EP1852878A1 - Power resistor module - Google Patents
Power resistor module Download PDFInfo
- Publication number
- EP1852878A1 EP1852878A1 EP07006864A EP07006864A EP1852878A1 EP 1852878 A1 EP1852878 A1 EP 1852878A1 EP 07006864 A EP07006864 A EP 07006864A EP 07006864 A EP07006864 A EP 07006864A EP 1852878 A1 EP1852878 A1 EP 1852878A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- power resistor
- resistor module
- wire
- housing element
- elements
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000009413 insulation Methods 0.000 claims abstract description 53
- 238000004519 manufacturing process Methods 0.000 claims abstract description 15
- 239000004020 conductor Substances 0.000 claims description 18
- 239000000463 material Substances 0.000 claims description 13
- 238000003825 pressing Methods 0.000 claims description 13
- 239000000395 magnesium oxide Substances 0.000 claims description 11
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 11
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 11
- 239000010445 mica Substances 0.000 claims description 11
- 229910052618 mica group Inorganic materials 0.000 claims description 11
- 239000000969 carrier Substances 0.000 claims description 9
- 239000004033 plastic Substances 0.000 claims description 2
- 238000010438 heat treatment Methods 0.000 description 14
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- 238000012546 transfer Methods 0.000 description 7
- 238000000034 method Methods 0.000 description 6
- 229910052782 aluminium Inorganic materials 0.000 description 5
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 5
- 238000010276 construction Methods 0.000 description 4
- 238000005338 heat storage Methods 0.000 description 4
- 239000000565 sealant Substances 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 229920001296 polysiloxane Polymers 0.000 description 3
- 230000001681 protective effect Effects 0.000 description 3
- 238000005452 bending Methods 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 239000004568 cement Substances 0.000 description 2
- 230000008878 coupling Effects 0.000 description 2
- 238000010168 coupling process Methods 0.000 description 2
- 238000005859 coupling reaction Methods 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 229920001721 polyimide Polymers 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000035939 shock Effects 0.000 description 2
- 238000003466 welding Methods 0.000 description 2
- 239000004642 Polyimide Substances 0.000 description 1
- RJDOZRNNYVAULJ-UHFFFAOYSA-L [O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[F-].[F-].[Mg++].[Mg++].[Mg++].[Al+3].[Si+4].[Si+4].[Si+4].[K+] Chemical compound [O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[F-].[F-].[Mg++].[Mg++].[Mg++].[Al+3].[Si+4].[Si+4].[Si+4].[K+] RJDOZRNNYVAULJ-UHFFFAOYSA-L 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
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- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 238000002788 crimping Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000005485 electric heating Methods 0.000 description 1
- 238000010292 electrical insulation Methods 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000003779 heat-resistant material Substances 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
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Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01C—RESISTORS
- H01C1/00—Details
- H01C1/08—Cooling, heating or ventilating arrangements
- H01C1/084—Cooling, heating or ventilating arrangements using self-cooling, e.g. fins, heat sinks
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01C—RESISTORS
- H01C3/00—Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49082—Resistor making
- Y10T29/49087—Resistor making with envelope or housing
Definitions
- the invention relates to a power resistor module for electrical circuits having at least one resistance element and at least one housing element, wherein the at least one resistance element is at least partially mounted between two electrically insulating, heat-conducting insulation elements in the housing member, and abut the insulation elements at least partially on the at least one housing element.
- the invention further relates to a method for producing an electrical power resistor module for an electrical circuit, wherein at least one resistance element is pressed between two electrically insulating, heat-conducting insulation elements, and at least one of the two insulation elements is at least partially pressed against a housing member.
- Power resistor modules are known as protective elements in electrical circuits, also called braking, discharging or protective resistors, and as electrical heating elements. They convert electrical energy into heat.
- resistance resistance modules often use resistance wires for converting the electrical energy into heat.
- a defined resistance alloy is wound on one or more insulation plates.
- the free wire ends of such a wire heating element are each connected by welding, crimping or the like with an electrical cable feed.
- the wire heater is electrically insulated and heat transferred to a suitable heat sink, such as a heat sink. an aluminum profile body, coupled.
- the magnesium oxide serves for the thermal coupling of the wire heating element to the profile body as well as for heat storage for a time-delayed heat release and buffering and for electrical insulation.
- the magnesium oxide must be compacted in a shaking process. Thereafter, more magnesium oxide is replenished, after which the profile body can be closed. For this purpose, another Mikanitplatte is inserted at the filling or cable side, in which cable openings for carrying out the connection lines for the wire heating element are present. Finally, the front sides of the profile are first sealed with a silicone sealing layer and finally with a layer of cement.
- a protective element for an electrical circuit is described.
- a PTC resistor element is arranged in a layered structure between two sheets, which in turn abut against a heat sink by a film electrically isolated.
- DE 85 03 272 U1 describes an electric heating element which has a PTC heating element which is clamped in a flat tube between two insulating Mikanit-Pressstoffplatten.
- the use of a heating wire or a Schudrahtchtl is in the DE 85 03 272 U1 but not mentioned.
- PTC heating elements are problematic because they are made of ceramic material and thus can easily break if they are not processed very accurately.
- PTC heating elements are more expensive than resistance wires of the same power.
- the invention is therefore based on the object to simplify the production of a power resistor module without sacrificing the efficiency.
- the at least one resistance element is a wire, at least partially applied to at least one of the insulation elements, in particular under bias.
- the surface contour of the wire is at least partially pressed in at least one of the insulation elements and / or embossed.
- This embodiment makes it possible that the wire is embedded in the insulating element and surrounded by its elastically to plastically deformed material, whereby an intimate contact is achieved.
- a power resistor module can be provided that this contains no magnesium oxide.
- this contains no magnesium oxide.
- the insulation element contains mica.
- Mica is a silicate mineral from natural deposits, which has an electrically insulating effect and is temperature resistant up to more than 600 ° C.
- the insulation elements are constructed of plate-shaped mica pressed material.
- Mica compact is also known as mica or synthetic mica and consists of pressed with a heat-resistant binder mica, which can be pressed with plates impregnated with binder under heat and high pressure in several layers to plates.
- the mica compact is also heat resistant up to 600 ° C and usually has a voltage or dielectric strength of over 10 kV / mm.
- the at least one housing element is an extruded profile.
- the at least one housing element can be easily manufactured by being simply cut to length by an extruded profile of the desired cross-section.
- the extruded profile is a hollow profile which has an opening on at least one side and forms at least one receiving channel, in which the at least one wire and the insulation elements are accommodated.
- the extruded profile formed as a hollow profile forms a solid housing body for a power resistance module according to the invention, which is stable and easy to seal.
- the at least one opening is closed with an elastic seal.
- an elastic seal or a prefabricated sealing element, can on the use of any sealing and auxiliary materials, such as. Silicone and cement are dispensed with.
- any sealing and auxiliary materials such as. Silicone and cement are dispensed with.
- the seal has at least one passage, the at least one with the at least one wire electrically receives connected electrical conductors.
- the electrical conductor can be easily led out of the sealed interior of the power resistor module.
- the sealing of the housing element can be improved according to a further advantageous embodiment for improved sealing of the passage for the electrical conductor, characterized in that the implementation is adapted in a compressed state of the gasket to a cross-sectional shape of the electrical conductor.
- the at least one wire is wound at least in sections on a carrier.
- the wire can be used in a wide or narrow laying evenly and uniformly in the power resistor module. This is particularly advantageous if the wire by itself has no mechanical stability necessary for the assembly and is difficult to handle on its own, especially in the case of mechanical processing.
- the wire and its electrical connection can be provided according to a further advantageous embodiment that on the support at least one fastening means is attached to which the at least one wire and / or the at least one electrical conductor is / is attached.
- the attachment means may be attached, for example, as a clip to the carrier, which may have any necessary recesses or eyelets. At this clip or Lötfahne then the wire and the electrical conductor can be attached and are thus fixed to the carrier, which further simplifies the handling and assembly of a power resistor module according to the invention.
- a plurality of carriers form at least one shock, in which a positive locking element is arranged, which connects the carrier.
- a positive locking element is arranged, which connects the carrier.
- an overlap of the carrier can be dispensed with, if the positive-locking element provides sufficient support of its own accord. This is especially for a flat and flat as possible construction of a power resistor module of Advantage, because it can be dispensed with the use of additional fillers, sealants or auxiliaries.
- the carriers are constructed identically. This can be achieved by having two e.g. plate-shaped carrier have an axis of symmetry and each having a portion for forming a shock, which fits snugly against a carrier rotated about the axis of symmetry.
- only one type of carrier is necessary, which simplifies material procurement. Material procurement and production costs can be further reduced if it is provided according to a further possible embodiment that the support and the insulation elements are constructed from the substantially same material.
- the at least one resistance element is arranged between the at least one housing element and at least one pressure element pretensioned against the resistance element, which is held by at least one holder supported on the housing element.
