The invention relates to an electrical switch element and an arrangement for an electrical switch element, in particular a contactor or relay, having a coil member, a yoke which has at least one yoke member and a control module for electrically controlling the switch element.

Electrical switch elements, for example, monostable contactors or relays in electric vehicles/hybrid vehicles, often have a control module which at least partially controls the switch element. For example, the control module may reduce the control power after the switching operation has been released. This may be carried out by pulse width modulation or switching of a low-resistance operating winding to a higher-resistance switch winding.

If the high starting power levels which are required for switching and which are necessary for starting the switching operation are limited to the operating time of the switch element, the power necessary to retain the switch element in the switched position may be limited. The energy reversal in the relay is thereby reduced and the thermal input by the magnetic coil into the environment substantially reduced. Consequently, it is possible, when a control module is used, to reduce the structural space required for the coil member and to decrease the drive system necessary for driving the switch element. An object of the invention is to further reduce the size of the electrical switch elements with the good assembly and connection possibilities being maintained.

This object is achieved according to the invention for the above-mentioned arrangement and the above-mentioned switch element in that the control module is arranged between the yoke member and the coil. By the control module being arranged between the yoke member and the coil, it is possible to further reduce the size of the switch element and to save structural space.

That basic notion of the invention can be improved by the following optional developments which are advantageous per se and can be combined independently of each other.

Thus, according to a first advantageous development, the control module may have a pocket, in which electrical structural elements are arranged, preferably on a printed circuit board. The pocket has protection walls which extend away from the yoke member. The protection walls allow an increase in the creep current path between the yoke member which is at the potential of the power supply current to be switched on many occasions. The electrical structural elements are used to control the switch element. The pocket may be open in the direction of the coil so that, for example, the printed circuit board can be positioned in the pocket from the coil side. Alternatively, the pocket may also be constructed to allow the printed circuit board to be pushed into the pocket from one of the narrow sides of the pocket.

The form of the yoke is often determined by the installation situation of the switch element or by a geometry of a contact switch chamber in which the contacts to be switched are arranged. In many cases, however, the yoke will have a U-shaped base member, with the open side of the U-shape being closed or being able to be closed by a separate yoke plate.

In the case of a rectangular shape of the outline of the contact switch chamber, it is advantageous for the base face of the yoke also to be rectangular. The yoke member may particularly extend parallel with a longitudinal axis of the coil member in a perpendicular manner. The plane of the printed circuit board preferably extends parallel with the plane of the yoke member.

The pocket may be formed by a separate carrier in which the printed circuit board is positioned. Such a carrier is preferably an injection-moulded component.

The control module with the printed circuit board or the electrical structural elements and optionally the carrier may preferably be a preassembled assembly unit in order to configure the assembly of the electrical switch element as simply as possible. The preassembled assembly unit may simply be connected to, for example, the coil member. According to another advantageous embodiment, the control module may have electrical connection elements which are configured so as to be able to be connected to complementary connection elements on the coil member. Since the control module is arranged according to the invention between the yoke member and the coil member and therefore very near the coil member, the coil member and the control module may be connected to each other directly without a line being necessary between them. The connection elements and the complementary connection elements may form a connector and a mating connector, the insertion direction preferably extending perpendicularly to the coil axis.

The complementary connection elements on the coil member may be in direct contact with a coil wire via, for example, an insulation displacement connection. In order to be able to support the control module and/or readily to electrically contact the control module, the control module may extend through a recess of the yoke, in particular the yoke member, to the outer side of the yoke. An outwardly extending portion for the control module may be provided with electrical connection elements which are accessible from the outer side of the yoke. The term "outer" is intended to refer to the space located outside the cubature of the yoke. The space inside the cubature of the yoke is referred to using the term "inner". The control module advantageously adjoins the recess in the definitively assembled state.

The control module, in particular the carrier, may have a guiding and retaining collar which projects parallel with the plane of the yoke member. In the assembled state, the yoke member is received in such a configuration between the control module and the guiding and retaining collar. The guiding and retaining collar may adjoin the yoke member at the outer side in the control module which is definitively assembled. However, it should be ensured that no press fit is present at this location so that unnecessarily high forces are not required during the assembly of the control module on the yoke member. It is further advantageous if the control module is displaceably received in the recess. In particular, the control module may be movably received by being displaced into the definitive assembly position thereof. The recess may have catch means so that the control module engages in the recess in the definitive assembly position.

A particularly simple assembly operation is possible if the recess opens towards a free end of the yoke member. The free end of the yoke member may, for example, face the yoke plate. In this embodiment, the switch element may simply be displaced from the free end along the recess into the definitive assembly position thereof.

