 1 is an example of a form that can be used in a high-current battery charge / discharge test apparatus as exemplified in Figure 5, and that the contactor can be manufactured in a shape suitable for electrical connection to high-current connection points.

[0036] The high-current contactor 2 of the present invention consists of a base member 4 made of copper material with excellent electrical conductivity, and an elastic support member 6 made of an alloy material of beryllium copper [BeCu] which has conductivity and elasticity, as the base metal welded to one side of the base member 4.

[0037] The elastic support member 6 of the high-current contactor 2 of the present invention forms the contact interface and is located on the contact bottom side of the contactor. Therefore, it should form a reliable spring tension contact and must be made of a material with excellent electrical conductivity.

[0038] According to the present invention, the beryllium copper alloy used in the elastic support member 6 of the high-current contactor 2 is a copper alloy that has good electrical conductivity, good mechanical spring properties, and good workability. In other words, beryllium copper (BeCu) used as the material for the elastic support member 6 of the present invention has excellent properties that are like a combination of the high conductivity of copper and the high strength of steel, making it ideal as a metal for the contact bottom side of the contactor.

[0039] In this invention, the elastic support member 6 is made of beryllium copper selected from among the types of beryllium copper alloys that have good electrical conductivity, excellent spring properties, and a component ratio that maintains high stress relaxation resistance even at high temperatures.

[0040] The elastic support member 6 in the present invention is most preferably made of a beryllium copper alloy, and may optionally include chromium copper alloy, tungsten copper alloy, nickel copper alloy, and other equivalent materials that are conductive and elastic.

[0041] First, in this invention, as an initial step in manufacturing the contactor 2 for high-current connections, a contactor base material is obtained by welding an elastic support member 6 made of beryllium copper to a base material member 4 made of copper.

[0042] Using the contactor base material obtained in this way, it is possible to manufacture various contactor shapes (test probes and contact pads) that suit the characteristics of the connection point. In the case of Figure 1, for example, it can be manufactured in a form in which a flat rectangular body is attached to the tip of a cylindrical rod so that it can be used as a high-current connection contactor 2 in a charge / discharge test device for high-current batteries.

[0043] After obtaining the contactor base material in this manner, the present invention constructs an elastic connection piece matrix assembly 14, as illustrated in Figure 1, by machining the contact bottom surface of the elastic support member 6 made of beryllium copper (BeCu) material located on the tip side of the contactor base material into a matrix shape and then heat-treating it, thereby minimizing contact resistance even for high currents of several hundred to several thousand amperes.

[0044] In other words, the elastic connection piece matrix assembly 14 of the present invention forms a matrix cluster of actual contact conductive spot matrices that allows large currents to flow simultaneously in a parallel path configuration at the contact interface, and each actual contact conductive spot in the matrix cluster has a reliable spring tension, thereby minimizing contact resistance.

[0045] More specifically, the elastic connection piece matrix assembly 14 of the high-current contactor 2 of the present invention is formed by machining a matrix shape on the entire contact bottom surface side of the elastic support member 6 made of beryllium copper (BeCu) material. As shown in Figures 2 and 3, dozens to hundreds of elastic connection pieces 10, each having an elastic leg portion 10a integrally extended from the base portion 8 of the elastic support member 6 made of beryllium copper material and an elastic contact foot portion 10b at the tip of the elastic leg portion 10a, are arranged in a matrix as shown in Figure 4. Each elastic connection piece 10 arranged in a matrix in the elastic connection piece matrix assembly 14 has spring tension and corresponds to an actual contact conductive spot in the actual contact conductive spot matrix group that is dispersed by high current to form each parallel path.

[0046] The design configuration of the elastic connection matrix assembly 14, which has a large number of elastic connection pieces 10 as an example shown in Figures 1 to 4, is preferably obtained by machining the X and Y axes of the matrix using a cutting method for the X and Y axes.

[0047] Among the cutting methods for the X and Y axes of a matrix according to the present invention, the wire cutting method using a wire is preferable. The wire cutting method can include the wire electrical discharge machining method and the diamond wire cutting method, and in the specific embodiment of the present invention, the wire electrical discharge machining method is more preferable.

