Switching system

Abstract

A switching system, in particular of an on-board electrical system of a motor vehicle having a first disc which has a first, a second, a third, and a fourth stationary contact. The second and the third stationary contact, are electrically contacted by a first contact bar of the first disc. The switching system also has a second disc which has a first, a second, a third, and a fourth movable contact. The first and the second movable contact are electrically contacted by a second contact bar of the second disc, and the third and the fourth movable contact are electrically contacted by a third contact bar of the second disc. The second disc is rotationally mounted about a rotational axis relative to the first disc, wherein all the contacts are electrically connected in series in an angular position. A circuit breaker is also provided that includes a switching system.

Claims

1. A switching system for an on-board electrical system of a motor vehicle, the system comprising: a first disk having a first stationary contact and a second stationary contact and a third stationary contact and a fourth stationary contact, the second stationary contact and the third stationary contact electrically contact each other via a first contact bar of the first disk; and a second disk having a first movable contact and a second movable contact and a third movable contact and a fourth movable contact, the first movable contact and the second movable contact electrically contact each other via a second contact bar of the second disk, the third movable contact and the fourth movable contact electrically contact each other via a third contact bar of the second disk, wherein the second disk is rotationally mounted about a rotational axis relative to the first disk, and wherein the second disk is spring-loaded via a leg spring.

2. The switching system according to claim 1, wherein the rotational axis is substantially perpendicular to the second disk or wherein the first disk is substantially parallel to the second disk.

3. The switching system according to claim 1, wherein the second disk comprises a disk body, wherein the second contact bar and the third contact bar are positioned on a side of the disk body located opposite the first disk, and/or wherein the movable contacts are arranged in recesses of the disk body.

4. The switching system according to claim 1, further comprising a housing comprising a housing shell and a housing cover, and within which the first and the second disk are positioned.

5. The switching system according to claim 4, wherein the first disk is formed by the housing shell.

6. The switching system according to claim 4, wherein the housing shell has an axis journal on which the second disk is mounted.

7. A circuit breaker, comprising: a switching system according to claim 1; and a current sensor.

8. The switching system according to claim 1, wherein each stationary contact is disposed rotationally symmetrical at 90 with respect to an adjacent one of the stationary contacts.

9. The switching system according to claim 1, wherein each of the stationary contacts and each of the movable contacts comprise cylindrical copper disks.

10. A switching system for an on-board electrical system of a motor vehicle, the system comprising: a first disk having a first stationary contact and a second stationary contact and a third stationary contact and a fourth stationary contact, the second stationary contact and the third stationary contact electrically contact each other via a first contact bar of the first disk; a second disk having a first movable contact and a second movable contact and a third movable contact and a fourth movable contact, the first movable contact and the second movable contact electrically contact each other via a second contact bar of the second disk, the third movable contact and the fourth movable contact electrically contact each other via a third contact bar of the second disk; and a latch for the second disk, wherein the second disk is rotationally mounted about a rotational axis relative to the first disk.

11. A switching system for an on-board electrical system of a motor vehicle, the system comprising: a first disk having a first stationary contact and a second stationary contact and a third stationary contact and a fourth stationary contact, the second stationary contact and the third stationary contact electrically contact each other via a first contact bar of the first disk; and a second disk having a first movable contact and a second movable contact and a third movable contact and a fourth movable contact, the first movable contact and the second movable contact electrically contact each other via a second contact bar of the second disk, the third movable contact and the fourth movable contact electrically contact each other via a third contact bar of the second disk, wherein the second disk is rotationally mounted about a rotational axis relative to the first disk, and wherein the first contact bar comprises a first section and a second section, the first section and the second section each comprising a copper strip.

12. The switching system according to claim 11, wherein the first section and the second section contact each other via a bimetallic element.

13. The switching system according to claim 11, wherein the first section electrically contacts a contact pin associated with the second stationary contact.

14. A switching system for an on-board electrical system of a motor vehicle, the system comprising: a first disk having a first stationary contact and a second stationary contact and a third stationary contact and a fourth stationary contact, the second stationary contact and the third stationary contact electrically contact each other via a first contact bar of the first disk; a second disk having a first movable contact and a second movable contact and a third movable contact and a fourth movable contact, the first movable contact and the second movable contact electrically contact each other via a second contact bar of the second disk, the third movable contact and the fourth movable contact electrically contact each other via a third contact bar of the second disk; and four contact pins embedded in each of the first disk and the second disk, wherein the second disk is rotationally mounted about a rotational axis relative to the first disk.