In order to reinforce the mechanical retention of the control module on the yoke member, according to another advantageous embodiment the control module may be provided with at least one projection. The projection may, at least in the definitive assembly position of the control module, extend through a complementary receiving member of the yoke, in particular the yoke member. The projection may be, for example, rib-like. Furthermore, the receiving member may be connected to the recess, in this instance the receiving member preferably extending away from the recess in the direction in which the control module is displaceable along the recess into the definitive assembly position. In this manner, the projection is automatically pushed into the receiving member when the control module is displaced into the definitive assembly position. The receiving member and projection produce a positive-locking connection which may receive forces acting on the control module.

The coil member may be provided at a front side with an assembly flange which projects forwards towards the yoke member, the assembly flange being connected to the control module. The assembly flange projects laterally relative to the remaining coil member so that it allows the connection with respect to the control module. The assembly flange is preferably arranged at the coil member side facing away from the switch contacts of the switch element and/or the yoke plate. It should not radially overlap the coil wound on the coil member so that the coil can also be wound without being impeded by the assembly flange.

The complementary connection elements, via which the switch module is connected to the coil wires, may be arranged in particular on the assembly flange.

The complementary connection elements on the assembly flange of the coil member preferably extend in the assembly flange perpendicularly relative to the longitudinal axis of the coil member. If the yoke has a socket which extends into the coil interior in the completely assembled switch element, the socket may have a flattened portion at least partially in a region opposite the yoke member in order to provide the necessary space for the complementary connection elements. Such a flattened portion may particularly be provided on a, for example, bead-like, peripheral abutment flange of the socket. The assembly flange preferably extends inside the cubature of the yoke perpendicularly relative to the yoke member from the coil member to the switch module.

Owing to the position of the assembly flange at a front side of the coil member, the assembly flange is under some circumstances very near the yoke so that steps must be taken in order to prevent creep currents between the yoke, coil member, complementary connection elements, connection elements and/or the control module. To this end, an insulation cap may be provided. The insulation cap is preferably between the assembly flange and the yoke and is preferably knob-like or cup-like with in particular peripheral side walls. In order to make assembly of the switch element easier, the control module and the coil member may be received together in the insulation cap. To this end, the control module and the coil member may be configured so as to be able to be preassembled to form an assembly unit which can be integrally introduced into the yoke and/or the insulation cap. The insulation cap may be added to that assembly unit as an additional element so that the control module, the coil member and the insulation cap can be introduced together into the yoke. Alternatively, it is also possible for the insulation cap to be introduced into the yoke first and subsequently the assembly unit comprising the coil member and the control module to be introduced into the insulation cap. As already set out above, a yoke plate which closes the magnetic circuit of the yoke may be provided at a front side of the coil member, in particular the front side thereof opposite the assembly flange. The yoke plate is preferably provided with at least one fixing device, to which the control module may be fitted. The control module and the yoke plate may be connected to each other, for example, in a positive-locking manner, via the fixing device. In such an embodiment, the control module and the yoke plate may first be preassembled, and additional components of the switch element which may be connected to the yoke plate, such as, for example, the contact switch chamber, to form an assembly unit. That assembly unit may then be connected to the coil member to form another assembly unit which is then introduced into the yoke, with or without an insulation cap. In order not to needlessly interrupt the magnetic circuit in the yoke and in the yoke plate, the yoke plate and the control module are preferably connected to each other outside the yoke.

The invention is explained in greater detail below with reference to an exemplary embodiment and the drawings. The feature combination described in this embodiment may be changed in accordance with the above explanations. Thus, it is possible to omit individual features if the effect connected with that feature is not the important aspect in a specific application.

In the drawings:

Figure 1 is a schematic perspective view of a switch element according to the invention;

Figure 2 is a schematic exploded view of the switch element of Figure 1 ; Figure 3 is a schematic perspective view of a switch module already shown in Figures 1 and 2. Initially, the construction of an electrical switch element 1 according to the invention is explained in general terms with reference to Figure 1.

The electrical switch element 1 , for example, a contactor or a relay, has a coil member 3, on which a coil 5 is wound. Furthermore, there is provided a yoke 7, in particular a U- shaped yoke, which may have a rectangular base face 9 and in particular a parallelepipedal cubature. The coil member 3 is received in the cubature 1 1 of the yoke 7. The yoke may be closed by a separate yoke plate 13 which may also belong to the yoke 7 in an integral manner in alternative embodiments.

At least one yoke member 15 extends parallel with a longitudinal axis 17 of the coil member 3 or coil 5.

