Elastically constructed busbar

Abstract

This invention relates to a busbar, particularly for use in electric vehicles. The busbar includes at least one particularly flattened connecting section and at least one electrical connector formed in a region at the end of the connecting section. The connecting section is elastically constructed and therefore has an arched region and at least one slot formed in the arched region. According to the invention, for busbars of the type mentioned at the beginning, the arched region of the elastically constructed connecting section is constructed in a crown shape, particularly a shell shape, a semi-shell shape, or a hemisphere shape.

Description

Technical Field

[0001] This invention relates to a busbar, particularly for use in electric vehicles. The busbar includes at least one particularly flat connecting section and at least one electrical connector formed in a region at the end of the connecting section. The connecting section is elastically configured and for this purpose has an arched region and at least one slot formed in the arched region. Background Technology

[0002] Busbars, for example, have connectors for connecting to other electrical components, such as components of power electronics in the automotive field, particularly in electric or hybrid vehicles. In the area of ​​the connector, assembly tolerances can be compensated for through large screw holes, but this reduces the current carrying capacity in the connection area. Thermomechanical forces or vibration loads may uncontrollably decrease in the area of ​​the busbar, potentially leading to damage at the contact points. Forces generated by varying thermal expansion at the contact points can persistently damage the contact points or the electrical components connected to them, increasing the transition resistance at the contact points.

[0003] A junction for two connecting devices of a conductor in an insulating housing is known from DE 20 2010 005 554 U1, wherein the connecting devices are connected to each other by a metal busbar.

[0004] A power distribution device for vehicle applications is known from DE 10 2015 115 464 A1, which has a power distribution bus arranged in a housing with specially configured assembly sections, the power distribution bus being separated from the rest of the bus by specially shaped gaps. Summary of the Invention

[0005] According to the invention, for the type of busbar mentioned at the beginning, the arched region of the elastically constructed connection section is constructed as a spherical crown, especially a shell, semi-shell, or hemispherical shape. This advantageously allows for elastic unloading of the joint in different degrees of rotational freedom. The connection section can thus be constructed as a tolerance-compensating element. The connection section can also be advantageously constructed to reduce mechanical loads in three different spatial directions, particularly forming an orthogonal system.

[0006] Preferably, the at least one gap is formed along the longitudinal extension of the connecting section towards the joint, or along the main directional component towards the joint. Preferably, the longitudinal extension of the connecting section is greater than its width extension transversely to its extension. Further advantageously, the busbar, and in particular the connecting section, can be provided cost-effectively as the punched sheet.

[0007] In a preferred embodiment, the busbar has a different radius of curvature in its extension toward the joint in the arched region, particularly in the connecting section, compared to its lateral extension extending laterally. This extension is preferably configured as the extension of the connecting line between the joints. In this way, a spring-like action can advantageously be achieved with a soft spring constant when rotating about the longitudinal extension.

[0008] In an advantageous embodiment, the bending radius is configured to be smaller in the extension toward the joint than in the lateral extension. This advantageously enables a good springing effect along the torsional direction.

[0009] In a preferred embodiment, the connecting section has at least two or more slits, each constructed as a gap, extending particularly parallel to each other in the arched region. This allows for the advantageous formation of tabs or sheets extending parallel to each other on the connecting section, thereby advantageously improving the mobility of the busbar. Preferably, two tabs or sheets are constructed adjacent to the gaps.

[0010] In another embodiment, the gaps are constructed in a wavy shape, particularly a sinusoidal shape, a trapezoidal shape, or a sawtooth shape. This allows for the advantageous formation of good torsion spring characteristics in the connecting section.

[0011] In a preferred embodiment, the busbar is composed of at least two stacked, arched plates, at least in the connecting section region. This advantageously allows for the formation of a stack of arched leaf springs. The plates are preferably spaced apart from each other in the connecting section region.

[0012] In a preferred embodiment, gaps are formed in each plate of the stacked sheet assembly forming the busbar. This allows for an advantageous improvement in the mobility of the sheet assembly through the thin sheets thus formed in each plate.