15. The switching system according to claim 14, wherein the contact pins are made of an electrically conductive material.

16. The switching system according to claim 14, wherein the first stationary contact, the second stationary contact, the third stationary contact and the fourth stationary contact are each connected to one of the contact pins.

17. The switching system according to claim 14, wherein each of the contact pins is disposed rotationally symmetrical at 90 with respect to an adjacent one of the contact pins.

18. A switching system for an on-board electrical system of a motor vehicle, the system comprising: a first disk comprising: a first stationary contact, a second stationary contact, a third stationary contact; a fourth stationary contact; and a first contact bar electrically contacting the second stationary contact to the third stationary contact; and a second disk, comprising: a first movable contact; a second movable contact; a third movable contact; a fourth movable contact; a second contact bar electrically contacting the first movable contact to the second movable contact; and a third contact bar electrically contacting the third movable contact to the fourth movable contact, wherein the second disk is rotationally mounted about a rotational axis relative to the first disk, wherein the second disk is spring-loaded via a lea spring.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:

(2) FIG. 1 is an exploded view of a circuit breaker comprising a switching system;

(3) FIG. 2 illustrates, in part, the assembled circuit breaker;

(4) FIG. 3 illustrates a circuit breaker; and

(5) FIG. 4 is a perspective view of a first disk of a circuit breaker.

DETAILED DESCRIPTION

(6) In FIG. 1, a circuit breaker 2 is illustrated in an exploded view, and in FIG. 2, in an assembled view, which is provided to switch an electrical voltage of 48 volts within an on-board electrical system of a motor vehicle. The circuit breaker 2 includes a switching system 4 having a housing 10 comprising a housing cover 6 and a housing shell 8. The housing cover 6 not shown in FIG. 2 and the housing shell 8 are each integrally made of a plastic material by means of injection molding and made of an electrically non-conductive material. The housing shell 8 is cup-shaped and comprises a housing bottom 12 and housing walls 14 circumferentially surrounding the latter. One of the housing walls 14 has two slots 16, within which in each case a connector 18 is arranged in the form of a disk which extends partially into the interior of the housing 10. In this case, the connectors 18 form the contact-connection of the circuit breaker 2 and are adapted for a corresponding switch box of the motor vehicle, which in particular has a corresponding receptacle for these connectors 18.

(7) An axis journal 20 is formed on the housing bottom 12, which is concentric with and parallel to a rotational axis 21. The journal 20 itself, however, is rotationally fixed to the housing bottom 12. The remaining free end of the journal 20 is supported in the mounted state on the housing cover 6, which is welded to the housing shell 8. Mounted on the axle journal 20 are a first disk 22, a torsion spring 24 and a second disk 26, wherein the leg spring 24 is positioned between the two disks 22, 26. Consequently, the first and second disks 22, 26 and the leg spring 24 are positioned within the housing 10. The first disk 22 is disposed between the leg spring 24 and the housing bottom 12. The first disk 22 is non-rotationally supported on the axle journal 20, whereas the second disk 26 is rotatably supported around the axle journal 20. Here, the second disk 26 is arranged perpendicular to the axis of rotation 21 and parallel to the first disk 22.

(8) Further, a spring element 28 in the form of a spiral spring, which is supported both on the second disk 26 and on the cover 6, is mounted on the axle journal 20. By means of the spring element 28, a mechanical contact is ensured between the first and second disks 22, 26. In other words, the spring element 28 serves to axially bias in one direction, parallel to the rotational axis 21, wherein, however, the applied force by the spring element 28 is comparatively low.

(9) Both the first disk 22 and the second disk 26 each comprise a disk body 30, 32 made of an electrically non-conductive material, in particular a plastic or a ceramic. The disk bodies 30, 32 each have a substantially circular cross section, perpendicular to the axis of rotation 21. In the center, each of the two disk bodies 30, 32 have a central recess 34, within which the axle journal 20 is positioned in the assembled state. Four contact pins 36 made of an electrically conductive material such as copper are embedded in each of the disk bodies 30, 32 in the axial direction, i.e., aligned parallel to the rotational axis 21 and arranged rotationally symmetrically, relative to the latter. Between adjacent contact pins 36, an angle of 90 is consequently formed, wherein the apex is located on the rotational axis 21. The contact pins are respectively arranged in pairs, diametrically with respect to the axis of rotation 21.