[0048] Wire-cut electrical discharge machining (EDM) is a machining method that uses a spark generated by an electrical discharge between a moving wire electrode and the contact bottom surface of an elastic support member 6 to cut a workpiece, much like a sawtooth. Because it uses thin wires of 0.05 to 0.3 mm, it is possible to perform much more precise work than with lasers or water pressure. Furthermore, elastic connecting pieces 10 in a matrix arrangement structure can be machined to desired precise dimensions and shapes via numerical control (NC).

[0049] The diamond wire cutting method is a processing method that uses a diamond wire cutter, which employs a diamond loop wire coated with diamond powder, to cut workpieces with ultra-high precision.

[0050] Referring again to Figure 2, the entire contact bottom surface side of the elastic support member 6 in the contactor base material is machined along the X-axis (row) and Y-axis (column), preferably by wire-cut electrical discharge machining, using numerical control to form the elastic connecting piece 10 of the elastic connecting piece matrix assembly 14, by having an elastic leg portion 10a that extends integrally from the base portion 8 in the inclined direction, and an elastic contact foot portion 10b at the tip of the elastic leg portion 10a.

[0051] As shown in Figure 2, in order to increase the actual contact area (effective contact area) of the high-current contact contact 2, the left-right width of the elastic contact foot 10b (see Figure 2) can be machined to be larger than the left-right width of the elastic leg 10a that acts as a spring (see Figure 2). As a result, as shown in Figure 2, residual pins that were excluded from wire-cut electrical discharge machining between the elastic leg 10a may remain.

[0052] In constructing the elastic connecting piece matrix assembly 14 provided by cutting the X-axis (rows) and Y-axis (columns) of the matrix according to the present invention, as shown in the example in Figure 1 or the example in Figure 9, it can be constructed with left and right elastic connecting piece matrix sections arranged on the left and right sides of the left and right center planes such that the inclination directions of the elastic legs 10a of the elastic connecting pieces 10 are symmetrical with respect to each other.

[0053] In one example shown in Figure 1, the left and right center lines form the axis of symmetry, and the elastic legs 10a of the elastic connecting piece 10 are formed at an angle on the left and right sides, facing each other as if greeting. In another example shown in Figure 9, the left and right center lines form the axis of symmetry, and the elastic legs 10a of the elastic connecting piece 10 are formed at an angle on the left and right sides, facing each other with their backs to each other as if greeting in opposite directions.

[0054] Furthermore, in constructing the elastic connecting piece matrix assembly 14 provided by cutting along the X-axis (rows) and Y-axis (columns) according to the embodiment of the present invention, as shown in another example in Figure 8, the elastic legs 10a of the elastic connecting pieces 10 can also be configured to be inclined to one side.

[0055] In addition, when constructing the elastic connection piece matrix assembly 14 provided by cutting the X-axis (row) and Y-axis (column) according to the embodiment of the present invention, the elastic legs 10a of the elastic connection piece 10 are not simply formed in an inclined manner. Instead, as shown in another example in FIGS. 10 and 11, it can be configured in a composite bending form.

[0056] That is, as shown in another example in FIGS. 10 and 11, the elastic support member 6 has an "S" - shaped elastic leg 10a integrally extended from the base 8 by cutting the entire contact bottom surface side along the X-axis and Y-axis, and an elastic contact foot 10b at the tip of the elastic leg 10a. The elastic connection pieces 10 heat-treated to have elastic durability are arranged in a matrix on the entire contact bottom surface side, thereby constituting the elastic connection piece matrix assembly 14.

[0057] In FIG. 10, a structure in which the "S" - shaped elastic leg 10a is formed in one stage is shown, and in FIG. 11, a structure in which the "S" - shaped elastic leg 10a is extended and formed in two stages is shown.

[0058] On the other hand, the elastic connection piece matrix assembly 14 of the high - current connection contactor 2 of the present invention can be formed by using cutting such as the wire - cut machining method of the X - axis and Y - axis. However, as another modification example as shown in FIG. 12, it can also be realized by precision wheel cutting and bending methods.

[0059] FIG. 12 is an illustration realized by using the wheel cutting and bending processing methods as another example for constructing the elastic connection piece matrix assembly 14 of the present invention.