[0013] In a preferred embodiment, the tabs formed between the two gaps each have a width between one and five millimeters. Thus, the bus can be advantageously configured as a connecting element that forms part of an electronic circuit.

[0014] In a preferred embodiment, the thickness of each sheet in the stacked assembly is between 0.05 and 0.3 mm. This allows the stacked assembly to be advantageously configured with high flexibility.

[0015] In a preferred embodiment, the width extension of the sheet or patch formed between the gaps, extending transversely to the gap extension, decreases from the center of the busbar towards the edge. This advantageously creates a good torsion spring effect around the longitudinal axis.

[0016] In a preferred embodiment, the stacked plates are material-locked together, particularly welded, in the joint area. In this way, the stacked plates can advantageously form a busbar, particularly a one-piece structure.

[0017] In a preferred embodiment, the bus is constructed of a copper alloy, such as CuSn6, comprising copper as the main component and six weight percent tin. In another embodiment, the copper alloy is, for example, a doped copper alloy comprising chromium, silver, iron, titanium, silicon, and copper as the largest proportion. The proportion of the dopant is, for example, 0.5 weight percent chromium, 0.1 weight percent silver, 0.08 weight percent iron, 0.06 weight percent titanium, and 0.03 weight percent silicon. The copper alloy is, for example, an alloy conforming to standard UNS 18080. Thus, the copper alloy advantageously possesses good electrical conductivity and a high modulus of elasticity, thereby providing the connection section with good elasticity and low ohmic loss.

[0018] The present invention also relates to an electric vehicle or hybrid vehicle having a bus of the type described above. The bus is preferably a conductive connecting element that at least indirectly connects the vehicle's inverter to the vehicle's motor.

[0019] This invention also relates to an inverter or DC-DC converter having at least one bus. The bus connects, for example, a DC-connected capacitor to a semiconductor switch-bridge, particularly a B6-bridge. The inverter is, for example, a component of a photovoltaic or wind power system. In this way, a large number of long electrical connections can be advantageously coupled together with minimal stress using the bus. In this way, the forces generated by different thermal expansions in the contact areas can be advantageously and elastically trapped in the connection sections of the bus. Attached Figure Description

[0020] The invention will now be described with reference to the accompanying drawings and other embodiments. Advantageous variations arise from combinations of features depicted in the dependent claims and in the drawings.

[0021] Figure 1An embodiment for a bus is shown, wherein electrical connectors are constructed at two opposing ends of the bus and an arched and elastically formed connection section extends between the connectors.

[0022] Figure 2 The cross-sectional view shows that in Figure 1 The connecting section shown in the cross-sectional view is arched;

[0023] Figure 3 An embodiment for a bus is shown, the bus having a resiliently constructed connection section, wherein multiple, particularly three, layers of punched mesh are stacked vertically for the bus.

[0024] Figure 4 The cross-sectional view shows that in Figure 3 The connection section shown in the figure. Detailed Implementation

[0025] Figure 1 An embodiment for a busbar 1 is shown. The busbar 1 has end sections 2 and 3 at opposite ends, wherein end sections 2 and 3 respectively form electrical connectors. The end sections 2 and 3 are connected to each other by means of a connecting section 5 and are respectively formed onto the connecting section. The connecting section 5 is elastically formed and has an arched region for this purpose. The arched region is constructed along the longitudinal extension 19 of the busbar 1 on a longitudinal section 4, which in this embodiment corresponds to the longitudinal dimension of the connecting section 5. The busbar 1 is thus constructed in an arched shape on the connecting section 5.

[0026] On the connecting section 5, the busbar 1 has a plurality of slots extending parallel to each other along the longitudinal extension 19. These slots thus separate the adjacent sheets arranged on the connecting section 5 and formed by these slots. The busbar 1 is produced, for example, from a sheet metal by punching and / or stamping, and therefore by deformation, such as cold deformation. The sheet metal is, for example, a copper plate.

