EP1852878B2 - Power resistor module - Google Patents
Power resistor module Download PDFInfo
- Publication number
- EP1852878B2 EP1852878B2 EP07006864.8A EP07006864A EP1852878B2 EP 1852878 B2 EP1852878 B2 EP 1852878B2 EP 07006864 A EP07006864 A EP 07006864A EP 1852878 B2 EP1852878 B2 EP 1852878B2
- Authority
- EP
- European Patent Office
- Prior art keywords
- wire
- housing element
- insulation elements
- power resistor
- resistor module
- 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.)
- Not-in-force
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- 239000010445 mica Substances 0.000 claims description 12
- 229910052618 mica group Inorganic materials 0.000 claims description 12
- 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
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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 pressed at least in sections against a housing element.
- 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 wires are often used to convert 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 heating element is electrically insulated and heat-transfer coupled to a suitable heat sink, such as an aluminum profile body.
- 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.
- Femer is in the 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 surface contour of the wire is impressed at least in sections into the insulation elements. This makes it possible that the wire is embedded in the insulation elements and is surrounded by the 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 insulating element contains mica.
- Mica is a silicate mineral from natural deposits, which has an electrically insulating effect and is temperature-resistant up to 600 degrees Celsius.
- 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 housing element is an extruded profile.
- the housing element can be easily manufactured by simply cutting it to length from 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. Trained as a hollow profile extruded profile forms a solid housing body for a power resistor 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 which receives at least one electrically connected to the at least one wire electrical conductor.
- 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 on a carrier at least in sections.
- the wire can be easily in a desired wide or narrow installation evenly and widely used in the 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 attached / is.
- 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.
- 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 between the at least one housing element and at least one biased against the resistive element pressure element is arranged, which is held by at least one support on the housing element support.
- 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 embodiment with a housing element and a pressure element, in this case two essentially identically constructed housing elements can serve to press the wire.
- the wire is accordingly arranged between the housing elements, which after reaching the desired contact pressure by suitable interlocking elements, such. Screws or rivets, to be joined together.
- suitable interlocking elements such as Screws or rivets, to be joined together.
- 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 contacts the sections of the carrier and the respectively applied insulating element between the webs of the wires surface contact 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 applied during pressing at least partially to both insulation elements.
- a more intimate Contact between the wire and the insulation elements can be made easily. This ensures a sufficient heat transfer requirements between the wire and the insulation elements.
- the surface contour of the wire is impressed at least in sections into the two insulation elements.
- 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.
- 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.
- the inventive method for producing the module provides that at the at least one housing element, a receiving channel is formed, in which the wire and the two insulating elements are used, and the housing element is compressed under plastic deformation of its cross section, so that the wire and this insulating elements be pressed in the receiving channel.
- the housing element is 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 insulating elements in the receiving channel.
- notches and indentations are additionally made on the housing element, so that zones of maximum bending stresses are secured against Auffedem.
- the at least one wire is wound at least in sections onto a carrier.
- the wire can be easier to introduce in the desired length and in a uniform area distribution in the module and the carrier can be used in later operation as an additional heat storage.
- a method according to the invention for producing a power resistance module according to the invention can be improved in that at least one seal inserted into an opening of the at least one housing element is sealingly clamped during a pressing operation.
- 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.
- FIGS Fig. 1 shows a schematic plan view and a sectional view of a power resistor module 1 designed according to the invention.
- 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. In the 7th stroke is in the middle Positive locking element 8 in the form of a rivet 8 'used, 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 of the housing element 2 facing away from the resistance element.
- the housing element 2 also has attachment elements 17 ', which serve for fastening the power resistor module 1.
- Fig. 2 is a power resistor module according to the invention in a sectional view along in FIG Fig. 1 shown section line AA shown.
- the carrier 5 is inserted with the wire 4 'in the receiving channel 3 of the housing element 2, wherein the housing element 2 is designed as a hollow profile 2 "or extruded profile 2"'.
- 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 ', carrier 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.
- the sandwich or stack-type construction of a resistance module 1 according to the invention enables a very simple production of a power resistance 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.
