Plug-in fuse element

Abstract

Embodiments disclose a plug-in fuse element comprising a strip-shaped sheet metal part having a first end section, a second end section, and an interposed center section, wherein the first end section is a flat plug-in contact; the second end section is a connecting region configured to connect to a stranded conductor, and the center section is an overcurrent protection device. In some embodiments, a stranded conductor is connected on at least one end to a connecting region of at least one plug-in fuse element. In some embodiments, a wiring system includes at least one stranded conductor connected via a flat plug-in contact of a plug-in fuse element to a flat conductor. In some embodiments, a vehicle comprises the at least one wiring system.

Claims

1. A plug-in fuse element for creating an electrical coupling between a flat conductor rail of a vehicle and a stranded conductor of the vehicle, the plug-in fuse element comprising: a strip-shaped sheet metal part extending longitudinally along a plane, the strip-shaped sheet metal part having a first end section, a second end section, and an interposed center section each extending longitudinally in a first direction along the plane, wherein: the first end section is a flat plug-in contact electrically connected to a laterally projecting tab of the flat conductor rail when the flat plug-in contact is inserted into a slot-shaped opening of a housing supported on the projecting tab, the flat plug-in contact configured to conduct heat away from the center section to the flat conductor rail; the second end section is a connecting region that directly connects to the stranded conductor and is configured to conduct heat away from the center section; and the center section is an overcurrent protection device.

2. The plug-in fuse element according to claim 1, wherein the first end section is formed as a tab.

3. The plug-in fuse element according to claim 1, wherein the flat plug-in contact includes a flat plug-in housing attached to the first end section by at least one areal contact.

4. The plug-in fuse element according to claim 1, further comprising: at least one cooling projection located on the sheet metal part and configured to dissipate heat from the overcurrent protection device.

5. The plug-in fuse element according to claim 1, wherein the sheet metal part is connected to at least one heat removal line configured to dissipate heat from the overcurrent protection device, the heat removal line being separate from the flat conductor rail and stranded conductor of the vehicle.

6. The plug-in fuse element according to claim 1, wherein the center section includes a cross-sectional taper formed as a fusible cutout.

7. The plug-in fuse element according to claim 1, wherein the center section includes at least one further component forming the overcurrent protection device.

8. The plug-in fuse element according to claim 1, further comprising: a thermally conductive housing surrounding at least the center section.

9. The plug-in fuse element according to claim 1, wherein: the strip-shaped sheet metal part includes two outer layers, the first outer layer made of a different metal from the second outer layer; a contact region of the flat plug-in contact is formed by one of the outer layers; and the connecting region is formed by the other outer layer.

10. The plug-in fuse element according to claim 1, wherein the plug-in fuse element includes at least one electrical filter, the electric filter reducing interfering magnetic or electric fields.

11. The plug-in fuse element according to claim 1, further comprising: a stranded conductor having at least one end connected to the connecting region of the plug-in fuse element.

12. The plug-in fuse element according to claim 11, wherein the stranded conductor further comprises: at least one wire connected to a cable lug, wherein the cable lug is connected via an areal contact to the second end section of the plug-in fuse element.

13. The plug-in fuse element according to claim 11, wherein the stranded conductor further comprises: at least one wire directly connected to the second end section of the plug-in fuse element.

14. A wiring system for a vehicle, comprising: a strip-shaped flat conductor rail extending longitudinally in a first direction within the vehicle, the flat conductor rail having a laterally projecting tab extending in a second direction perpendicular to the first direction, wherein the projecting tab supports a housing having a slot-shaped opening for establishing an electrical connection; a plug-in fuse element comprising a strip-shaped sheet metal part extending longitudinally in the second direction along a plane, the strip-shaped sheet metal part having a first end section, a second end section, and an interposed center section each extending longitudinally in the second direction along the plane, wherein: the first end section is a flat plug-in contact electrically connected to the laterally projecting tab when the flat plug-in contact is inserted into the slot-shaped opening of the housing, wherein the flat plug-in contact is configured to conduct heat away from the center section to the flat conductor rail; the second end section is a connecting region configured to conduct heat away from the center section; and the center section is an overcurrent protection device; and a stranded conductor having at least one end directly connected to the connecting region of the plug-in fuse element; wherein the at least one end of the stranded conductor is connected, via the flat plug-in contact of the plug-in fuse element connected to the laterally projecting tab, to the strip-shaped flat conductor.