- a contact pressure on the resistance element relative to the housing element can be easily constructed.
- a pressing element is for example a metal plate used. It is Z. B. possible that the housing element is a simple one-sided ribbed aluminum profile body, on the flattened side of the resistance element is arranged. The pressure element can then be pressed against the resistance element or the insulating elements surrounding the resistance element. If the desired contact pressure is reached, then the pressing element can be easily fixed with the holder supported on the housing element.
- the holder can be designed as a simple, the pressing element and the housing element comprehensive bracket. However, it can just as well be pre-assembled or formed on the housing element and fixed by simple bending, snapping or other friction, form, force or cohesive closure or fastening techniques.
- the wire is arranged between at least two housing elements, which are connected to one another by positive-locking elements. Similar to the execution With a housing element and a pressure element in this case two substantially identically constructed housing elements can serve to press the wire.
- the wire is accordingly arranged between the housing elements, which are connected to each other after reaching the desired contact pressure by suitable interlocking elements, such as screws or rivets.
- suitable interlocking elements such as screws or rivets.
- the housing element in the desired position by any cohesive bonding techniques, such. As welding, soldering or gluing, to connect together.
- the assembly of a power resistor module according to the invention can be generally simplified according to a further, possible advantageous embodiment, if it is provided that the carrier and the insulation elements are arranged substantially in a flat stack structure. Thus, the carrier receiving the resistance wire can be sandwiched between the insulation elements. The carrier and the insulation elements thus form an easy-to-process unit.
- the stack construction can be particularly advantageous because the stack can be pressed in such a way that contact the extending between the webs of wires sections of the carrier and the respective adjacent insulation element surface and thus the wire in completely embedded in a compact stack and enclosed by the material of the carrier and the insulation elements.
- the resistance element can be particularly easily applied to the insulating element by the at least one housing element is elastically deformed to form a force acting on the at least one resistance element biasing force.
- the above object is achieved in that a wire is used as the resistance element, which is at least partially applied to at least one of the two insulation elements during the pressing.
- a wire is used as the resistance element, which is at least partially applied to at least one of the two insulation elements during the pressing.
- An inventive method for producing a power resistor module can be improved in that the surface contour of the wire is at least partially pressed in at least one of the two insulation elements and / or embossed.
- the wire may have a round, flat or angular contour. Both the insulation element and the wire can plastically deform during the pressing or embossing. By impressing the wire is formally embedded in the material of the insulating element and at least partially enclosed by it, whereby the heat transfer area between the wire and the insulating element is increased. The heat transfer between wire and insulation element is thus improved and the power resistor module becomes more compact.
- An inventive method for producing a power resistor module for an electrical circuit can be further improved by providing that on the at least one housing member, a receiving channel is formed, in which the wire and the two insulating elements are used, and the at least one housing element under plastic deformation its cross-section is compressed, so that the wire and the insulation elements are pressed in the receiving channel.
- the housing element can be designed so that it remains after the pressing in a desired cross-sectional shape in which it exerts a pressure corresponding to the requirements of the wire and the insulation elements in the receiving channel.
- additional notches and indentations on the housing element can be made so that zones of maximum bending stresses are secured against springing.
- a method according to the invention for producing an electrical power resistance module can be further improved in that the at least one wire is wound on a carrier at least in sections.
- the wire can be easier in the desired length and in a uniform area distribution in the power resistor module bring and the carrier can be used in later operation as an additional heat storage.
- An inventive method for producing a power resistor module according to the invention can be improved by at least one in an opening of the at least one housing element used seal is sealingly clamped in a pressing operation. Thus, it can be dispensed with the use of further sealants, if it is provided that the seal ensures adequate sealing of the interior of the power resistor module according to the invention.
- the entire inventive power resistor module can be pressed and sealed in a single pressing operation. It is also possible first to press the wire and the insulation elements and then clamp the seal sealingly when compressing the receiving channel of a housing element or between a plurality of housing elements.
- FIG. 1 is a schematic plan view and a Sectional view of an inventively designed power resistor module 1 shows.
- the power resistor module 1 has a housing element 2, which is designed as an aluminum profile 2 '.
- the housing element 2 has a receiving channel 3 for a resistance element 4, which converts electrical energy into heat output.
- the resistance element 4 is designed as a wire 4 ', which is wound on two carriers 5.
- the carriers 5 have attachment portions 6 which form a joint 7.
- a positive locking element 8 in the form of a rivet 8 ' is used in the middle, which connects the carrier 5.
- the carrier 5 does not overlap in the region of the joint 7.
- a fastening means 9 in the form of a contact or Lötfahne 9 ' is attached to each of the two carriers 5, to which in each case the wire 4' and the stripped end 10 of an electrical conductor 11 are attached.
- the wire 4 ' can be soldered, welded or adhesively bonded at its attachment point 12.
- the most suitable connection technology between the wire 4 'and the fastening means 9 for the particular application can be selected, which also applies to the attachment of the electrical conductor 11 to the fastening means 9.
- the wire 4 'or the resistance element 4 and the electrical conductor 11 can also be connected directly to one another.
- seals 15, 15 used to protect the receiving channel 3 of the housing element 2 against ingress of dirt and liquids, or corrosive media.
- the electrical conductor 11 is inserted through a passage 16 in the seal 15 from the outside into the housing element 2.
- ribs 17 for surface enlargement and improved heat transfer of the heat generated by the resistance element 4 to the environment are formed on the side facing away from the resistance element of the housing element 2.
- the housing element 2 also has attachment elements 17 ', which serve for fastening the power resistor module 1.
- FIG. 2 shows a power resistor module according to the invention in a sectional view along the section line A-A shown in FIG.
- the carrier 5 is inserted with the wire 4 'in the receiving channel 3 of the housing element 2, wherein the housing element 2 as a hollow profile 2 "or extruded profile 2'" is executed.
- the carrier 5 is arranged between two insulating elements 18, whereby the wire 4 'applied to the carrier 5 is electrically insulated from the housing element 2.
- the two insulation elements 18 and the carrier 5 are stacked in a flat stack structure 19 and are flush with each other.
- Carrier 5 and insulation elements 18 are designed as Mikanitpressstoffplatten, in which the wire 4 'formally digs, whereby a good heat transfer from the wire 4' is ensured to the surrounding insulation elements 18. Due to the intimate contacting of wire 4 ', carriers 5 and insulation elements 18, the heat storage capacity of the power resistor module 1 is ensured.
- a power resistor module 1 it is possible to dispense with the use of any fillers, such as magnesium oxide (MgO).
- MgO magnesium oxide
- the use of prefabricated seals 15, 15 ' also makes a sealing of the power resistor module 1 with any excipients, such as silicone or the like superfluous.
- Fig. 2 is also clear that the sandwich, or stack-like structure of a resistance module 1 according to the invention allows a very simple production of a power resistor module 1 according to the invention.
- the resistance element 4 or the carrier 5 and the wound on him wire 4 'and the insulation elements 18 can be easily adjusted in the receiving channel 3 of the housing element 2.
- the housing element 2 can be embodied as a hollow profile 2 "opened on one or both sides. Subsequently, the hollow profile 2" can be compressed along its center line M or flat, whereby its side surfaces 20 bulge inward and the height h of the housing element 2 is reduced. The side surfaces 20 can be pressed in for additional support by additional tools.
- FIG. 3 an inventively designed seal 15 is shown in a schematic perspective view.
- the seal 15 can be inserted into the opening 13 in the housing element 2 in an insertion direction x.
- the electrical conductors 11 are guided through passages 16 in the seal 15.
- the seal 15 may also be configured as a seal 15 'without bushings 16, if no electrical conductors 11 are to be passed through them.
- the bushings 16 have an elliptical cross-section, wherein the main axis E of the elliptical passage 16 is parallel to the height axis Z of the seal and the housing element.
- the height H 'of the seal also decreases with the height H of the housing element 2 and the major axes E of the ellipse are shortened until the passages 16 optimally have a circular shape Have cross-section. This ensures optimum sealing of electrical conductors 11 with round cross-sections in the passages 16.
- the seal 15 has lamellae 21, which further improve the sealing effect with respect to the housing element 2 of the seal.
- FIG. 4 shows a schematic perspective view of a seal 15 inserted into a receiving channel 3 of a housing element 2.
- the housing element is already compressed in the Z direction, whereby the seal 15 is closely enclosed by the housing element 2 and compressed in the Z direction.
- housing elements 2 can also be embodied as simple plate bodies, against which an insulation element 18 rests, in which a resistance element 4 or a corresponding power module is pressed in according to the invention and thus embedded.
- Winding a resistance element 4 in the form of a wire 4 'onto a support 5 is optional and depends on the respective material thickness of the resistance element 4. If the resistance element 4 in itself has sufficient stability, it can also be easily arranged and pressed directly between two insulation elements 18.
- a stack construction 19 can also be arranged between two housing elements 2 designed as a plate body, which are pressed together and held together by any positive locking elements.