- a seal 15 designed according to the invention 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. If that Housing element 2 is pressed together with inserted seal 15 in the Z direction, then decreases with the height H of the housing member 2 and the height H 'of the seal and the major axes E of the ellipse are shortened until the bushings 16 optimally have a circular cross-section , This ensures optimum sealing of electrical conductors 11 with round cross-sections in the passages 16.
- the seal 15 has fins 21, which further improve the sealing effect with respect to the housing element 2 of the seal.
- Fig. 4 is a schematic perspective view of a seal 15 used in a receiving channel 3 of a housing element 2 is shown.
- 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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- Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
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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 pressed at least in sections against a housing element.
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, wie er beispielsweise aus der
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
Femer 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 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 durch die Merkmale des Anspruchs 1 bzw. ein Verfahren gemäß Patentanspruch 13 gelöst. Vorteilhafte Weiterbildungen der Erfindung sind Gegenstand der Unteransprüche.This object is achieved for the above-mentioned power resistor module by the features of claim 1 and a method according to
Diese einfache Lösung hat den Vorteil, dass der Draht die erzeuget 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 generate 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 insulation element and / or the wire is elastically deformed and there is a surface contact between the insulation 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 ist erfindungsgemäss vorgesehen, dass die Oberflächenkontur des Drahtes zumindest abschnittsweise in die Isolationselemente eingeprägt ist. Dadurch ist es möglich, dass der Draht in den Isolationselementen eingebettet ist und von dessen plastisch verformten Material umgeben ist, womit eine innige Kontaktierung erreicht wird.Thus, it is provided according to the invention that the surface contour of the wire is impressed at least in sections into the insulation elements. This makes it possible that the wire is embedded in the insulation elements and is surrounded by the 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.
Erfindungsgemäss enthält das Isolationselement Glimmer. Glimmer ist ein Silikat-Mineral aus natürlichen Vorkommen, das elektrisch isolierend wirkt und bis 600 Grad Celsius temperaturbeständig ist.According to the invention, the insulating element contains mica. Mica is a silicate mineral from natural deposits, which has an electrically insulating effect and is temperature-resistant up to 600 degrees Celsius.
Erfindungsgemäss sind die Isolationselemente aus plattenförmigem Glimmerpressstoff aufgebaut. 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 the invention, 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.
Erfindungsgemäss ist das Gehäuseelement ein Strangpressprofil. Somit kann das Gehäuseelement einfach hergestellt werden, indem es von einem Strangpressprofil des gewünschten Querschnitts einfach abgelängt wird. Dabei ist das Strangpressprofil ein Hohlprofil, welches an wenigstens einer Seite eine Oeffnung aufweist und wenigstens einen Aufnahmekanal bildet, in dem der wenigstens eine Draht und die Isolationselemente aufgenommen sind. Das als Hohlprofil ausgebildete Strangpressprofil bildet einen soliden Gehäusekörper für ein erfindungsgemäßes Leistungswiderstandsmodul, welcher stabil und einfach abzudichten ist.According to the invention, the housing element is an extruded profile. Thus, the housing element can be easily manufactured by simply cutting it to length from an extruded profile of the desired cross-section. In this case, 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. Trained as a hollow profile extruded profile forms a solid housing body for a power resistor 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 which receives at least one electrically connected to the at least one wire electrical conductor. 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.