A control module 19 is arranged between the coil member 3 and the yoke 7, in particular the yoke member 15 thereof. The control module 17 is used to electrically control the switch element 1 , for example, in order to limit a switching current in terms of time and/or magnitude. As Figure 1 shows, the control module 19 has electrical structural elements 21. The control module is preferably arranged completely inside the cubature 1 1 of the yoke 7. From the outer side of the yoke, the control module 19 can be electrically contacted via a connection 23. The connection 23 is provided with terminals 25 to this end.

In the direction of the longitudinal axis 17, a contact chamber module 27 adjoins the yoke 7, in Figure 1 the side of the yoke plate 13. The contact chamber module 27 receives the switch contacts (not shown) of the electrical switch element 1 , which contacts are intended to be switched and which are moved by means of a drive element 31 which can be driven by the coil 5. The drive element 31 extends at a front side 29 of the coil member 3 into the interior of the contact chamber module 27.

The coil member 3 is provided with an assembly flange 35, which projects preferably at one side relative to the coil 5 in the direction of the control module 19 or the yoke member 15, at one of the front sides thereof; in the embodiment of Figure 1 this is merely by way of example the front side 33 which is opposite the yoke-plate-side front side 29 and which is directed away from the contact chamber module 27. The assembly flange 35 preferably does not overlap the coil 5 transversely relative to the longitudinal direction 17 of the coil member 3 so that it can be wound. The assembly flange 35 may extend perpendicularly around the yoke members 15, as Figure 1 shows. The control module 19 is electrically connected to the coil member 3 via the assembly flange 35. An insulation cap 37 is at the front side 33, at which the control module is electrically connected to the coil member 3. The insulation cap is cup-like with a preferably peripheral wall 39. The coil member 3 and the control module 19 are arranged in the insulation cap. The insulation cap is used to increase the creep current paths between the yoke 7 and the connection between the assembly flange 35 and the coil member 3.

The electrical switch element 1 may readily be mounted because it is constructed from a small number of preassembled assembly units which can be integrally handled. Figure 2 shows this.

Accordingly, a first assembly unit 41 comprises the coil member 3 which is fitted to the contact chamber module 27. From this first assembly unit, a second assembly unit 43 is formed by fitting the control module 19 and is then introduced into the yoke 7. The insulation cap 37 may be inserted into the yoke 7 before the second assembly unit 43 is introduced, or also preassembled on the second assembly unit 43.

In a variant of this construction, the first assembly unit 41 may also be formed from the coil member 3 and the control module 19, the contact chamber module 27 being positioned on the first assembly unit 41 in order to form the second assembly unit 43.

Figure 2 shows additional exemplary features of the switch element 1 according to the invention.

For instance, the yoke member 15 has a recess 45 through which the control module 19, in particular the connection 23 thereof, extends.

A socket 46 may protrude into the interior of the yoke 7 from the base face 9 of the yoke. The socket 46 projects into the interior of the coil 5 or the coil member 3 when the switch element 1 is completely assembled. The socket 46 may have a preferably peripheral abutment flange 47 at the base thereof. The abutment flange 47 is approximately bead- like and projects radially from the remaining socket 46.

The control module 19 may have a guiding and retaining collar 48. When the control module is mounted, the guiding and retaining collar 48 extends parallel with the plane of the yoke member 15 into which it preferably protrudes in a peripheral manner so as to be directed away from the control module. As Figure 1 shows, the yoke member is between a rear wall of the control module 19 and the guiding and retaining collar in the definitive assembly position. The guiding and retaining collar may adjoin the yoke member 15 externally. The control module may be displaceably received in the recess 45, preferably in the direction of the longitudinal axis 17 of the coil member 3. In particular, the definitive assembly position is reached after displacing the control module 19 along the recess 45.

The recess 45 may open in the direction towards a free end 51 of the yoke member 15. This allows the control module 19 to be pushed along the recess into the definitive assembly position from above in the direction of the longitudinal axis 17 of the coil member 3. The guiding and retaining collar further supports the control module 19 so that forces acting on the control module are directed into the stable yoke 7.

Furthermore, the control module 19 can further be supported by a projection 53, in this instance a rib-shaped projection 53. The projection 53 advantageously extends in the direction in which the control module 19 is displaceable in the recess 45. In the present embodiment, this is the direction of the longitudinal axis 17, with other directions also being possible. The displaceability in the direction of the longitudinal axis 17 has the advantage that the yoke member 15 is not weakened by the recess 45, in particular when it opens outwards, because the yoke member 15 is provided at the free end 51 with fixing elements 55 which engage in the yoke plate 13.