- brackets 24 (not shown), which exert a contact pressure on a pressure element 25 (not shown), which holds a stack structure 19 compressed.
- a power resistor module 1 with one or more seals 15, 15 'to seal is optional, it can be used depending on the requirements and any types of sealant.
- the plate-shaped design of insulation elements 18 is immaterial to the inventive idea of pressing a resistance element 4 into an insulation element.
- an insulating element 18 can be made of both the already mentioned pressed mica (micanite) and other electrically insulating, heat-resistant materials such.
- B. polyimide exist.
- the insulation element 18 can thus also be used as a film such. As polyimide film (Kapton) be executed.
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- Oscillators With Electromechanical Resonators (AREA)
Abstract
Description
Die Erfindung betrifft ein Leistungswiderstandsmodul für elektrische Schaltkreise mit wenigstens einem Widerstandselement und wenigstens einem Gehäuseelement, wobei das wenigstens eine Widerstandselement zumindest abschnittsweise zwischen zwei elektrisch isolierenden, wärmeleitenden Isolationselementen in dem Gehäuseelement montiert ist, und die Isolationselemente jeweils zumindest abschnittsweise an dem wenigstens einen Gehäuseelement anliegen. Die Erfindung betrifft ferner ein Verfahren zum Herstellen eines elektrischen Leistungswiderstandsmoduls für einen elektrischen Schaltkreis, wobei wenigstens ein Widerstandselement zwischen zwei elektrisch isolierenden, wärmeleitenden Isolationselementen verpresst wird, und wenigstens eines der beiden Isolationselemente zumindest abschnittsweise gegen ein Gehäuseelement gepresst wird.The invention relates to a power resistor module for electrical circuits having at least one resistance element and at least one housing element, wherein the at least one resistance element is at least partially mounted between two electrically insulating, heat-conducting insulation elements in the housing member, and abut the insulation elements at least partially on the at least one housing element. The invention further relates to a method for producing an electrical power resistor module for an electrical circuit, wherein at least one resistance element is pressed between two electrically insulating, heat-conducting insulation elements, and at least one of the two insulation elements is at least partially pressed against a housing member.
Leistungswiderstandsmodule sind als Schutzelemente in elektrischen Schaltkreisen, auch genannt Brems-, Entlade- oder Schutzwiderstände, sowie als elektrische Heizelemente bekannt. Sie wandeln elektrische Energie in Wärme um.Power resistor modules are known as protective elements in electrical circuits, also called braking, discharging or protective resistors, and as electrical heating elements. They convert electrical energy into heat.
Mit einem Bremswiderstand wird beispielsweise überschüssige elektrische Energie im Bremsbetrieb eines Elektromotors abgebaut. Dabei muss vor allem sichergestellt werden, dass das Leistungswiderstandsmodul Hochspannungsimpulse sicher in Wärme umwandelt und an die Umgebung abführt.With a braking resistor, for example, excess electrical energy is reduced in the braking operation of an electric motor. Above all, it must be ensured that the power resistor module safely converts high-voltage pulses into heat and dissipates them to the environment.
Gemäß dem Stand der Technik werden in Leistungswiderstandsmodulen oft Widerstandsdrähte zur Umwandlung der elektrischen Energie in Wärme eingesetzt. So wird ein entsprechend der geforderten Leistung dimensionierter Heizdraht einer definierten Widerstandslegierung auf eine oder mehrere Isolationsplatten gewickelt. Die freien Drahtenden eines solchen Drahtheizelementes werden jeweils durch Schweißen, Crimpen oder Ähnliches mit einer elektrischen Kabelzuführung verbunden. Für eine verbesserte Wärmespeicherfähigkeit und Wärmeübertragung an die Umgebung wird das Drahtheizelement elektrisch isoliert und wärmeübertragend an einen geeigneten Kühlkörper, wie z.B. einen Aluminiumprofilkörper, gekoppelt.According to the prior art, resistance resistance modules often use resistance wires for converting the electrical energy into heat. Thus, according to the required power dimensioned heating wire of a defined resistance alloy is wound on one or more insulation plates. The free wire ends of such a wire heating element are each connected by welding, crimping or the like with an electrical cable feed. For improved heat storage and heat transfer to the environment, the wire heater is electrically insulated and heat transferred to a suitable heat sink, such as a heat sink. an aluminum profile body, coupled.
Im Stand der Technik sind Maßnahmen bekannt, wie ein Drahtheizelement elektrisch isoliert und wärmeübertragend an einen Aluminiumkühlkörper gekoppelt werden kann. So ist in der
In der
Ferner ist in der
Der Einsatz von PTC-Heizelementen ist problematisch, da diese aus keramischem Material aufgebaut sind und somit leicht brechen können, wenn sie nicht sehr exakt verarbeitet werden. Darüber hinaus sind PTC-Heizelemente teurer als Widerstandsdrähte gleicher Leistung.The use of PTC heating elements is problematic because they are made of ceramic material and thus can easily break if they are not processed very accurately. In addition, PTC heating elements are more expensive than resistance wires of the same power.
Die im Stand der Technik bekannten Maßnahmen zur elektrisch isolierten thermischen Ankopplung eines Drahtheizelementes an einen Profilkörper sowie zur Abdichtung des Profilkörpers sind zeitaufwendig und teuer. Es sind zu viele Arbeitsschritte zur Einbringung des Magnesiumoxids notwendig und die Kosten sowie der Zeitaufwand für die verwendeten Dichtmittel und deren Trockenzeit sind ebenfalls zu hoch.The measures known in the prior art for the electrically insulated thermal coupling of a wire heating element to a profile body and for sealing the Profile body are time consuming and expensive. There are too many steps for the introduction of magnesium oxide necessary and the cost and the time required for the sealants used and their drying time are also too high.
Der Erfindung liegt folglich die Aufgabe zugrunde, die Herstellung eines Leistungswiderstandsmoduls ohne Abstriche am Wirkungsgrad zu vereinfachen.The invention is therefore based on the object to simplify the production of a power resistor module without sacrificing the efficiency.
Diese Aufgabe wird erfindungsgemäß für das eingangs genannte Leistungswiderstandsmodul dadurch gelöst, dass das wenigstens eine Widerstandselement ein Draht ist, der zumindest abschnittsweise an wenigstens einem der Isolationselemente, insbesondere unter Vorspannung, anliegt.This object is achieved according to the invention for the above-mentioned power resistor module in that the at least one resistance element is a wire, at least partially applied to at least one of the insulation elements, in particular under bias.
Diese einfache Lösung hat den Vorteil, dass der Draht die erzeugte Wärmeenergie direkt an das Isolationselement abgeben kann und von dem Gehäuseelement elektrisch isoliert in dem Leistungswiderstandsmodul aufgenommen ist. Durch das Anliegen unter Vorspannung ist das Isolationselement und/oder der Draht elastisch verformt und es besteht eine flächige Kontaktierung zwischen dem Isolationselement und dem Draht, die den Anforderungen an die Wärmeübertragung und -speicherung in einem gattungsgemäßen Leistungswiderstandsmodul genügt.This simple solution has the advantage that the wire can deliver the heat energy generated directly to the insulating element and is electrically isolated from the housing element in the power resistor module. By biasing bias the insulating element and / or the wire is elastically deformed and there is a surface contact between the insulating element and the wire, which meets the requirements for heat transfer and storage in a generic power resistor module.
Die erfindungsgemäße Lösung kann mit den folgenden weiteren, jeweils für sich vorteilhaften Ausgestaltungen, beliebig kombiniert und weiter verbessert werden.The solution according to the invention can be combined with the following further, each for themselves advantageous embodiments, and further improved.
So kann in einer ersten, möglichen vorteilhaften Ausgestaltungsform vorgesehen werden, dass die Oberflächenkontur des Drahtes zumindest abschnittsweise in wenigstens eines der Isolationselemente eingedrückt und/oder eingeprägt ist. Diese Ausgestaltungsform ermöglicht es, dass der Draht im Isolationselement eingebettet und von dessen elastisch bis plastisch verformten Material umgeben ist, womit eine innige Kontaktierung erreicht wird.Thus it can be provided in a first, possible advantageous embodiment that the surface contour of the wire is at least partially pressed in at least one of the insulation elements and / or embossed. This embodiment makes it possible that the wire is embedded in the insulating element and surrounded by its elastically to plastically deformed material, whereby an intimate contact is achieved.
Gemäß einer weiteren möglichen Ausgestaltungsform eines Leistungswiderstandsmoduls kann vorgesehen werden, dass dieses kein Magnesiumoxid enthält. Dadurch kann auf die zeitaufwendige Verarbeitung des Magnesiumoxids verzichtet werden und die Materialkosten für das Magnesiumoxid werden eingespart.According to another possible embodiment of a power resistor module can be provided that this contains no magnesium oxide. As a result, the time-consuming processing of the magnesium oxide can be dispensed with and the material costs for the magnesium oxide can be saved.