Erfindungsgemäss ist der wenigstens eine Draht zumindest abschnittsweise auf einen Träger gewickelt. Somit lässt sich der Draht einfach in einer gewünscht weiten oder engen Verlegung gleichmässig und flächendeckend in das Modul 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 Modul einzusetzen.According to the invention, the at least one wire is wound on a carrier at least in sections. Thus, the wire can be easily in a desired wide or narrow installation evenly and widely used in the 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 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 attached / is. 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 particularly advantageous for a flat and as flat as possible construction of a power resistor module, because it is possible to dispense 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 between the at least one housing element and at least one biased against the resistive element pressure element is arranged, which is held by at least one support on the housing element support. 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 embodiment with a housing element and a pressure element, in this case two essentially identically constructed housing elements can serve to press the wire. The wire is accordingly arranged between the housing elements, which after reaching the desired contact pressure by suitable interlocking elements, such. Screws or rivets, to be joined together. 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 contacts the sections of the carrier and the respectively applied insulating element between the webs of the wires surface contact 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 Widerstandselementwirkenden 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 Moduls für einen elektrischen Schaltkreis wird die obige Aufgabe dadurch gelöst, dass als Widerstandselement ein Draht verwendet wird, der beim Verpressen zumindest abschnittsweise an beide Isolationselemente angelegt wird. Somit kann ein inniger Kontakt zwischen dem Draht und den Isolationselementen einfach hergestellt werden. dadurch ist ein den Anforderungen genügender Wärmeübergang zwischen dem Draht und den Isolationselementen gewährleistet.With regard to the above-mentioned method for producing a module for an electrical circuit, the above object is achieved in that a wire is used as the resistance element, which is applied during pressing at least partially to both insulation elements. Thus, a more intimate Contact between the wire and the insulation elements can be made easily. This ensures a sufficient heat transfer requirements between the wire and the insulation elements.
Gemäss dem erfindungsgemäßen Verfahren ist die Oberflächenkontur des Drahts zumindest abschnittsweise in die beiden Isolationselemente eingeprägt. 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.According to the method according to the invention, the surface contour of the wire is impressed at least in sections into the two insulation elements. 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.
Das erfindungsgemäße Verfahren zu Herstellen des Moduls sieht vor, dass an dem wenigstens einen Gehäuseelement ein Aufnahmekanal gebildet wird, in den der Draht und die beiden Isolationselemente eingesetzt werden, und das Gehäuseelement unter plastischer Verformung seines Querschnitts zusammengedrückt wird, so dass der Draht und dies Isolationselemente im Aufnahmekanal verpresst werden. Dabei ist das Gehäuseelement so ausgestaltet, dass es nach dem verpressen in einer gewünschten Querschnittsform verbleibt, in der es eine denAnforderungen entsprechenden Anpressdruck auf den Draht und die Isolationselemente im Aufnahmekanal ausübt. Um das Gehäuseelement in der gewünschten Querschnittsform zu fixieren, sind zusätzlich Einkerbungen und Einprägungen am Gehäuseelement vorgenommen, damit Zonen maximaler Biegespannungen gegen Auffedem gesichert sind.The inventive method for producing the module provides that at the at least one housing element, a receiving channel is formed, in which the wire and the two insulating elements are used, and the housing element is compressed under plastic deformation of its cross section, so that the wire and this insulating elements be pressed in the receiving channel. In this case, the housing element is 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 insulating elements in the receiving channel. In order to fix the housing element in the desired cross-sectional shape, notches and indentations are additionally made on the housing element, so that zones of maximum bending stresses are secured against Auffedem.
Gemäss dem erfindungsgemäßen Verfahren zum Herstellen des Leistungswiderstandsmoduls ist der wenigstens eine Draht zumindest abschnittsweise auf einen Träger gewickelt. Somit lässt sich der Draht einfacher in der gewünschten Länge und in einer gleichmässigen flächigen Verteilung in das Modul einbringen und der Träger kann im späteren Betrieb als zusätzlicher Wärmespeicher genutzt werden.According to the method according to the invention for producing the power resistor module, the at least one wire is wound at least in sections onto a carrier. Thus, the wire can be easier to introduce in the desired length and in a uniform area distribution in the module 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.A method according to the invention for producing a power resistance module according to the invention can be improved in that at least one seal inserted into an opening of the at least one housing element is sealingly clamped during 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
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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.
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Fig. 1 a schematic plan view and half-side sectional view of a power resistor module according to the invention; -
Fig. 2 a schematic sectional view of a power resistor module according to the invention; -
Fig. 3 a schematic perspective view of a seal according to the invention for a power resistor module according to the invention; -
Fig. 4 a schematic perspective view of a seal according to the invention used in a power resistor module according to the invention.