[0027] The busbar 1 has sheets 6, 7, 8, 9, 10, and 11 arranged adjacent to each other on the connecting section 5. Sheets 6 and 7 are separated from each other by slot 12, sheets 7 and 8 by slot 13, sheets 8 and 9 by slot 14, sheets 9 and 10 by slot 15, and sheets 10 and 11 by slot 16. Slots 12, 13, 14, 15, and 16 are created, for example, by means of punching, sawing, milling, or laser cutting. The connecting section 5 is thus constructed as a structure capable of elastic movement in different translational and / or rotational degrees of freedom, such that the joints 3 and 2 are mechanically decoupled from each other.

[0028] Figure 2 Along in Figure 1 The cross section 17 shown in the figure, transverse to the longitudinal axis 19, is illustrated in cross section. Figure 1 The busbar 1 is shown in the diagram. The sheets 6, 7, 8, 9, 10, and 11 together extend an arch formed by connecting section 5, wherein the arch is constructed as a circular arc in this embodiment. The arch angle 18 associated with the arch is 90 degrees in this embodiment. In another embodiment, the arch angle 18 can be between 45 degrees and 140 degrees.

[0029] Figure 3 An embodiment for a busbar 20 is shown, the busbar comprising a stack of three stacked plates 21, 22, and 23. The plates 21, 22, and 23 are produced by punching and deformation, respectively. The plates 21, 22, and 23 are respectively joined together in a longitudinal section 25 along a longitudinal extension 41 of the busbar 20 by means of resistance welding, spot welding, laser welding, or brazing, especially hard brazing. An electrical connector 27 is thus formed on the longitudinal section 25, which can be connected to another punched mesh or lead frame, for example by welding, tightening, interlocking, or riveting, or brazed to a circuit base in a soldering oven by means of surface mount technology, especially SMD technology (SMD = Surface-Mounted-Device), using reflow brazing technology. The connector for tightening is constructed, for example, with a through-hole through which a screw can pass.

[0030] The connector 27 forms an end section of the busbar 20, wherein another electrical connector 28 is constructed along the longitudinal extension 41 at the opposite end, extending along the longitudinal extension 41. Connectors 27 and 28 are respectively formed onto a connection section 29, which extends along the longitudinal extension 41 and is constructed in an arched shape. In this embodiment, the arch is constructed as a dome shape.

[0031] Individual plates 21, 22, and 23 each have a thin sheet separated from each other by a gap on the connecting section 29 of the busbar. The thin sheets of the individual plate 23, namely sheets 30, 31, 32, 33, 34, 36, 37, 38, 39, and 40, are exemplary labeled. The busbar 20 has a slit 35 on the connecting section 29, which in this embodiment is formed by an opening or gap 35 extending along the longitudinal extension 41. The gap 35 is arranged between sheets 34 and 36 and has a width larger than the gap formed between the individual sheets. The gaps between the sheets each have a width smaller than the width of the sheets separated from each other by the gaps.

[0032] The thickness of a single plate is, for example, 0.1 mm. The busbar can consist of at least two or more... Figure 3 It is composed of three individual plates stacked one on top of the other, as shown. The busbar is different from... Figure 3 The diagram shows a structure composed of five, more than five, ten, more than ten, fifteen, more than fifteen, or twenty individual plates stacked vertically. The width of these plates is, for example, between half a millimeter and three millimeters, preferably one millimeter. The slits can be cut into individual plates, for example, before or after constructing the arch. The slits are formed relatively straight in the flat projection of the connecting sections and extend parallel to each other in this embodiment. Figure 3 Unlike what is shown, the gap is constructed in a wavy shape, especially a sinusoidal shape, a trapezoidal shape, especially a rectangle or a triangle, particularly in a flat projection.