Gemäß einer weiteren, möglichen vorteilhaften Ausgestaltungsform kann vorgesehen werden, dass das Isolationselement Glimmer beinhaltet. Glimmer ist ein Silikat-Mineral aus natürlichen Vorkommen, das elektrisch isolierend wirkt und bis über 600°C temperaturbeständig ist.According to another, possible advantageous embodiment, it can be provided that the insulation element contains mica. Mica is a silicate mineral from natural deposits, which has an electrically insulating effect and is temperature resistant up to more than 600 ° C.
Gemäß einer weiteren, möglichen vorteilhaften Ausgestaltungsform kann vorgesehen werden, dass die Isolationselemente aus plattenförmigem Glimmerpressstoff aufgebaut sind. Glimmerpressstoff ist auch als Kunstglimmer oder Mikanit bekannt und besteht aus mit einem hitzebeständigen Bindemittel gepressten Glimmer, der auch mit durch Bindemittel imprägnierten Papieren unter Hitze und hohem Druck in mehreren Lagen zu Platten verpresst werden kann. Der Glimmerpressstoff ist ebenfalls bis zu 600°C hitzebeständig und besitzt in der Regel eine Spannungs- bzw. Durchschlagsfestigkeit von über 10 kV/mm.According to a further, possible advantageous embodiment it can be provided that the insulation elements are constructed of plate-shaped mica pressed material. Mica compact is also known as mica or synthetic mica and consists of pressed with a heat-resistant binder mica, which can be pressed with plates impregnated with binder under heat and high pressure in several layers to plates. The mica compact is also heat resistant up to 600 ° C and usually has a voltage or dielectric strength of over 10 kV / mm.
Gemäß einer weiteren, vorteilhaften Ausgestaltungsform kann vorgesehen werden, dass das wenigstens eine Gehäuseelement ein Strangpressprofil ist. Somit kann das wenigstens eine Gehäuseelement einfach hergestellt werden, indem es von einem Strangpressprofil des gewünschten Querschnitts einfach abgelängt wird. Dabei ist es vorteilhafterweise möglich, dass das Strangpressprofil ein Hohlprofil ist, welches an wenigstens einer Seite eine Öffnung aufweist und wenigstens einen Aufnahmekanal bildet, in dem der wenigstens eine Draht und die Isolationselemente aufgenommen sind. Somit bildet das als Hohlprofil ausgebildete Strangpressprofil einen soliden Gehäusekörper für ein erfindungsgemäßes Leistungswiderstandsmodul, welcher stabil und einfach abzudichten ist.According to a further advantageous embodiment, it can be provided that the at least one housing element is an extruded profile. Thus, the at least one housing element can be easily manufactured by being simply cut to length by an extruded profile of the desired cross-section. In this case, it is advantageously possible that the extruded profile is a hollow profile which has an opening on at least one side and forms at least one receiving channel, in which the at least one wire and the insulation elements are accommodated. Thus, the extruded profile formed as a hollow profile forms a solid housing body for a power resistance module according to the invention, which is stable and easy to seal.
Dazu ist es gemäß einer weiteren, vorteilhaften Ausgestaltungsform möglich, dass die mindestens eine Öffnung mit einer elastischen Dichtung verschlossen ist. Durch die Verwendung einer elastischen Dichtung, bzw. eines vorgefertigten Dichtelementes, kann auf den Einsatz etwaiger Dichtungs- und Hilfsstoffe, wie z.B. Silikon und Zement verzichtet werden. Somit lässt sich eine schnelle und kostengünstige Abdichtung eines erfindungsgemäßen Leistungswiderstandsmoduls erreichen.For this purpose, it is possible according to a further advantageous embodiment that the at least one opening is closed with an elastic seal. By the use of an elastic seal, or a prefabricated sealing element, can on the use of any sealing and auxiliary materials, such as. Silicone and cement are dispensed with. Thus, a rapid and cost-effective sealing of a power resistor module according to the invention can be achieved.
Dabei kann vorteilhafterweise vorgesehen werden, dass die Dichtung mindestens eine Durchführung aufweist, die wenigstens ein mit dem wenigstens einen Draht elektrisch verbundenen elektrischen Leiter aufnimmt. Somit kann der elektrische Leiter einfach aus dem abgedichteten Innenraum des Leistungswiderstandsmoduls herausgeführt werden.It can be advantageously provided that the seal has at least one passage, the at least one with the at least one wire electrically receives connected electrical conductors. Thus, the electrical conductor can be easily led out of the sealed interior of the power resistor module.
Die Abdichtung des Gehäuseelementes kann gemäß einer weiteren, vorteilhaften Ausgestaltungsform zur verbesserten Abdichtung der Durchführung für den elektrischen Leiter dadurch verbessert werden, dass die Durchführung in einem komprimierten Zustand der Dichtung an eine Querschnittsform des elektrischen Leiters angepasst ist.The sealing of the housing element can be improved according to a further advantageous embodiment for improved sealing of the passage for the electrical conductor, characterized in that the implementation is adapted in a compressed state of the gasket to a cross-sectional shape of the electrical conductor.
Gemäß einer weiteren, möglichen vorteilhaften Ausgestaltungsform kann vorgesehen werden, dass der wenigstens eine Draht zumindest abschnittsweise auf einen Träger gewickelt ist. Somit lässt sich der Draht einfach in einer gewünscht weiten oder engen Verlegung gleichmäßig und flächendeckend in das Leistungswiderstandsmodul einsetzen. Dies ist insbesondere dann vorteilhaft, wenn der Draht für sich alleine keine für die Montage notwendige mechanische Stabilität aufweist und insbesondere bei der maschinellen Verarbeitung für sich alleine schwer handhabbar ist. Sicherlich können auch Drähte mit einer Materialstärke eingesetzt werden, die von sich aus dazu ausreicht, den Draht in einem gewünschten Verlauf in das Leistungswiderstandsmodul einzusetzen.According to a further, possible advantageous embodiment it can be provided that the at least one wire is wound at least in sections on a carrier. Thus, the wire can be used in a wide or narrow laying evenly and uniformly in the power resistor module. This is particularly advantageous if the wire by itself has no mechanical stability necessary for the assembly and is difficult to handle on its own, especially in the case of mechanical processing. Of course, it is also possible to use wires with a material thickness which is sufficient in itself to insert the wire into the power resistor module in a desired course.
Zur einfacheren Handhabung des Drahtes und seines elektrischen Anschlusses kann gemäß einer weiteren vorteilhaften Ausgestaltungsform vorgesehen werden, dass an dem Träger wenigstens ein Befestigungsmittel angebracht ist, an welchem der wenigstens eine Draht und/oder der wenigstens eine elektrische Leiter befestigt sind/ist. Das Befestigungsmittel kann beispielsweise als eine Klammer an dem Träger befestigt werden, der dazu die eventuell nötigen Aussparungen oder Ösen aufweisen kann. An dieser Klammer bzw. Lötfahne können dann der Draht und der elektrischer Leiter befestigt werden und sind somit an dem Träger fixiert, was die Handhabbarkeit und Montage eines erfindungsgemäßen Leistungswiderstandsmoduls weiter vereinfacht.For easier handling of the wire and its electrical connection can be provided according to a further advantageous embodiment that on the support at least one fastening means is attached to which the at least one wire and / or the at least one electrical conductor is / is attached. The attachment means may be attached, for example, as a clip to the carrier, which may have any necessary recesses or eyelets. At this clip or Lötfahne then the wire and the electrical conductor can be attached and are thus fixed to the carrier, which further simplifies the handling and assembly of a power resistor module according to the invention.
Für einen modulartigen Zusammenschluss mehrerer Träger zur Vergrößerung der Heizleistung eines erfindungsgemäßen Leistungswiderstandsmoduls kann gemäß einer weiteren, vorteilhaften Ausgestaltungsform vorgesehen werden, dass mehrere Träger mindestens einen Stoß bilden, in welchem ein Formschlusselement angeordnet ist, welches die Träger verbindet. Dabei kann auf eine Überlappung der Träger verzichtet werden, wenn das Formschlusselement von sich aus genügend Halt bietet. Dies ist insbesondere für einen ebenen und möglichst flachen Aufbau eines Leistungswiderstandsmoduls von Vorteil, weil auf die Verwendung zusätzlicher Füll-, Dicht- oder Hilfsstoffe verzichtet werden kann.For a modular combination of multiple carriers to increase the heat output of a power resistor module according to the invention can be provided according to a further advantageous embodiment that a plurality of carriers form at least one shock, in which a positive locking element is arranged, which connects the carrier. In this case, an overlap of the carrier can be dispensed with, if the positive-locking element provides sufficient support of its own accord. This is especially for a flat and flat as possible construction of a power resistor module of Advantage, because it can be dispensed with the use of additional fillers, sealants or auxiliaries.