Zunächst wird der Aufbau eines erfindungsgemäßen Leistungswiderstandsmoduls 1 mit Bezug auf die
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 power resistor module 1 has a
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
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
Femer 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.Furthermore, 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 of the
In
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
In
Mit dem Widerstandselement 4, bzw. Draht 4' verbundene elektrische Leiter 11 ragen dann, wie auch schon in
In
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
Femer besitzt die Dichtung 15 Lamellen 21, welche die Dichtwirkung gegenüber den Gehäuseelement 2 der Dichtung weiter verbessern.Furthermore, the
In
Im in
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
Femer 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.Furthermore, 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 power resistor module 1 with one or
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 (14)
- A power resistor module (1) for electrical circuits, comprising at least one resistor element (4) and at least one housing element (2), wherein the at least one resistor element (4) is impressed at least section-wise between two electrically insulating, thermally conductive insulation elements (18) in the housing element (2), and the insulation elements (18) at least section-wise abut against the at least one housing element (2), wherein the at least one resistor element (4) is a wire (4'), which at least section-wise abuts against at least one of the insulation elements (18) and the insulation elements (18) are made of a plate-shaped, pressed mica material and the at least one wire (4') is wound at least section-wise onto a carrier (5), characterized in that by compressing, the surface contour of the wire (4') is impressed at least section-wise into the insulation elements (18), wherein the at least one housing element (2) is an extruded profile (2"') formed as a hollow profile having at least one opening (13) on at least one side (14) and forming at least one receiving channel (3) in which the at least one wire (4') and the insulation elements (18) are received, wherein the hollow profile (2") is compressed while plastically deforming the cross-section thereof, so that the wire (4') and the insulation elements (18) are compressed within the receiving channel (3), wherein, in order to fix the desired cross-sectional shape of the housing element, additional notches or impressions are provided on the housing element, so that zones of maximum bending stresses are secured against unbending.
- The power resistor module (1) according to claim 1, characterized in that it does not contain magnesium oxide.
- The power resistor module (1) according to claim 1 or 2, characterized in that the at least one opening (13) is sealed with an elastic seal (15, 15').
- The power resistor module (1) according to claim 3, characterized in that the seal (15) has at least one leadthrough (16) receiving at least one electric conductor (11) electrically connected to the wire (4').
- The power resistor module (1) according to claim 4, characterized in that the leadthrough (16) is adapted, in a compressed state of the seal (15), to a cross-sectional shape of the electric conductor (11).
- The power resistor module (1) according to claim 5, characterized in that at least one fixing element (9) is mounted on the carrier (5), to which fixing element the at least one wire (4') and/or the at least one electric conductor (11) is/are fixed.
- The power resistor module (1) according to claim 1 or 6, characterized in that a plurality of carriers (5) form at least one abutment (7) in which a form-fit element (8) to connect the carriers (5) is disposed.
- The power resistor module (1) according to claim 7, characterized in that the carriers (5) are constructed identically.
- The power resistor module (1) according to any of the preceding claims, characterized in that the at least one resistor element (4) is mounted between the at least one housing element (2) and at least one press-on element (25) preloaded against the at least one resistor element (4), which is held by at least one holder (24) supported against the at least one housing element (2).
- The power resistor module (1) according to any of the preceding claims, characterized in that the wire (4') is disposed between at least two housing elements (2) that are connected to each other by form-fit elements (23).
- The power resistor module (1) according to any of claims 1 or 6 to 10, characterized in that the carrier (5) and the insulation elements (18) are substantially disposed in a flat stack structure (19).
- The power resistor module (1) according to any of the preceding claims, characterized in that the at least one housing element (2) is elastically deformed by producing a preloading force acting on the at least one resistor element (4).