15. The wiring system according to claim 14, further comprising: at least one cooling projection located on the strip-shaped sheet metal part of the plug-in fuse element, wherein the cooling projection is configured to dissipate heat from the overcurrent protection device.

16. The wiring system according to claim 14, wherein the strip-shaped sheet metal part of the plug-in fuse element is connected to at least one heat removal line configured to dissipate heat from the overcurrent protection device, the heat removal line being separate from the flat conductor rail and stranded conductor of the vehicle.

17. The wiring system according to claim 14, wherein the plug-in fuse element further comprises: a thermally conductive housing surrounding at least the center section.

18. The wiring system according to claim 14, wherein: the strip-shaped sheet metal part includes two outer layers, the first outer layer made of a different metal from the second outer layer; a contact region of the flat plug-in contact is formed by one of the outer layers; and the connecting region is formed by the other outer layer.

19. The wiring system according to claim 14, wherein the stranded conductor further comprises: at least one wire connected to a cable lug, wherein the cable lug is connected via an areal contact to the second end section of the plug-in fuse element.

20. A wiring system for a vehicle, comprising: a flat conductor rail extending longitudinally in a first direction along a vehicle body floor from a front end of the vehicle to a rear end of the vehicle, the flat conductor rail having a laterally projecting tab extending in a second direction perpendicular to the first direction, wherein the projecting tab supports a housing having a slot-shaped opening for establishing an electrical connection; a plug-in fuse element comprising a strip-shaped sheet metal part extending longitudinally in the second direction along a plane, the strip-shaped sheet metal part having a first end section, a second end section, and an interposed center section each extending longitudinally in the second direction along the plane, wherein: the first end section is a flat plug-in contact electrically connected to the laterally projecting tab when the flat plug-in contact is inserted into the slot-shaped opening of the housing, wherein the flat plug-in contact is configured to conduct heat away from the center section to the flat conductor rail; the second end section is a connecting region configured to conduct heat away from the center section; and the center section is an overcurrent protection device; and a stranded conductor having at least one end directly connected to the connecting region of the plug-in fuse element; wherein the at least one end of the stranded conductor is connected, via the flat plug-in contact of the plug-in fuse element connected to the laterally projecting tab, to the flat conductor.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIGS. 1A-B show an oblique view and a magnified view, respectively, of a section of a wiring system of a vehicle according to a first exemplary embodiment comprising a plug-in fuse element;

(2) FIG. 2 shows an oblique view of a section of a wiring system of a vehicle according to a second exemplary embodiment comprising a plug-in fuse element;

(3) FIG. 3 shows an oblique view of a section of a wiring system of a vehicle according to a third exemplary embodiment comprising a plug-in fuse element;

(4) FIG. 4 shows an oblique view of a section of a wiring system of a vehicle according to a fourth exemplary embodiment comprising a plug-in fuse element; and

(5) FIG. 5 shows an oblique view of an exploded illustration of a section of a wiring system according to the fourth exemplary embodiment.

DETAILED DESCRIPTION

(6) FIG. 1A shows an oblique view of a section of a wiring system L1 of a vehicle in the form of a motor vehicle P, for example. The wiring system L1 comprises a strip-shaped flat conductor F1, which can extend, for example, along a floor pan contour (not shown) from an rear compartment (not shown) to an engine compartment (not shown) of the motor vehicle P, and can be made of aluminum or an aluminum alloy, for example. Such a flat conductor F1 can also be referred to as a flat conductor rail. In the engine compartment, the flat conductor F1 can be connected to a battery, for example.

(7) The flat conductor F1 can comprise one or more lateral flat plug-in contacts, of which one flat plug-in contact is shown here in the form of a (female) flat plug-in housing G1.

(8) The flat plug-in housing G1 comprises a laterally projecting tab Z of the flat conductor F1, which at the end comprises additional components, such as a further housing part T, a clamping mechanism (not shown), and the like. The tab Z provides a contact region with a male flat plug-in contact to be inserted into the flat plug-in housing G1. The flat plug-in contact is to be inserted into a slot-shaped insertion opening S of the flat plug-in housing G1 for establishing a plug connection. The flat plug-in housing G1 can be designed as a ZIF housing and retain, and essentially lock, the flat plug-in contact, such as by a selectively released and retaining clamping or pressing mechanism (not shown).