(10) The first disk 22 has a first stationary contact 38, a second stationary contact 40, a third stationary contact 42 and a fourth stationary contact 44 positioned on the surface of the disk body 30 of the first disk 22, facing the second disk 26, which are connected to each of the contact pins 36. Here, each of the stationary contacts 38, 40, 42, 44 is assigned to one of the contact pins 36. The connection of the stationary contacts 38, 40, 42, 44 to the contact pins 36 is effected, for example, by means of welding or soldering.

(11) The first disk 22 further includes a first contact bar 46 having a first section 48 and a second section 50, which are each composed of a copper strip. The two sections 48, 50 electrically contact one another via a bimetallic element 52 (bimetallic snap-disk/bimetallic strip) of the first contact bar 46. The first portion 48 of the first contact bar 46 also electrically contacts the contact pin 36, which is associated with the second stationary contact 40. In other words, the first section 48 electrically contacts the second stationary contact 40. The second section 50 electrically contacts the contact pin 36, which is associated with the third stationary contact 42. Consequently, the second stationary contact 40 and the third stationary contact 42 electrically contact each other by means of the first contact bar 46.

(12) By means of the associated contact pin 36, the first stationary contact 38 electrically contacts a fourth contact bar 54 made of a copper strip, which in turn electrically contacts one of the connectors 18. By means of the associated contact pin 36, the fourth stationary contact 44 electrically contacts a fifth contact bar 56 made of a copper strip, which in turn electrically contacts the remaining connector 18. The contact bars 46, 54, 56 are located, with the exception of the bimetallic element 52, completely on the side of the disk body 30 of the first disk 22, which faces away from the second disk 26, so that an electrical short circuit between these elements and elements of the second disk 26 is ruled out.

(13) The second disk 26 has a first movable contact 58, a second movable contact 60, a third movable contact 62 and a fourth movable contact 64, one of which respectively electrically contact one of the contact pins 36 of the second disk 26 and is connected to said pin. The second disk 26 also includes a second contact bar 66 and a third contact bar 68, which are each formed by a copper strip. The second and third contact bar 66, 68 are positioned on the side of the disk body 32 of the second disk 26 located opposite the first disk 22, wherein said second contact bar 66 electrically contacts the first movable contact 58 and the second movable contact 60 by means of two of the contact pins 36. The third contact bar 68 electrically contacts the contact pins 36 which are associated with the third movable contact 62 and the fourth movable contact 64, so that the third movable contact 62 and the fourth movable contact 64 electrically contact each other by means of the third contact bar 68. The stationary contacts 38, 40, 42, 44 and the movable contacts 58, 60, 62, 64 are similarly designed and are produced from small cylindrical disks made of copper.

(14) The first disk 22 further comprises a first pin 70 on which one of the legs 72 of the leg spring 24 is supported in the assembled state. The second disk 26 also has such a pin 70 on which the remaining leg 72 of the leg spring 24 is supported, so that the second disk 26 is spring-loaded. Further, the second disk 26 has a groove 74 on its circumference, within which the bimetallic element 52 rests in the activated state, i.e., in the electrically conductive state of the circuit breaker 2. Thus, the groove 74 and the bimetal element 52 form a latch 76; hence, the second disk 26 is held rotationally fixed by means of the leg spring 24 in spite of the spring load. The bimetallic element 52 also serves as a current sensor 78. In the event of an overcurrent, the bimetallic element 52 is heated and consequently bent, releasing the latch 76.

(15) The circuit breaker 2 further comprises an actuating mechanism 80 having a cylinder 82, which is guided at its free end, from the housing through an opening 84 of the housing wall 14, which is located substantially opposite the slots 16. At the remaining free end of the cylinder 82, i.e., at the free end which is located within the housing 10, a triangular element 84 is integrally formed, which is supported on a further pin 86 spaced apart from the rotational axis 21. The triangular element 84 is spring-loaded by a spring 88 which is supported on the inner wall of the housing wall 14.