[0060] Referring to FIG. 12, in order to provide the elastic support member 6 of the contactor base material with elastic connection pieces 10 arranged in a matrix on the entire contact bottom surface side, at least one of the X - axis and Y - axis of the matrix is provided with a plurality of cutting grooves 31 on the base 8 as shown in (a) of FIG. 12 by wheel cutting. At this time, a stopper convex portion 16 for limiting the elastic depth of the elastic connection piece matrix assembly 14 is also provided in advance.

[0061] As a result, the matrix-shaped upright support pieces 30 remain, extending upright from the base 8, sandwiching the cutting groove 31 provided on the base 8.

[0062] Subsequently, as shown in Figure 12(b), an iron core 32 or the like is inserted into the cutting groove 31, and the upright support pieces 30 arranged in a matrix structure as shown in Figure 12(c) are bent to be inclined, thereby forming an elastic connecting piece 10 having an elastic leg portion 10a and an elastic contact foot portion 10b at the tip of the elastic leg portion 10a. Thus, the elastic connecting piece matrix assembly 14 of the present invention is realized when the elastic connecting piece 10 thus provided is arranged in a matrix across the entire bottom surface of the elastic support member 6, and the elastic connecting piece matrix assembly 14 is also provided on one side with a stopper projection 16 for limiting the elastic depth of the elastic connecting piece matrix assembly 14.

[0063] When providing the elastic connecting piece matrix assembly 14 of the present invention as described above, it is preferable to provide it using an X-axis and Y-axis cutting method such as wire-cut electrical discharge machining, and if necessary, it can also be provided using a precision wheel cutting and bending method as illustrated in Figure 12.

[0064] Furthermore, when forming the elastic connection matrix assembly 14 of the high-current connection contactor 2 of the present invention by machining, as shown in Figure 2, it is preferable to further provide a stopper projection 16 on a part of the contact bottom surface side of the elastic support member 6 to limit the elastic depth of the elastic connection piece 10 of the elastic connection piece matrix assembly 14, and it is even more preferable to form it on the deeper side of the contact bottom surface.

[0065] Although Figures 8 to 11 do not show the state in which the stopper projection 16 as shown in Figure 2 is provided, it is preferable that the stopper projection 16 as shown in Figure 2 is provided on the deeper side of the contact bottom surface of the elastic support member 6.

[0066] After the elastic connecting pieces 10 constituting the elastic connecting piece matrix assembly 14 of the present invention are machined and provided, the upper surface of each elastic contact foot 10b of the elastic connecting piece 10 constituting the elastic connecting piece matrix assembly 14 is subjected to flatness adjustment processing by a wire-cut electrical discharge machining method or the like, so that flat machined surfaces of the same level are formed on the elastic contact foot 10b of the elastic connecting piece 10.

[0067] The flat machined surfaces at the same level formed on all elastic contact feet 10b of the elastic connection piece matrix assembly 14 are brought close to a perfect plane, thereby increasing the effective contact area that reduces contact resistance. In other words, the elastic connection pieces 10 of the elastic connection piece matrix assembly 14 are maximized to become actual contact conductive spots in the actual contact conductive spot matrix group.

[0068] In this invention, after forming the elastic connection piece matrix assembly 14 on the elastic support member 6 by the cutting process described above, the elastic support member 6 including the elastic connection piece matrix assembly 14 is heat-treated to restore the elastic durability of the elastic connection pieces 10 that were burnt out by the heat generated during the cutting process, to improve fatigue resistance, and to increase conductivity.

[0069] The heat treatment method according to the present invention is an age hardening treatment.

[0070] The age hardening treatment, which is a heat treatment for the elastic connection matrix assembly 14 of beryllium copper material, is performed below the solution annealing temperature. During the age hardening process, hard, fine particles rich in beryllium are generated within the beryllium copper structure and distributed throughout the structure, which plays a role in improving the strength due to the heat treatment.

[0071] By performing a heat treatment such as age hardening on the elastic connection piece matrix assembly 14 of the elastic support member 6, the elastic connection pieces 10 of the elastic connection piece matrix assembly 14 of the high-current contactor 2 of the present invention are given complete mechanical spring properties. That is, the elastic connection pieces 10 of the elastic connection piece matrix assembly 14 of the high-current contactor 2 of the present invention have elastic durability and fatigue resistance, possess reliable spring tension, and also have increased conductivity.