Gemäß einer weiteren, möglichen Ausgestaltungsform kann vorgesehen werden, dass die Träger identisch aufgebaut sind. Dies lässt sich dadurch erreichen, dass zwei z.B. plattenförmige Träger eine Symmetrieachse besitzen und jeweils einen Abschnitt zur Bildung eines Stoßes aufweisen, welcher an einem um die Symmetrieachse gedrehten Träger passend anliegt. Somit ist nur ein Trägertyp notwendig, was die Materialbeschaffung vereinfacht. Materialbeschaffungs- und Herstellungsaufwand lassen sich weiter verringern, wenn gemäß einer weiteren, möglichen Ausgestaltungsform vorgesehen ist, dass der Träger und die Isolationselemente aus dem im Wesentlichen gleichen Material aufgebaut sind.According to another possible embodiment, it can be provided that the carriers are constructed identically. This can be achieved by having two e.g. plate-shaped carrier have an axis of symmetry and each having a portion for forming a shock, which fits snugly against a carrier rotated about the axis of symmetry. Thus, only one type of carrier is necessary, which simplifies material procurement. Material procurement and production costs can be further reduced if it is provided according to a further possible embodiment that the support and the insulation elements are constructed from the substantially same material.
Gemäß einer weiteren, möglichen vorteilhaften Ausgestaltungsform kann vorgesehen werden, dass das wenigstens eine Widerstandselement zwischen dem wenigstens einem Gehäuseelement und wenigstens einem gegen das Widerstandselement vorgespannten Andrückelement angeordnet ist, das von wenigstens einer sich an dem Gehäuseelement abstützenden Halterung gehalten ist. Somit kann ein Anpressdruck auf das Widerstandselement gegenüber dem Gehäuseelement einfach aufgebaut werden. Als Andrückelement ist dabei beispielsweise eine Metallplatte einsetzbar. Es ist z. B. möglich, dass das Gehäuseelement ein einfacher einseitig mit Rippen versehener Aluminiumprofilkörper ist, an dessen abgeflachter Seite das Widerstandselement angeordnet ist. Das Andrückelement kann dann gegen das Widerstandselement oder die das Widerstandselement umgebenen Isolationselemente gedrückt werden. Ist der gewünschte Anpressdruck erreicht, so kann das Andrückelement einfach mit der sich am Gehäuseelement abstützenden Halterung fixiert werden. Die Halterung kann als einfache, das Andrückelement und das Gehäuseelement umfassende Klammer ausgestaltet sein. Sie kann jedoch genauso gut am Gehäuseelement vormontiert oder ausgeformt sein und durch einfaches Umbiegen, Schnappen oder sonstige reib-, form-, kraft- oder stoffschlüssige Verschluss- oder Befestigungstechniken fixiert sein.According to a further, possible advantageous embodiment, it can be provided that the at least one resistance element is arranged between the at least one housing element and at least one pressure element pretensioned against the resistance element, which is held by at least one holder supported on the housing element. Thus, a contact pressure on the resistance element relative to the housing element can be easily constructed. As a pressing element is for example a metal plate used. It is Z. B. possible that the housing element is a simple one-sided ribbed aluminum profile body, on the flattened side of the resistance element is arranged. The pressure element can then be pressed against the resistance element or the insulating elements surrounding the resistance element. If the desired contact pressure is reached, then the pressing element can be easily fixed with the holder supported on the housing element. The holder can be designed as a simple, the pressing element and the housing element comprehensive bracket. However, it can just as well be pre-assembled or formed on the housing element and fixed by simple bending, snapping or other friction, form, force or cohesive closure or fastening techniques.
Gemäß einer weiteren, möglichen vorteilhaften Ausgestaltungsform kann auch vorgesehen werden, dass der Draht zwischen mindestens zwei Gehäuseelementen angeordnet ist, welche durch Formschlusselemente miteinander verbunden sind. Ähnlich der Ausführung mit einem Gehäuseelement und einem Andrückelement können hierbei zwei im Wesentlichen identisch aufgebaute Gehäuseelemente dazu dienen, den Draht zu verpressen. Der Draht wird dementsprechend zwischen den Gehäuseelementen angeordnet, welche nach Erreichung des gewünschten Anpressdruckes durch geeignete Formschlusselemente, wie z.B. Schrauben oder Nieten, miteinander verbunden werden. Es ist auch denkbar, die Gehäuseelement in der gewünschten Position durch eventuelle stoffschlüssige Verbindungstechniken, wie z. B. Schweißen, Löten oder Kleben, miteinander zu verbinden.According to a further, possible advantageous embodiment, it can also be provided that the wire is arranged between at least two housing elements, which are connected to one another by positive-locking elements. Similar to the execution With a housing element and a pressure element in this case two substantially identically constructed housing elements can serve to press the wire. The wire is accordingly arranged between the housing elements, which are connected to each other after reaching the desired contact pressure by suitable interlocking elements, such as screws or rivets. It is also conceivable, the housing element in the desired position by any cohesive bonding techniques, such. As welding, soldering or gluing, to connect together.
Die Montage eines erfindungsgemäßen Leistungswiderstandsmoduls lässt sich gemäß einer weiteren, möglichen vorteilhaften Ausgestaltungsform generell vereinfachen, wenn vorgesehen wird, dass der Träger und die Isolationselemente im Wesentlichen in einem flächigen Stapelaufbau angeordnet sind. So kann der den Widerstandsdraht aufnehmende Träger sandwichartig zwischen den Isolationselementen angeordnet werden. Der Träger und die Isolationselemente bilden somit eine leicht zu verarbeitende Einheit.The assembly of a power resistor module according to the invention can be generally simplified according to a further, possible advantageous embodiment, if it is provided that the carrier and the insulation elements are arranged substantially in a flat stack structure. Thus, the carrier receiving the resistance wire can be sandwiched between the insulation elements. The carrier and the insulation elements thus form an easy-to-process unit.
Wenn der Draht erfindungsgemäß in dem Leistungswiderstandsmodul verpresst ist, kann der Stapelaufbau insbesondere von Vorteil sein, weil der Stapel derartig verpresst werden kann, dass sich die zwischen den Bahnen der Drähte verlaufenden Abschnitte des Trägers und des jeweils anliegenden Isolationselementes flächig kontaktieren und der Draht somit in einem kompakten Stapel vollständig eingebettet und vom Material des Trägers und der Isolationselemente eingeschlossen ist.If the wire is pressed according to the invention in the power resistor module, the stack construction can be particularly advantageous because the stack can be pressed in such a way that contact the extending between the webs of wires sections of the carrier and the respective adjacent insulation element surface and thus the wire in completely embedded in a compact stack and enclosed by the material of the carrier and the insulation elements.
Gemäß einer weiteren, möglichen vorteilhaften Ausgestaltungsform kann das Widerstandselement besonders einfach an das Isolationselement angelegt werden, indem das wenigstens eine Gehäuseelement unter Bildung einer auf das wenigstens eine Widerstandselement wirkenden Vorspannkraft elastisch verformt ist.According to a further, possible advantageous embodiment of the resistance element can be particularly easily applied to the insulating element by the at least one housing element is elastically deformed to form a force acting on the at least one resistance element biasing force.
Hinsichtlich des eingangs genannten Verfahrens zum Herstellen eines Leistungswiderstandsmoduls für einen elektrischen Schaltkreis wird die obige Aufgabe erfindungsgemäß dadurch gelöst, dass als Widerstandselement ein Draht verwendet wird, der bei dem Verpressen zumindest abschnittsweise an wenigstens eines der beiden Isolationselemente angelegt wird. Somit kann ein inniger Kontakt zwischen dem Draht und dem Isolationselement einfach hergestellt werden. Dadurch ist ein den Anforderungen genügender Wärmeübergang zwischen dem Draht und dem Isolationselement gewährleistet.With regard to the above-mentioned method for producing a power resistor module for an electrical circuit, the above object is achieved in that a wire is used as the resistance element, which is at least partially applied to at least one of the two insulation elements during the pressing. Thus, intimate contact between the wire and the insulating member can be easily made. This ensures a sufficient heat transfer requirements between the wire and the insulation element.
Ein erfindungsgemäßes Verfahren zum Herstellen eines Leistungswiderstandsmoduls kann dadurch verbessert werden, dass die Oberflächenkontur des Drahtes zumindest abschnittsweise in wenigstens eines der beiden Isolationselemente eingedrückt und/oder eingeprägt wird. Der Draht kann eine runde, flache oder eckige Kontur aufweisen. Sowohl das Isolationselement als auch der Draht können sich bei dem Verpressen bzw. Einprägen plastisch verformen. Durch das Einprägen ist der Draht in das Material des Isolationselementes förmlich eingebettet und zumindest teilweise von ihm umschlossen, wodurch die Wärmeübertragungsfläche zwischen Draht und Isolationselement vergrößert wird. Der Wärmeübergang zwischen Draht und Isolationselement ist somit verbessert und das Leistungswiderstandsmodul wird kompakter.An inventive method for producing a power resistor module can be improved in that the surface contour of the wire is at least partially pressed in at least one of the two insulation elements and / or embossed. The wire may have a round, flat or angular contour. Both the insulation element and the wire can plastically deform during the pressing or embossing. By impressing the wire is formally embedded in the material of the insulating element and at least partially enclosed by it, whereby the heat transfer area between the wire and the insulating element is increased. The heat transfer between wire and insulation element is thus improved and the power resistor module becomes more compact.