[0033] Figure 4 The cross-sectional view shows that in Figure 3 The busbar 20 shown in the figure has a cross-section transverse to the longitudinal axis 41 in the arched region 29. The individual plates 21, 22, and 23 in this embodiment correspondingly have the same arch, and particularly in the region of the arch, have the same radius of curvature that defines the arch. The arched arcs opened by the plates 30, 31, 32, 33, 34, 36, 37, 38, 39, and 40 have an arch angle of 45 degrees in this embodiment. A soft torsion spring can be formed by means of a stack of plates or tabs arranged relative to each other, formed by the intermediate gap 35, in this embodiment comprising five plates or tabs respectively. This allows the correspondingly flattened joints 27 and 28 to spring relative to each other in a manner that allows rotation about an axis formed along the longitudinal extension 41, thus forming a torsion spring.

Claims

1. A busbar (1, 20) comprising at least one connecting section (5, 29) together with at least one electrical connector (2, 3, 27, 28) formed in a region at an end of the connecting section (5, 29), wherein the connecting section (5, 29) is elastically configured and for this purpose has an arched region (4, 24) and at least one slot (12, 13, 14, 15, 16) formed in the arched region (4, 24). Its features are, The arched regions (4, 24) are constructed in a spherical shape, thereby enabling the connecting sections (5, 29) to be configured to reduce mechanical loads in three different spatial directions. The arched regions (4, 24) have a bending radius in the extension (19, 41) of the connecting sections (5, 29) toward the joints (2, 3, 27, 28) and a bending radius in the lateral extension extending laterally to the extensions (19, 41), wherein the bending radius in the extension (19, 41) of the connecting sections (5, 29) toward the joints (2, 3, 27, 28) is constructed to be smaller than the bending radius in the lateral extension extending laterally to the extensions (19, 41).

2. The busbars (1, 20) according to claim 1. Its features are, The connecting sections (5, 29) have at least two or more parallel slits (12, 13, 14, 15, 16) in the arched region (4, 24) that are respectively constructed as slits.

3. The busbar (1, 20) according to claim 1 or 2. Its features are, The gaps (12, 13, 14, 15, 16) are constructed in a wavy shape.

4. The busbar (1, 20) according to claim 1 or 2. Its features are, The busbar is composed of at least two stacked, arched plates (21, 22, 23) in at least the region of the connecting sections (5, 29).

5. The busbars (1, 20) according to claim 4. Its features are, Slots (12, 13, 14, 15, 16) are constructed in each plate (21, 22, 23) of the stacked laminations that form the busbars (1, 20).

6. The busbar (1, 20) according to claim 1 or 2. Its features are, The tabs (6, 7, 8, 9, 10, 11, 30, 31, 32, 33, 34, 36, 37, 38, 39, 40) formed between the gaps (12, 13, 14, 15, 16) have widths between one millimeter and five millimeters.

7. The busbars (1, 20) according to claim 4. Its features are, The thickness of each plate in the stacked plates (21, 22, 23) is between 0.05 and 0.3 mm.

8. The busbar (1, 20) according to claim 1 or 2. Its features are, The width extension of the sheet or patch formed between the gaps (12, 13, 14, 15, 16) along the transverse extension of the gap extension decreases from the center of the busbar toward the edge.

9. The busbar (1, 20) according to claim 1 or 2. Its features are, The stacked plates (21, 22, 23) are material-locked together with each other in the area of ​​the joint.

10. The busbar (1, 20) according to claim 1. Its features are, The connecting sections (5, 29) are formed in a flat shape.

11. The busbar (1, 20) according to claim 1. Its features are, The arched regions (4, 24) are constructed in a hemispherical shape.

12. The busbars (1, 20) according to claim 1. Its features are, The connecting sections (5, 29) are constructed to reduce the mechanical load in three spatial directions that are different from each other and form an orthogonal system.

13. The busbars (1, 20) according to claim 3. Its features are, The gaps (12, 13, 14, 15, 16) are sinusoidal in shape.

14. The busbar (1, 20) according to claim 9. Its features are, The stacked plates (21, 22, 23) are welded to each other in the area of ​​the joint.

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