In such an embodiment, the recess 45 is provided with a receiving member which is constructed so as to correspond to the projection 53. The receiving member 57 extends in the displacement direction of the control module 19 away from the recess 45. The connection 23 of the control module 19 may be constructed in a plug-like manner. In the embodiment illustrated, it also carries out a dual function as a retention element as a result of the positive-locking connection with respect to the recess 45.

As can further be seen in Figure 2, the control module 19 is provided with electrical connection elements 59 which are arranged so as to be accessible from the side of the coil member 3.

For example, the electrical connection elements 59 are blade-like contact blades which project towards the coil member 3.

The assembly flange 35 is provided with complementary connection elements 61 at the side thereof facing the control module 19. The complementary connection elements 61 of the coil member 3 preferably contact the coil wire(s) of the coil 5 (not shown) directly, for example, via insulation displacement connections. The connection elements 59 may be readily introduced from the rear wall 49 of the control module 19 to the side facing the coil member 3. Furthermore, the assembly flange and the control module may be connected to each other via additional fixing elements, for example, catch connections. Alternatively, the connection elements 59, 61 may also produce an adequate retention force.

The complementary connection elements 61 have an installation length 62 in the direction perpendicular to the longitudinal axis 17. If the length 62 is large, a flattened portion 63 on the socket 46 and/or the abutment flange 47 may have to be provided in order to provide space for the complementary connection elements 64. Alternatively or additionally, for example, the wall thickness of the socket and/or abutment flange may be reduced at the sides opposite the complementary connection elements.

In order not to unnecessarily load the assembly flange 35, however, it is advantageous for the mechanical connection between the coil member 3 and the control module 19 to be brought about via the yoke 7, in particular the yoke plate 13. To this end, the yoke plate may be provided with a fixing element 63, for example, a catch projection which projects towards the control module 19. The catch projection may project beyond the cubature of the yoke 7 and the yoke member 15 so that the mechanical connection between the control module 19 and the yoke 7 or coil member 3 occurs outside the yoke 7. In the embodiment of Figure 2, the fixing element of the control module 19 complementary to the fixing element 64 of the yoke plate 13 is arranged in the region of the connection 23, that is to say, outside the yoke 7 in the definitive assembly position.

Finally, the possible construction of a control module 19 is further described in greater detail below with reference to Figure 3.

The control module 19 may have a pocket 65 which receives at least one printed circuit board 67. The electrical structural elements 21 are arranged on the printed circuit board 67.

The pocket 65 has at least at three sides protection walls 69 which project beyond the printed circuit board 67 and which project away from the yoke member 15 (cf. Figure 1 ). The protection walls 69 are used to increase the creep current paths between the yoke member 15 and the printed circuit board 67. They further protect the structural elements 21 before the control module 19 is assembled. The printed circuit board 67 is located in the control module 19 parallel with the yoke member 15 and the longitudinal axis 17. Merely by way of example, the pocket 65 opens in Figure 3 towards the coil member 3 so that the printed circuit board can be positioned in the coil member from this side. It is also conceivable for the pocket 65 to be closed at this location and the printed circuit board to be pushed through one of the narrow sides 71 into the pocket 65.

The control module 19 also forms with the preassembled printed circuit board 67 a preassembled assembly unit. To this end, the printed circuit board is retained in a one- piece carrier 73, which is preferably injection-moulded from plastics material and which also forms the connection 23.

List of reference numerals

1 Electrical switch element

3 Coil member

5 Coil

7 Yoke

9 Base face

10 Socket

1 1 Cubature of the yoke

12 Abutment flange

13 Yoke plate

14 Flattened portion

15 Yoke member

17 Longitudinal axis of coil member

19 Control module

21 Electrical structural elements

23 Connection of control module

25 Terminal of connection

27 Contact chamber module

29 Front side of coil member

31 Drive element

33 Front side of coil member

35 Assembly flange

37 Insulation cap

39 Wall of insulation cap

41 First assembly unit

43 Second assembly unit

45 Recess in yoke member

46 Socket

47 Abutment flange

48 Guiding and retaining collar

49 Rear wall of control module

51 Free end of yoke member

53 Projection of control module

55 Fixing elements of yoke member

57 Receiving member

59 Electrical connection elements of control module

61 Complementary connection elements of coil member

62 Installation length of complementary connection elements of coil member

63 Flattened portion

64 Fixing element of yoke plate

65 Pocket

67 Printed circuit board

69 Protection walls

71 Narrow sides

73 Carrier