Ein erfindungsgemäßes Verfahren zum Herstellen eines Leistungswiderstandsmoduls für einen elektrischen Schaltkreis kann weiter verbessert werden, indem vorgesehen wird, dass an dem wenigstens einen Gehäuseelement ein Aufnahmekanal gebildet wird, in den der Draht und die beiden Isolationselemente eingesetzt werden, und das wenigstens eine Gehäuseelement unter plastischer Verformung seines Querschnitts zusammengedrückt wird, so dass der Draht und die Isolationselemente im Aufnahmekanal verpresst werden. Dabei kann das Gehäuseelement so ausgestaltet sein, dass es nach dem Verpressen in einer gewünschten Querschnittsform verbleibt, in der es einen den Anforderungen entsprechenden Anpressdruck auf den Draht und die Isolationselemente im Aufnahmekanal ausübt. Um das Gehäuseelement in der gewünschten Querschnittsform zu fixieren, können zusätzlich Einkerbungen und Einprägungen am Gehäuseelement vorgenommen werden, damit Zonen maximaler Biegespannungen gegen Auffedern gesichert sind.An inventive method for producing a power resistor module for an electrical circuit can be further improved by providing that on the at least one housing member, a receiving channel is formed, in which the wire and the two insulating elements are used, and the at least one housing element under plastic deformation its cross-section is compressed, so that the wire and the insulation elements are pressed in the receiving channel. In this case, the housing element can be designed so that it remains after the pressing in a desired cross-sectional shape in which it exerts a pressure corresponding to the requirements of the wire and the insulation elements in the receiving channel. In order to fix the housing element in the desired cross-sectional shape, additional notches and indentations on the housing element can be made so that zones of maximum bending stresses are secured against springing.
Ein erfindungsgemäßes Verfahren zum Herstellen eines elektrischen Leistungswiderstandsmoduls kann dadurch weiter verbessert werden, dass der wenigstens eine Draht zumindest abschnittsweise auf einen Träger gewickelt wird. Somit lässt sich der Draht einfacher in der gewünschten Länge und in einer gleichmäßigen flächigen Verteilung in das Leistungswiderstandsmodul einbringen und der Träger kann im späteren Betrieb als zusätzlicher Wärmespeicher genutzt werden.A method according to the invention for producing an electrical power resistance module can be further improved in that the at least one wire is wound on a carrier at least in sections. Thus, the wire can be easier in the desired length and in a uniform area distribution in the power resistor module bring and the carrier can be used in later operation as an additional heat storage.
Ein erfindungsgemäßes Verfahren zum Herstellen eines erfindungsgemäßen Leistungswiderstandsmoduls kann dadurch verbessert werden, dass wenigstens eine in eine Öffnung des wenigstens einen Gehäuseelementes eingesetzte Dichtung bei einem Pressvorgang abdichtend eingeklemmt wird. Somit kann auf die Verwendung weiterer Dichtstoffe verzichtet werden, wenn vorgesehen ist, dass die Dichtung eine ausreichende Abdichtung des Innenraumes des erfindungsgemäßen Leistungswiderstandsmoduls gewährleistet.An inventive method for producing a power resistor module according to the invention can be improved by at least one in an opening of the at least one housing element used seal is sealingly clamped in a pressing operation. Thus, it can be dispensed with the use of further sealants, if it is provided that the seal ensures adequate sealing of the interior of the power resistor module according to the invention.
Durch das Einklemmen der Dichtung während eines Pressvorgangs kann das gesamte erfinderische Leistungswiderstandsmodul in einem einzigen Pressvorgang verpresst und abgedichtet werden. Es ist auch möglich, zuerst den Draht und die Isolationselemente zu verpressen und anschließend die Dichtung beim Zusammendrücken des Aufnahmekanals eines Gehäuseelementes oder zwischen mehreren Gehäuseelementen abdichtend einzuklemmen.By clamping the gasket during a pressing operation, the entire inventive power resistor module can be pressed and sealed in a single pressing operation. It is also possible first to press the wire and the insulation elements and then clamp the seal sealingly when compressing the receiving channel of a housing element or between a plurality of housing elements.
Im Folgenden wird die Erfindung anhand vorteilhafter Ausführungsformen mit Bezug auf die Zeichnungen beispielhaft näher erläutert. Die beschriebenen Ausführungsformen stellen dabei lediglich mögliche Ausgestaltungen dar, bei denen jedoch die einzelnen Merkmale, wie oben beschrieben ist, unabhängig voneinander realisiert oder weggelassen werden können.In the following, the invention will be explained in more detail by way of example with reference to advantageous embodiments with reference to the drawings. The described embodiments represent only possible embodiments in which, however, the individual features, as described above, can be realized independently of one another or omitted.
Es zeigen
- Fig. 1 eine schematische Draufsicht sowie halbseitige Schnittansicht eines erfindungsgemäßen Leistungswiderstandsmoduls;
- Fig. 2 eine schematischen Schnittansicht eines erfindungsgemäßen Leistungswiderstandsmoduls;
- Fig. 3 eine schematische Perspektivansicht einer erfindungsgemäßen Dichtung für ein erfindungsgemäßes Leistungswiderstandsmodul;
- Fig. 4 eine schematische Perspektivansicht einer in ein erfindungsgemäßes Leistungswiderstandsmodul eingesetzten erfindungsgemäßen Dichtung.
- Fig. 1 is a schematic plan view and half-side sectional view of a power resistor module according to the invention;
- 2 is a schematic sectional view of a power resistor module according to the invention;
- 3 shows a schematic perspective view of a seal according to the invention for a power resistance module according to the invention;
- 4 shows a schematic perspective view of a seal according to the invention used in a power resistance module according to the invention.
Zunächst wird der Aufbau eines erfindungsgemäßen Leistungswiderstandsmoduls 1 mit Bezug auf die Fig. 1 beschrieben, welche eine schematische Draufsicht sowie eine Schnittansicht eines erfindungsgemäß ausgestalteten Leistungswiderstandsmoduls 1 zeigt.First, the structure of a
Das Leistungswiderstandmodul 1 besitzt ein Gehäuseelement 2, welches als Aluminiumprofil 2' ausgeführt ist. Das Gehäuseelement 2 besitzt einen Aufnahmekanal 3 für ein Widerstandelement 4, welches elektrische Energie in Wärmeleistung umwandelt. Das Widerstandselement 4 ist als ein Draht 4' ausgeführt, welcher auf zwei Träger 5 gewickelt ist. Die Träger 5 besitzen Befestigungsabschnitte 6, die einen Stoß 7 bilden. In den Stoß 7 ist mittig ein Formschlusselement 8 in Form eines Niets 8' eingesetzt, der die Träger 5 verbindet. Um eine besonders flache Bauform des Leistungswiderstandsmoduls 1 zu ermöglichen überlappen sich die Träger 5 im Bereich des Stoßes 7 nicht.The
Des Weiteren ist an jeden der beiden Träger 5 ein Befestigungsmittel 9 in Form einer Kontakt- bzw. Lötfahne 9' angebracht, an welcher jeweils der Draht 4' und das abisolierte Ende 10 eines elektrischen Leiters 11 befestigt sind. Dazu kann der Draht 4' an seinem Befestigungspunkt 12 angelötet, -geschweißt oder elektrisch leitend geklebt sein. Es kann generell die für den jeweiligen Anwendungsfall am Besten geeignete Verbindungstechnik zwischen dem Draht 4' und dem Befestigungsmittel 9 gewählt werden, was auch für die Anbringung des elektrischen Leiters 11 an dem Befestigungsmittel 9 gilt. Der Draht 4' bzw. das Widerstandselement 4 und der elektrische Leiter 11 können auch direkt miteinander verbunden werden.Furthermore, a fastening means 9 in the form of a contact or Lötfahne 9 'is attached to each of the two carriers 5, to which in each case the wire 4' and the stripped end 10 of an electrical conductor 11 are attached. For this purpose, the wire 4 'can be soldered, welded or adhesively bonded at its attachment point 12. In general, the most suitable connection technology between the wire 4 'and the fastening means 9 for the particular application can be selected, which also applies to the attachment of the electrical conductor 11 to the fastening means 9. The wire 4 'or the resistance element 4 and the electrical conductor 11 can also be connected directly to one another.