(9) The wiring system L1 furthermore comprises a stranded conductor in the form of a cable K comprising at least one metal wire D (see FIG. 2). The cable K is connected at the remote end thereof (not shown) to a consumer (not shown) and is to be connected at the shown near end thereof to the flat conductor F1 so as to enable a defined electrical ground return. For this purpose, the cable K is equipped at the shown near end with a plug-in fuse element 1, which forms both an overcurrent protection device as well as the male flat plug-in contact for insertion into the flat plug-in housing G1.

(10) For this purpose, the plug-in fuse element 1 comprises a substantially strip-shaped sheet metal part 2 having a first end section 3, a second end section 4, and an interposed center section 5. The first end section 2 is designed as a simple tab, which alone serves as the male flat plug-in contact and can be inserted into the slot-shaped insertion opening S of the flat plug-in housing G1.

(11) The second end section 4 is designed as an areal connecting region for the connection to the cable K. For this purpose, the near end of the cable K is equipped with a cable lug B made of copper, which is connected to the second end section 4 in an areal and fixed manner (for example, form-fitting), for example by way of press-joining.

(12) The center section 5 is designed as an overcurrent protection device, and for this purpose has a drastically tapered, and in this example curved, cross-sectional shape. The center section 5 is thus designed as a fusible element or fusible cutout.

(13) For its protection and for its mechanical reinforcement, the center section 5 is surrounded by a thermally conductive housing 6 (for example, coated with metal or made of a thermally conductive plastic material), which also holds regions of the first end section 3 and of the second end section 4 connecting thereto. The housing 6, together with the center section 5, can represent a functional component of the overcurrent protection device.

(14) The sheet metal part 2 can be designed as a bimetallic strip having an outer layer 8 made of copper on the upper face 12 and an outer layer 9 made of aluminum on the lower face 13 here, by way of example (see also FIG. 1B, showing a magnified view of section C in FIG. 1A). At the second end section 4, the upper face 12 made of copper can be connected in an areal manner to the copper cable lug B, while the lower face 13 made of aluminum on the first end section 3 is held in areal contact with the tab Z, which is made of aluminum, of the flat conductor F1.

(15) Alternatively, the tab Z can be designed as a bimetallic element, for example, when the sheet metal part 2 consists entirely of copper. However, it is also possible to entirely dispense with a bimetallic design and, for example, tolerate a material mismatch in a contact region.

(16) The plug-in fuse element 1 can furthermore comprise at least one electrical filter 14. It is also possible for a heat removal cable (not shown) to be connected thereto.

(17) In addition, a further housing (not shown) may be provided to protect against media and provide mechanical reinforcement, which extends from the cable K (for example, from the cable lug B thereof) to the tab Z of the flat conductor F1, and is fixed thereby. Such a housing can protect and reinforce the entire plug-in fuse element 1, together with the contact regions to the flat conductor F1 and to the cable K.

(18) When an electrical current of normal intensity flows between the cable K and the flat conductor F1, the center section 5 is heated more strongly than the end sections 2 and 3, yet without fusing. The heat should be dissipated as effectively as possible so as to prevent aging of the center section 5 and material softening. This is achieved by way of the plug-in fuse element 1 in that only a very low thermal resistance is achievable between the center section 5 and the flat conductor F1, due to the flat plug-in contacting by the large-surface-area and fixed contact between the first end section 3 and the tab Z. As a result, in turn, heat can be dissipated very effectively from the center section 5 to the flat conductor F1. Due to the large-surface-area and fixed contact between the second end section 4 and the cable lug B, it is also possible to dissipate heat very effectively from the center section 5 to the cable K. This also provides a robust current conduction that is immune to interference between the cable K and the flat conductor F1.

(19) FIG. 2 shows an oblique view of a wiring system L2 according to a second exemplary embodiment. The wiring system L2 is designed very similar to the wiring system L1 and comprises the same plug-in fuse element 1. In contrast to the wiring system L1, stripped wires D of the cable K are now attached directly to the second end section 4 of the sheet metal part 2, or to the corresponding connecting region. This may carried out, for example, by way of soldering or welding such as ultrasonic welding, or laser welding.

(20) FIG. 3 shows an oblique view of a section of a wiring system L3 according to a third exemplary embodiment. The wiring system L3 is designed similar to the wiring system L2 and has the same direct connection of a plug-in fuse element 11 to the cable K.