[0072] Furthermore, in this invention, after performing a heat treatment similar to that used for age hardening, the elastic connection piece matrix assembly 14 of the age-hardened elastic support member 6 is plated with an electrical contact material to form an electrical contact plating layer 12 on the elastic connection piece 10, as shown in Figures 2, 8 to 11.

[0073] Although not shown in Figure 12, a similar flattening surface treatment and heat treatment are performed to form the plating layer 12 for electrical contacts (Figure 12(d)).

[0074] The plating layer 12 for electrical contacts formed on the elastic connecting piece 10 is preferably made of a material with good conductivity and durability, and hard gold plating and hard silver plating are included here.

[0075] As described above, the elastic connection piece matrix assembly 14 of the high-current contactor 2 of the present invention is machined to have elastic connection pieces 10 that are integrally extended from the base 8 of the beryllium copper elastic support member 6. After machining so that the elastic connection pieces are arranged in a matrix ranging from several tens to several hundred, heat treatment is performed so that the actual contact area (effective contact area) of the elastic connection piece matrix assembly 14 is increased so that it is as close as possible to the entire bottom surface of the elastic support member 6 by the numerous elastic connection pieces 10 arranged in a matrix. In other words, a large number of actual contact conductive spots are formed on the contact bottom surface side of the high-current contactor 2, which forms the contact interface, by the elastic connection pieces 10 arranged in a matrix.

[0076] As a result, in the high-current contactor 2 of the present invention, the high current flows dispersed through the actual contact conductive spots of a large number of elastic connecting pieces 10 arranged in a matrix, and each elastic connecting piece 10 forms a reliable spring tension, thereby minimizing contact resistance at the contact interface.

[0077] The inventors of this application have confirmed that the contact resistance is minimized to approximately 1 / 10th of the contact resistance when the high-current connection contactor 2 of the present invention is not used.

[0078] Figures 5 to 7 show an example of applying the high-current connection contactor 2 of the present invention, as illustrated in Figures 1 to 4, to a charge / discharge test apparatus for a high-current battery.

[0079] Figure 5 is a perspective view of a battery durability test apparatus 100, which is an example of a battery charge / discharge test apparatus for high-current batteries employing the high-current connection contactor 2 of Figure 1 according to an embodiment of the present invention. Figure 6 is an exploded perspective view of the clamp jig portion of Figure 5, on which the high-current connection contactor 2 of the present invention is installed. Figure 7 is an operating diagram of the high-current connection contactor 2 of the present invention employed in the battery durability test apparatus 100 of Figure 5.

[0080] The high-current contactor 2 used in the battery durability test apparatus 100 is mainly called a probe, is connected to the high-current power supply line 26, is installed in the clamp fixture 20, and is raised and lowered by the operator's knob 24.

[0081] After placing the battery pack 22 into the battery durability test apparatus 100 as illustrated in Figure 5, the high-current connection contactor 2 of the present invention is lowered from state (a) in Figure 7 to state (b) using a clamp jig 20 to which the high-current connection contactor 2 of the present invention is attached. The elastic connection piece matrix assembly 14 of the contactor 2 then elastically contacts the electrode terminals 22a of the battery pack 22. Even if the high-current connection contactor 2 is lowered excessively, each elastic connection piece 10 arranged in a matrix in the elastic connection piece matrix assembly 14 is protected without losing its elasticity by the stopper protrusion 16 formed in the depth of the elastic support member 6.

[0082] In this invention, the structure of the elastic connection piece matrix assembly 14 of the high-current connection contactor 2 forms a matrix cluster of actual contact conductive spots. As a result, the actual contact area (effective contact area) with the electrode terminals 22a of the battery pack 22 is maximized by numerous actual contact conductive spots. Furthermore, since each actual contact conductive spot formed by the elastic connection piece 10 has reliable spring tension, contact resistance at the contact interface is minimized according to this invention.

[0083] Furthermore, in this invention, even with regard to fluctuations in the contact configuration of the high-current connection contactor 2 due to surrounding environmental factors such as the weight of the power supply line 26 and the difficulty of precisely raising and lowering the high-current connection contactor 2 vertically, adaptive measures are taken due to the characteristic that a reliable spring tension is formed in the actual contact conductive spot matrix cluster, and the range of fluctuations in the contact resistance value is almost eliminated.