In Öffnungen 13 an den Stirnseiten 14 des Gehäuseelementes 2 sind Dichtungen 15, 15' eingesetzt, um den Aufnahmekanal 3 des Gehäuseelementes 2 gegen ein Eindringen von Schmutz und Flüssigkeiten, bzw. korrosiven Medien zu schützen. Der elektrische Leiter 11 ist durch eine Durchführung 16 in der Dichtung 15 von Außen in das Gehäuseelement 2 eingeführt.In openings 13 on the end faces 14 of the
Ferner sind auf der dem Widerstandselement abgewandten Seite des Gehäuseelementes 2 Rippen 17 zur Oberflächenvergrößerung und verbesserten Wärmeübertragung der durch das Widerstandselement 4 erzeugten Wärme an die Umgebung ausgeformt. An den Stirnseiten 14 weist das Gehäuseelement 2 außerdem Anbringungselemente 17' auf, die zur Befestigung des Leistungswiderstandsmoduls 1 dienen.Further, ribs 17 for surface enlargement and improved heat transfer of the heat generated by the resistance element 4 to the environment are formed on the side facing away from the resistance element of the
In Fig. 2 ist ein erfindungsgemäßes Leistungswiderstandsmodul in einer Schnittansicht entlang der in Fig. 1 gezeigten Schnittlinie A-A gezeigt. Hier wird deutlich, dass der Träger 5 mit dem Draht 4' in den Aufnahmekanal 3 des Gehäuseelementes 2 eingeführt ist, wobei das Gehäuseelement 2 als Hohlprofil 2" bzw. Strangpressprofil 2'" ausgeführt ist.FIG. 2 shows a power resistor module according to the invention in a sectional view along the section line A-A shown in FIG. Here it is clear that the carrier 5 is inserted with the wire 4 'in the receiving
Der Träger 5 ist zwischen zwei Isolationselementen 18 angeordnet, wodurch der auf den Träger 5 aufgebrachte Draht 4' elektrisch vom Gehäuseelement 2 isoliert ist.The carrier 5 is arranged between two
Wie in Fig. 2 zu erkennen ist sind die beiden Isolationselemente 18 und der Träger 5 in einem flächigen Stapelaufbau 19 geschichtet und liegen bündig aneinander. Dies bedeutet, dass sich der Draht 4' durch ein Zusammenpressen des Stapelaufbaus 19 in die Isolationselemente und/oder den Träger 5 eingedrückt hat, wodurch die Isolationselemente 18 und/oder der Träger 5 an den Stellen, an welchen der Draht 4' liegt, förmlich eingeprägt sind. Träger 5 sowie Isolationselemente 18 sind als Mikanitpressstoffplatten ausgeführt, in welche sich der Draht 4' förmlich eingräbt, wodurch eine gute Wärmeübertragung vom Draht 4' an die umliegenden Isolationselemente 18 gewährleistet ist. Durch die innige Kontaktierung von Draht 4', Trägern 5 und Isolationselementen 18 ist auch die Wärmespeicherfähigkeit des Leistungswiderstandsmoduls 1 gewährleistet. Somit kann im erfindungsgemäßen Aufbau eines Leistungswiderstandmoduls 1 auf die Verwendung etwaiger Füllstoffe, wie Magnesiumoxid (MgO) verzichtet werden. Die Verwendung vorgefertigter Dichtungen 15, 15' macht zudem eine Abdichtung des Leistungswiderstandsmoduls 1 mit etwaigen Hilfsstoffen, wie Silikon oder ähnlichen überflüssig.As can be seen in Fig. 2, the two
In Fig. 2 wird außerdem deutlich, dass der sandwich-, bzw. stapelartige Aufbau eines erfindungsgemäßen Widerstandsmoduls 1 eine sehr einfache Fertigung eines erfindungsgemäßen Leistungswiderstandsmoduls 1 ermöglicht. Das Widerstandselement 4 bzw. der Träger 5 und der auf ihn aufgewickelte Draht 4' sowie die Isolationselemente 18 können einfach in den Aufnahmekanal 3 des Gehäuseelementes 2 eingestellt werden. Dabei kann das Gehäuseelement 2 als ein- oder beidseitig geöffnetes Hohlprofil 2" ausgeführt sein. Anschließend kann das Hohlprofil 2" entlang seiner Mittellinie M oder flächig zusammengepresst werden, wodurch sich seine Seitenflächen 20 nach Innen wölben und die Höhe h des Gehäuseelementes 2 verringert ist. Die Seitenflächen 20 können für einen verbesserten Halt durch zusätzliche Werkzeuge eingedrückt werden.In Fig. 2 is also clear that the sandwich, or stack-like structure of a
Mit dem Widerstandselement 4, bzw. Draht 4' verbundene elektrische Leiter 11 ragen dann, wie auch schon in Fig. 1 gezeigt aus einer Öffnung 13 im Gehäuseelement 2. Die Dichtung 15, 15' können schon vor dem Verpressen des Gehäuseelementes 2 in die Öffnungen 13 im Hohlprofil 2" eingesetzt sein, wobei die elektrischen Leiter 11 durch die Durchführungen 16 in der Dichtung 15 geführt sind.Electrical conductors 11 connected to the resistance element 4 or wire 4 'then protrude, as already shown in FIG. 1, from an opening 13 in the
In Fig. 3 ist eine erfindungsgemäß ausgestaltete Dichtung 15 in einer schematischen Perspektivansicht gezeigt. Die Dichtung 15 kann in einer Einführrichtung x in die Öffnung 13 im Gehäuseelement 2 eingesetzt werden. Die elektrischen Leiter 11 werden dabei durch Durchführungen 16 in der Dichtung 15 geführt. Die Dichtung 15 kann auch als Dichtung 15' ohne Durchführungen 16 ausgestaltet sein, wenn keine elektrischen Leiter 11 durch sie hindurchgeführt werden sollen.In Fig. 3, an inventively designed
Die Durchführungen 16 weisen einen elliptischen Querschnitt auf, wobei die Hauptachse E der elliptischen Durchführung 16 parallel zur Höhenachse Z der Dichtung sowie des Gehäuseelementes liegt. Wenn das Gehäuseelement 2 mit eingesetzter Dichtung 15 in der Z-Richtung zusammengepresst wird, dann verringert sich mit der Höhe H des Gehäuseelementes 2 auch die Höhe H' der Dichtung und die Hauptachsen E der Ellipse werden verkürzt, bis die Durchführungen 16 optimaler Weise einen kreisrunden Querschnitt aufweisen. Dadurch ist eine optimale Abdichtung von elektrischen Leitern 11 mit runden Querschnitten in den Durchführungen 16 gewährleistet.The
Ferner besitzt die Dichtung 15 Lamellen 21, welche die Dichtwirkung gegenüber den Gehäuseelement 2 der Dichtung weiter verbessern.Furthermore, the
In Fig. 4 ist eine schematische Perspektivansicht einer in einen Aufnahmekanal 3 eines Gehäuseelementes 2 eingesetzten Dichtung 15 gezeigt. Das Gehäuseelement ist bereits in Z-Richtung zusammengepresst, wodurch die Dichtung 15 eng vom Gehäuseelement 2 umschlossen und in Z-Richtung komprimiert ist.FIG. 4 shows a schematic perspective view of a
Im in Fig. 4 gezeigten komprimierten Zustand der Dichtung 15 weisen ihre Durchführungen 16 einen kreisrunden Querschnitt auf. Um die Dichtwirkung auch an den Seitenflächen 20 des Gehäuseelementes 2 zu gewährleisten, ist die Dichtung 15 an ihren Längsenden 22 leicht nach Innen gewölbt bzw. konkav eingeschnürt. Die Dichtung 15 passt sich somit optimal den ebenfalls nach Innen eingedrückten bzw. konkav eingeschnürten Seitenflächen des Gehäuseelementes 3 an und eine optimale Abdichtung ist entlang des gesamten Umfangs der Dichtung 15 bzw. der Öffnung 13 im Gehäuseelement 2 gewährleistet.In the compressed state of the
Innerhalb des Erfindungsgedankens sind Abweichungen von den oben beschriebenen Ausführungsformen möglich. So können Gehäuseelemente 2 auch als einfache Plattenkörper ausgeführt sein, an denen ein Isolationselement 18 anliegt, in welches ein Widerstandselement 4 bzw. ein entsprechendes Leistungsmodul erfindungsgemäß eingepresst und dadurch eingebettet ist. Ein Widerstandselement 4 in Form eines Drahtes 4' auf einen Träger 5 aufzuwickeln ist optional und hängt von der jeweiligen Materialstärke des Widerstandselements 4 ab. Wenn das Widerstandselement 4 an sich eine ausreichende Stabilität aufweist kann es auch einfach direkt zwischen zwei Isolationselementen 18 angeordnet und verpresst werden.Within the inventive concept, deviations from the embodiments described above are possible. Thus,
Ein Stapelaufbau 19 kann auch zwischen zwei als Plattenkörper ausgeführten Gehäuseelementen 2 angeordnet sein, welche zusammengepresst und durch etwaige Formschlusselemente zusammengehalten sind.A stack construction 19 can also be arranged between two
Ferner ist es auch denkbar, an einem Gehäuseelement 2 Halterungen 24 (nicht gezeigt) auszuformen, welche einen Anpressdruck auf ein Andrückelement 25 (nicht gezeigt) ausüben, das einen Stapelaufbau 19 zusammengepresst hält.Further, it is also conceivable to form on a