(21) The plug-in fuse element 11 differs from the plug-in fuse element 1 by now including a heat sink 7 on the first end section 3 of the sheet metal part 2. The heat sink 7 can be a separately-produced sheet metal part, which is connected in an areal and rigid manner to the first end section 3, such as welded thereto or joined by clinching. For example, a narrow aluminum or copper strip can be bent vertically at the two end regions, so that a center region of the strip connecting the end regions is connected in an areal manner to the first end section 3 of the sheet metal part, and the end regions thereof project vertically, for example as cooling ribs or cooling fins. This can be carried out analogously on the second end section 4.

(22) Alternatively, a multi-piece heat sink comprising cooling ribs, for example, can be provided by being formed in one piece from the first end section 3. This can take place, for example, by separating the sheet metal part 2 together with tabs extending laterally on the first end section 3, the tabs then being folded. This can be carried out analogously on the second end section 4.

(23) FIG. 4 shows an oblique view of a section of a wiring system L4 according to a fourth exemplary embodiment. The wiring system L4 differs from the wiring systems L1 to L3 in that now a flat plug-in housing G2 is attached to a plug-in fuse element 21, and the tab Z of a flat conductor F2 serves as the male flat plug-in contact. The female flat plug-in contact is thus formed by a combination of the flat plug-in housing G2 and the first end section 3. The flat plug-in housing G2 is rigidly connected for this purpose to the first end section 3 of the sheet metal part 2, such as by way of press-joining, welding and the like, via a contact rail 22, which provides a contact surface for areal contacting of the tab Z.

(24) FIG. 5 shows an oblique view of an exploded illustration of a section of a wiring system L4 according to the fourth exemplary embodiment.

(25) The wires D of the cable K can be rigidly connected at the ends to a connecting element, such as the cable lug B, by way of a joining method, such as by way of crimping or welding. The cable K is thus equipped with the cable lug B, which can also be referred to as a cable assembly.

(26) In addition, the sheet metal part 2, which has already been equipped with the housing 6, for example, can be rigidly connected to the flat plug-in housing G2 by way of joining so as to form the plug-in fuse element 21. For this purpose, the contact rail 22 of the flat plug-in housing G2 can be connected to the first end section 3 of the sheet metal part 2, for example by way of press-joining or clinching or toxing or else by way of welding and the like.

(27) The cable lug B can thereafter be rigidly connected to the second end section 4 of the sheet metal part 2 by way of a joining method, such as press-joining, welding, screwing or crimping or the like.

(28) The cable K can be plugged with the plug-in fuse element 21 fastened thereto onto the tab Z of the flat conductor F2. The cable can be held thereon, for example, by way of a clamping mechanism and/or by way of a screw connection and the like.

(29) The section from the cable K to the tab Z, or at least a portion thereof, can additionally be surrounded by a further seal (not shown), such as a molded-on sealing compound or a housing. The further seal can serve as protection against media and as a mechanical reinforcement, for example.

(30) The present disclosure is not limited to the shown exemplary embodiments.

(31) In all wiring systems L1 to L4, the sheet metal part 2 and/or the flat conductor F1 or F2 can be designed as single-layer or as multi-layer part, such as a bimetallic ribbon or strip.

(32) In general, a, an or the like may be understood to mean a singular or a plural form, in particular within the meaning of at least one or one or more or the like, unless this is explicitly excluded, such as by the expression exactly one or the like.

(33) Numerical information can also comprise exactly the indicated number as well as a typical tolerance range, unless this is explicitly excluded.

(34) While the present disclosure is illustrated and described in detail according to the above embodiments, the present disclosure is not limited to these embodiments and additional embodiments may be implemented. Further, other embodiments and various modifications will be apparent to those skilled in the art from consideration of the specification and practice of one or more embodiments disclosed herein, without departing from the scope of the present disclosure.

LIST OF REFERENCE NUMERALS

(35) 1 Plug-in fuse element 2 Sheet metal part 3 First end section 4 Second end section 5 Center section 6 Housing 7 Heat sink 11 Plug-in fuse element 21 Plug-in fuse element 22 Contact rail A Lead B Cable lug F1 Flat conductor F2 Flat conductor G1 Flat plug-in housing G2 Flat plug-in housing K Cable L1 Wiring system L2 Wiring system L3 Wiring system L4 Wiring system P Motor vehicle S Insertion opening of the flat plug-in housing Z Tab