(16) By actuating the actuating mechanism 80, the switching system 4 is placed in an electrically conductive state. For this purpose, the cylinder 82 is pressed into the housing 10 and the second disk 26 is brought into engagement with the bimetallic element 52 against the spring force of the torsion spring 24, so that the latch 76 is established. Consequently, the second disk 26 is moved to a certain angular position, relative to the first disk 22. Here, the first stationary contact 38 rests directly mechanically on the first movable contact 58, the second stationary contact 40 rests directly mechanically on the second movable contact 60, the third stationary contact 42 rests directly mechanically on the third movable contact 62 and the fourth stationary contact 44 rests directly mechanically on the fourth movable contact 64, so that all contacts 38, 40, 42, 44, 58, 60, 62, 64, are electrically connected in series and therefore, an electric current flow is possible between the two connectors 18 via all the contacts 38, 40, 42, 44, 58, 60, 62, 64 via the contact bars 46, 54, 56, 66, 68.

(17) In the event of an overcurrent between the two connectors 18, the overcurrent is detected by the current sensor 78 and the latch 76 is dissolved due to the deformation of the bimetallic element 52, resulting in the second disk 26 being substantially rotated 45 about the axis of rotation 21 as a result of the torsion spring 24. Due to the electrical voltage applied between the two connectors 18, in each case an arc is formed between the first stationary contact 38 and the first movable contact 58, and between the second movable contact 60 and the second stationary contact 40, and between the third stationary contact 42 and the third movable contact 62, and between the fourth movable contact 64 and the fourth stationary contact 44. These are connected in series to each other, and therefore, the electrical voltage required for the formation and maintenance of the arcs is relatively high. In addition, due to the relatively large number of contact points of arcs with one of the contacts 38, 40, 42, 44, 58, 60, 62, 64, a comparatively large contact voltage is present which further increases the arc voltage. Further, because of the increase of the respective arcs due to the rotational movement, the distance between respective mutually associated contacts is increased, which further increases the arc voltage. Also, the arcs are in direct contact with the disk bodies 30, 32 of the first and second disks 22, 26, which cools them and, consequently, increases the electrical resistance, which leads to a further increase in arc voltage.

(18) Due to the rotational movement, it is possible to design the circuit breaker 2 relatively flat, wherein furthermore the current sensor 78 is not used directly as an actuator for the contact opening, which is why said sensor is not damaged by the resulting melting loss. Rather, the current sensor 78 is only used to release the latch 76.

(19) FIG. 3 shows a further embodiment of the circuit breaker 2 in an exploded view, wherein only the first disk 22 has been modified. The second disk 26, the latch 76 and the actuating mechanism 80, however, have been left unchanged, as well as the connectors 18. The first disk 22 is formed by means of the housing bottom 12 which takes over the function of the disk body 30, which is not provided. The first contact bar 46 with the two sections 48, 50 and the fourth contact bar 54 and the fifth contact bar 56 are directly connected to the housing bottom 12. The stationary contacts 38, 40, 42, 44 are electrically contacted directly with the respective contact bars 46, 54, 56 and connected thereto with their free end. As a result, the axial overall height, i.e., the dimension of the circuit breaker 2 along the rotational axis 21, is reduced, as well as the number of required parts.

(20) FIG. 4 shows a further embodiment of the first disk 22, which is particularly preferably similarly designed to the second disk 26. The disk body 30 of the first disk 22 and the disk body 32 of the second disk 26 have four recesses 90 in place of the contact pins 36, within which the respective contacts 38, 40, 42, 44, 58, 60, 62, 64 are positively positioned, of which in this case only the second and third stationary contact 40, 42 and the second and third movable contact 60, 62 are shown. The contacts 38, 40, 42, 44, 58, 60, 62, 64 are flush with the surface facing the respective other disk 22, 26 so that the disks 22, 26 have a planar surface on this side. Also, the pin 70 is omitted.

(21) The leg spring 24 is located on the side of the other pin 86 of the second disk 26 and is, for example, supported on the cover 6. The first disk 22 also has two bores 92 that are radially outwardly offset relative to the central recess 34, within which projections engage which are not shown and which are integrally formed on the housing bottom 12 so that the first disk 22 is held rotationally fixed. The bores 92 are, for example, not provided in the second disk 26, or, if identical parts are used, no further components are inserted in the assembled state. In the embodiment shown in FIG. 1, the bores 92 are also provided.

(22) The invention is not limited to the exemplary embodiments described above. Rather, other variations of the invention can be derived therefrom by those skilled in the art without departing from the scope of the invention. In particular, all individual features described in connection with the various embodiments may also be combined in other ways without departing from the scope of the invention.

(23) The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.