[0084] Figure 13 shows a schematic configuration of an electronic contactor (MC: Magnetic Contactor) 200 employing the high-current connection contactor 2 according to another embodiment of the present invention shown in Figure 12, and is an example in which the high-current connection contactor 2 is applied to a moving tip 48.

[0085] The electronic contactor 200 illustrated in Figure 13 is equipped with a movable tip 48 and a fixed tip 50 as switching contacts for opening and closing lines through which high current flows, and a high-current connection contactor 2 in the form shown in Figure 12, according to another embodiment of the present invention, is mounted on the movable tip 48.

[0086] The electronic contactor 200 in Figure 13 is mainly used when remotely controlling a high-power load power supply. Power is applied to a coil 40 wound around an iron core, and as current flows through the coil 40, the fixed core 42 seated together with the coil 40 becomes an electromagnet, attracting the moving core 46 of the upper armature 44. As a result, the movable tip 48, which is part of the high-current connection contactor 2 of the present invention, contacts the lower fixed tip 50, causing a large current to flow and the load, such as a motor connected to the circuit, to operate.

[0087] According to the present invention, the structure of the elastic contact piece matrix assembly 14 of the high-current contactor 2 provided on the movable tip 48 forms a matrix cluster of actual contact conductive spots. As a result, the actual contact area (effective contact area) with the fixed tip 50 is maximized by the numerous actual contact conductive spots of the elastic contact pieces 10 in the matrix structure. Furthermore, each actual contact conductive spot formed by the elastic contact piece 10 has reliable spring tension, and the contact resistance at the contact interface between the movable tip 48 and the fixed tip 50 is minimized.

[0088] When the movable chip 48 and the fixed chip 50 are in contact and energized, if the power is turned off by remote control or other means, the magnetism of the electromagnet formed on the fixed core 42 disappears, and the armature 44 retracts due to the force of the spring 54 placed in the case 52, causing the contact point between the fixed chip 50 and the movable chip 48 to separate. As a result, the lines of the electronic contactor 200 are interrupted, and no large current flows to the load.

[0089] As an example of the present invention employing a high-current connection contactor 2 that enables selective electrical connection to connection points with high currents ranging from several hundred to several thousand amperes, there is an electronic contactor (MC: Magnetic Contactor) as shown in Figure 13. It should be understood that this invention can also be applied to other similar devices such as circuit breakers (NFB), vacuum circuit breakers (VCB), power breakers, switches, transformers, etc.

[0090] In the description of the best embodiment of the present invention described above, a specific example was described in which both the X and Y axes of the matrix are machined to form the elastic connecting piece matrix assembly 14. However, either the X or Y axis of the matrix can also be formed by extrusion molding, and various modifications can be implemented without departing from the scope of the present invention, such as forming the basic form by primary extrusion or other molding processes and then forming it by secondary detailed machining. Therefore, the scope of the present invention should not be determined by the described embodiments, but by the claims and equivalents thereof. [Industrial applicability]

[0091] The present invention can be used for charging and discharging tests of high-current batteries, or to minimize contact resistance during selective electrical connections in electrical contact devices such as circuit breakers (NFB: No Fuse Breaker) that interrupt current in the event of abnormal conditions such as overload or wire breakage.

Claims

1. In a contactor for high-current connection, it is composed of an elastic support member made of an alloy material having conductivity and elasticity. The elastic support member has elastic leg portions integrally extending in an inclined direction from a base portion by machining the X-axis and Y-axis of a matrix on the entire contact bottom surface side, and elastic contact leg portions at the tips of the elastic leg portions. Elastic connection pieces heat-treated to have elastic durability are arranged in a matrix on the entire contact bottom surface side, thereby constituting an elastic connection piece matrix assembly. A contactor for high-current connection, characterized in that.

2. The elastic connection piece matrix assembly constitutes left and right elastic connection piece matrix portions arranged on the left and right sides of the left-right center line plane such that the inclined directions of the elastic leg portions of the elastic connection pieces are symmetric with each other. The contactor for high-current connection according to claim 1, characterized in that.

3. The elastic connection piece matrix assembly is configured such that all of the elastic leg portions of the elastic connection pieces face one side inclined direction. The contactor for high-current connection according to claim 1, characterized in that.