Ein Leistungswiderstandsmodul 1 mit einer oder mehreren Dichtungen 15, 15' abzudichten ist optional, es können dazu je nach Anforderungen auch jegliche Arten von Dichtmittel verwendet werden.A
Die plattenförmige Ausführung von Isolationselementen 18 ist für den Erfindungsgedanken des Einpressens eines Widerstandselementes 4 in ein Isolationselement unwesentlich. Es sind beliebige, in vorteilhafter Weise aufeinander abgestimmte geometrische Formen des Widerstandselementes 4, Gehäuseelementes 2 und der Isolationselemente 18 möglich. Ferner kann ein Isolationselement 18 sowohl aus dem schon genannten Pressglimmer (Mikanit) als auch aus anderen elektrisch isolierenden, hitzebeständigen Materialien, wie z. B. Polyimid bestehen. Das Isolationselement 18 kann somit auch als Folie, wie z. B. Polyimid-Folie (Kapton) ausgeführt sein.The plate-shaped design of
Claims (24)
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
DE502007005586T DE502007005586D1 (en) | 2007-04-02 | 2007-04-02 | Power resistor module |
AT07006864T ATE488015T1 (en) | 2007-04-02 | 2007-04-02 | POWER RESISTANCE MODULE |
EP07006864.8A EP1852878B2 (en) | 2007-04-02 | 2007-04-02 | Power resistor module |
US12/075,615 US7940156B2 (en) | 2007-04-02 | 2008-03-12 | Power resistor module |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP07006864.8A EP1852878B2 (en) | 2007-04-02 | 2007-04-02 | Power resistor module |
Publications (4)
Publication Number | Publication Date |
---|---|
EP1852878A1 true EP1852878A1 (en) | 2007-11-07 |
EP1852878A8 EP1852878A8 (en) | 2008-11-12 |
EP1852878B1 EP1852878B1 (en) | 2010-11-10 |
EP1852878B2 EP1852878B2 (en) | 2016-06-01 |
Family
ID=39873994
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP07006864.8A Not-in-force EP1852878B2 (en) | 2007-04-02 | 2007-04-02 | Power resistor module |
Country Status (4)
Country | Link |
---|---|
US (1) | US7940156B2 (en) |
EP (1) | EP1852878B2 (en) |
AT (1) | ATE488015T1 (en) |
DE (1) | DE502007005586D1 (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102009043032A1 (en) | 2009-09-28 | 2011-03-31 | Dbk David + Baader Gmbh | Heating module for high volt heating device and heater of vehicle, has electrical resistance element, where heat is transferred on medium by heat distribution element |
DE102009043040A1 (en) | 2009-09-28 | 2011-03-31 | Dbk David + Baader Gmbh | Heater for vehicle, comprises heating module packet which has multiple heating modules that are arranged parallel to each other, where module has resistance element |
DE102009043041A1 (en) | 2009-09-28 | 2011-03-31 | Dbk David + Baader Gmbh | Heater for vehicle, comprises heating module packet which has multiple heating modules that are arranged parallel to each other, where module has resistance element and heat dissipation element for housing |
DE102011000719A1 (en) | 2010-02-13 | 2011-08-18 | DBK David + Baader GmbH, 76870 | Method for operating electric heater for heating airflow in air-conditioning system of car, involves reading temperature of resistor heating elements based on resistance, and changing electric power of heating elements based on temperature |
DE102011002144A1 (en) | 2011-02-25 | 2012-08-30 | Dbk David + Baader Gmbh | Method for actuating electric heater used in motor car, involves resistance heating element to which power supply is reduced or shutdown, when measured resistance is greater than or equal to positive temperature coefficient resistor |
DE102016125124A1 (en) * | 2016-12-21 | 2018-06-21 | Dbk David + Baader Gmbh | discharge |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
KR101420033B1 (en) * | 2010-03-11 | 2014-07-15 | 가부시키가이샤 시마쓰세사쿠쇼 | Turbo molecular pump device |
JP6122613B2 (en) * | 2012-11-02 | 2017-04-26 | ミクロン電気株式会社 | Method for manufacturing power resistor |
DE102014102601A1 (en) | 2013-12-24 | 2015-06-25 | Dbk David + Baader Gmbh | Resistor and method of making such a resistor |
DE102017113600A1 (en) * | 2017-06-20 | 2018-12-20 | Vishay Electronic Gmbh | power resistor |
DE202018101634U1 (en) | 2018-03-23 | 2018-04-03 | Türk & Hillinger GmbH | Device for converting electrical energy into heat and electrical heating device with such a device |
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DE8503272U1 (en) | 1985-02-06 | 1985-05-23 | Fritz Eichenauer GmbH & Co KG, 6744 Kandel | ELECTRIC RADIATOR |
DE19628471C2 (en) † | 1995-07-14 | 2003-08-28 | Eldis Ehmki & Schmid Ohg | package resistance |
DE20101106U1 (en) | 2001-01-22 | 2001-04-05 | David + Baader - DBK - GmbH, 76870 Kandel | Protection element in an electrical circuit |
FR2828785B1 (en) † | 2001-08-14 | 2004-01-23 | Bernard Peyronny | BODY OF ELECTRIC HEATER WET IN A CALORIES ACCUMULATOR BLOCK |
DE20311068U1 (en) † | 2003-07-18 | 2003-09-25 | Türk & Hillinger GmbH, 78532 Tuttlingen | Braking resistance for electrical motors is in form of coil winding on a former set within a heat dissipating block of metal |
DE202004015807U1 (en) † | 2004-10-13 | 2005-01-13 | Türk & Hillinger GmbH | Thermal fuse switch for braking resistor |
DE502005000629D1 (en) † | 2005-01-14 | 2007-06-06 | Dbk David & Baader Gmbh | Sealed radiator |
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2007
- 2007-04-02 EP EP07006864.8A patent/EP1852878B2/en not_active Not-in-force
- 2007-04-02 DE DE502007005586T patent/DE502007005586D1/en active Active
- 2007-04-02 AT AT07006864T patent/ATE488015T1/en active
-
2008
- 2008-03-12 US US12/075,615 patent/US7940156B2/en not_active Expired - Fee Related
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DE2626409A1 (en) * | 1976-06-12 | 1977-12-15 | Wigo Widmann Soehne Gottlob | Heating element for hair or hand dryer - with extruded profiled heating body contg. coil sealed with ceramic or silicone rubber |
DE4242699A1 (en) * | 1992-12-17 | 1993-05-19 | Alfred Hodek | Power resistor for chassis mounting - has resistive element between two insulating layers which are pressed between metal plates forming housing. |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102009043032A1 (en) | 2009-09-28 | 2011-03-31 | Dbk David + Baader Gmbh | Heating module for high volt heating device and heater of vehicle, has electrical resistance element, where heat is transferred on medium by heat distribution element |
DE102009043040A1 (en) | 2009-09-28 | 2011-03-31 | Dbk David + Baader Gmbh | Heater for vehicle, comprises heating module packet which has multiple heating modules that are arranged parallel to each other, where module has resistance element |
DE102009043041A1 (en) | 2009-09-28 | 2011-03-31 | Dbk David + Baader Gmbh | Heater for vehicle, comprises heating module packet which has multiple heating modules that are arranged parallel to each other, where module has resistance element and heat dissipation element for housing |
DE102011000719A1 (en) | 2010-02-13 | 2011-08-18 | DBK David + Baader GmbH, 76870 | Method for operating electric heater for heating airflow in air-conditioning system of car, involves reading temperature of resistor heating elements based on resistance, and changing electric power of heating elements based on temperature |
DE102011002144A1 (en) | 2011-02-25 | 2012-08-30 | Dbk David + Baader Gmbh | Method for actuating electric heater used in motor car, involves resistance heating element to which power supply is reduced or shutdown, when measured resistance is greater than or equal to positive temperature coefficient resistor |
DE102016125124A1 (en) * | 2016-12-21 | 2018-06-21 | Dbk David + Baader Gmbh | discharge |
Also Published As
Publication number | Publication date |
---|---|
US7940156B2 (en) | 2011-05-10 |
ATE488015T1 (en) | 2010-11-15 |
EP1852878A8 (en) | 2008-11-12 |
EP1852878B2 (en) | 2016-06-01 |
EP1852878B1 (en) | 2010-11-10 |
US20080266047A1 (en) | 2008-10-30 |
DE502007005586D1 (en) | 2010-12-23 |
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