- A method for producing an electrical power resistor module (1) for an electrical circuit, wherein at least one resistor element (4) is compressed with two electrically insulating, thermally conductive insulation elements (18), and at least one of the two insulation elements (18) is pressed at least section-wise against a housing element (2), characterized in that a wire (4') is used as the resistor element (4), which is placed at least section-wise against at least one of the two insulation elements (18) during the compressing step, the at least one wire (4') is wound at least section-wise onto a carrier (5), wherein the insulation element (18) contains mica, the insulation elements (18) are made of a plate-shaped, pressed mica material, wherein by compressing, the surface contour of the wire (4') is impressed at least section-wise into the two insulation elements (18), wherein the at least one housing element (2) is an extruded profile (2") formed as a hollow profile having at least one opening (13) on at least one side (14) and forming at least one receiving channel (3) in which the at least one wire (4') and the insulation elements (18) are received, wherein the at least one housing element (2) is compressed while plastically deforming the cross-section thereof, so that the wire (4') and the insulation elements (18) are compressed within the receiving channel (3), wherein, in order to fix the desired cross-sectional shape of the housing element, additional notches or impressions are provided on the housing element, so that zones of maximum bending stresses are secured against unbending.
- The method for producing an electrical power resistor module (1) according to claim 13, characterized in that at least one seal (15) inserted into an opening (13) of the at least one housing element (2) is clamped in a sealing manner during a pressing process.
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AT07006864T ATE488015T1 (en) | 2007-04-02 | 2007-04-02 | POWER RESISTANCE MODULE |
DE502007005586T DE502007005586D1 (en) | 2007-04-02 | 2007-04-02 | Power resistor 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 EP1852878A1 (en) | 2007-11-07 |
EP1852878A8 EP1852878A8 (en) | 2008-11-12 |
EP1852878B1 EP1852878B1 (en) | 2010-11-10 |
EP1852878B2 true 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 (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102019103770B4 (en) | 2018-03-23 | 2024-06-27 | Türk + Hillinger GmbH | Device for converting electrical energy into heat and electric heating device with such a device |
Families Citing this family (10)
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 |
CN102782331B (en) * | 2010-03-11 | 2015-04-22 | 株式会社岛津制作所 | Turbo molecular pump device |
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 |
JP6122613B2 (en) * | 2012-11-02 | 2017-04-26 | ミクロン電気株式会社 | Method for manufacturing power resistor |
DE202014010469U1 (en) | 2013-12-24 | 2015-08-26 | Dbk David + Baader Gmbh | resistance |
DE102016125124A1 (en) * | 2016-12-21 | 2018-06-21 | Dbk David + Baader Gmbh | discharge |
DE102017113600A1 (en) * | 2017-06-20 | 2018-12-20 | Vishay Electronic Gmbh | power resistor |
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2007
- 2007-04-02 DE DE502007005586T patent/DE502007005586D1/en active Active
- 2007-04-02 AT AT07006864T patent/ATE488015T1/en active
- 2007-04-02 EP EP07006864.8A patent/EP1852878B2/en not_active Not-in-force
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2008
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US3789191A (en) † | 1972-09-01 | 1974-01-29 | Ppg Industries Inc | Temperature sensor |
US4203197A (en) † | 1976-03-18 | 1980-05-20 | Fast Heat Element Mfg. Co., Inc. | Method for making a ceramic bond heater |
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DE19628471A1 (en) † | 1995-07-14 | 1997-01-16 | Eldis Ehmki & Schmid Ohg | Aluminium{@ housed electrical resistor - has rectangular cross=section with coils wound onto ceramic strip carriers located in housing with space filled with sintered aluminium oxide powder |
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DE20311068U1 (en) † | 2003-07-18 | 2003-09-25 | Tuerk & Hillinger Gmbh | Braking resistance for electrical motors is in form of coil winding on a former set within a heat dissipating block of metal |
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DE102019103770B4 (en) | 2018-03-23 | 2024-06-27 | Türk + Hillinger GmbH | Device for converting electrical energy into heat and electric heating device with such a device |
Also Published As
Publication number | Publication date |
---|---|
DE502007005586D1 (en) | 2010-12-23 |
EP1852878A1 (en) | 2007-11-07 |
ATE488015T1 (en) | 2010-11-15 |
US7940156B2 (en) | 2011-05-10 |
EP1852878A8 (en) | 2008-11-12 |
US20080266047A1 (en) | 2008-10-30 |
EP1852878B1 (en) | 2010-11-10 |
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