4. In a contactor for high-current connection, it is composed of an elastic support member made of an alloy material having conductivity and elasticity. The elastic support member has a "self" - shaped elastic leg portion integrally extending from a base portion by machining the X-axis and Y-axis of a matrix on the entire contact bottom surface side, and elastic contact leg portions at the tips of the elastic leg portions. Elastic connection pieces heat-treated to have elastic durability are arranged in a matrix on the entire contact bottom surface side, thereby constituting an elastic coupling piece matrix assembly. A contactor for high-current connection, characterized in that.

5. In a contactor for high-current connection, it is composed of an elastic support member made of an alloy material having conductivity and elasticity. The elastic support member forms a standing support piece in a matrix form integrally standing and extending from a base portion by machining the X-axis and Y-axis of a matrix in order to provide elastic connection pieces arranged in a matrix on the entire contact bottom surface side. Elastic leg portions obtained by bending each of the standing support pieces to be inclined, and elastic contact leg portions at the tips of the elastic leg portions. Elastic connection pieces heat-treated to have elastic durability are arranged in a matrix on the entire contact bottom surface side, thereby constituting an elastic connection piece matrix assembly. A contactor for high-current connection, characterized in that.

6. The elastic contact leg portion of the elastic connection piece is configured such that a flat processing surface of the same level is formed by flatness adjustment processing. The contactor for high-current connection according to any one of claims 1, claim 4, and claim 5, characterized in that.

7. A high-current contactor according to any one of claims 1, 4, or 5, characterized in that the elastic contact feet within the elastic contact pieces of the elastic contact matrix of the elastic support member are configured to have an electrical contact plating layer formed from an electrical contact material.

8. A high-current contactor according to any one of claims 1, 4, or 5, further comprising a stopper projection on a portion of the contact bottom surface side of the elastic support member for limiting the elastic depth of the elastic connection piece matrix assembly.

9. The high-current contactor according to claim 1 or claim 4, characterized in that the X-axis and Y-axis machining is performed by one of wire-cut electrical discharge machining and diamond wire-cut machining.

10. In a method for manufacturing a contactor for high-current connections, The process of obtaining a contactor base material with an elastic support member made of a conductive and elastic alloy material, The process of obtaining an elastic connection piece matrix assembly in which elastic connecting pieces, formed such that elastic legs are integrally extended from the base in an inclined direction by machining the X and Y axes of the matrix and elastic connecting pieces have elastic contact feet at the tips of the elastic legs, are arranged in a matrix across the entire contact bottom surface side of the elastic support member of the contactor base material, A method for manufacturing a contactor for high-current connections, characterized by comprising a process of performing age hardening as a heat treatment to increase the elastic durability, fatigue resistance, and conductivity of an assembly of elastic connection pieces constituting an elastic support member.

11. In a method for manufacturing a contactor for high-current connections, The process of obtaining a contactor base material with an elastic support member made of a conductive and elastic alloy material, The process of forming an upright support piece in the shape of a matrix, which is integrally extended upright from the base, by machining the X and Y axes of the matrix, in order to provide elastic connecting pieces arranged in a matrix across the entire bottom surface of the contactor base, A process to obtain an elastic connecting piece matrix assembly in which elastic legs obtained by bending each of the upright support pieces to be inclined, and elastic connecting pieces formed to have elastic contact feet at the tips of the elastic legs, are arranged in a matrix across the entire contact bottom surface, A method for manufacturing a contactor for high-current connections, characterized by comprising a process of performing age hardening as a heat treatment in order to increase the elastic durability, fatigue resistance, and conductivity of the assembly of elastic connection pieces constituting the elastic support member.

12. A method for manufacturing a high-current contactor according to claim 10 or claim 11, further comprising a step of adjusting the flatness of the elastic contact feet of the elastic contact pieces to form a flat surface of the same level in the elastic contact piece matrix assembly, in the process of obtaining an elastic contact piece matrix assembly.

13. A method for manufacturing a high-current contactor according to claim 10 or 11, further comprising the step of plating an assembly of elastic connecting pieces of an age-hardened elastic support member with an electrical contact material to form an electrical contact plating layer on the elastic connecting pieces.

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