Electrical contact between conductor cable and connection partner, battery cell connection system and method for manufacturing thereof

Abstract

A device with electrical contact between an electrical conductor of a conductor cable and an electrical connection partner, wherein the conductor is embedded in a contact plane in an insulating sheath of a flat conductor cable, wherein the electrical conductor is stripped of the insulating sheath at least on one contact side in a predetermined contact section, wherein the contact section of the conductor is bent with the contact side from the contact plane beyond the insulating sheath, wherein the contact side of the contact section of the conductor is placed on the electrical connection partner and directly connected to the electrical connection partner. The invention also relates to a battery cell connection system for a vehicle battery module, comprising a contact element and a sensing cable. The surface of the wire and / or the contact element comprises a surface area increasing feature in the area where they are in contact with each other. The surface area increasing feature improves the soldering process, as a higher soldering force can be achieved and more material transfer between the soldered parts is achieved. The invention also relates to a method of manufacturing a battery cell connection system.

Description

Technical Field

[0001] The present invention relates to the construction of an electrical contact between an electrical conductor of a conductor cable, particularly an electrical conductor of a flexible flat conductor cable, and an electrical connection mating member, and a method for manufacturing an apparatus having an electrical contact between the electrical conductor of a conductor cable, particularly an electrical conductor of a flexible flat conductor cable, and an electrical contact member.

[0002] The present invention also relates to a battery cell connection system for vehicle battery modules, particularly for battery modules of electric or hybrid vehicles, the battery cell connection system comprising contact elements for receiving electrodes of at least one battery cell and a sensing cable comprising wires electrically and mechanically connecting a battery cell monitoring unit and the contact elements. The present invention also relates to a method for attaching the sensing cable to the contact elements of the battery cell connection system as described above. Background Technology

[0003] An electrical connection device is known from EP 0 699 353 B1, in which a flexible circuit device is connected to a planar substrate. The flexible circuit device includes a flexible flat strip of circuit device, wherein at least one end of the circuit device in the longitudinal direction is bent backwards onto itself to form an elastic spring, such that the upper side of the backward-bent portion is adjacent to the surface of the unbent portion of the strip. The conductor is not insulated on the surface side, preventing the surface from bending backwards, thus allowing it to be elastically pressed against the conductive traces of the planar substrate. In another embodiment, the flexible flat conductor cable includes a notch in the contact direction, which is placed on the contact. Summary of the Invention

[0004] The first object of the present invention is to provide an improved apparatus having electrical contact between an electrical conductor of a conductor cable, particularly an electrical conductor of a flexible flat conductor cable, and a connecting mating member, and to provide an improved method for establishing electrical contact between an electrical connecting mating member and an electrical conductor of a conductor cable, particularly an electrical conductor of a flexible flat conductor cable.

[0005] Battery cell connection systems are known in the art, for example from DE102014219178A1, and are used in battery modules of electric or hybrid vehicles to connect multiple battery cells to each other. To monitor the state of the battery cells, it is necessary to monitor parameters such as battery temperature, capacity, or state of load. For this purpose, a monitoring unit is electrically connected to each battery cell via a cable through the contact elements of the battery cell connection system. The monitoring unit can also be used to balance the battery cells. In this case, it can be referred to as a monitoring and balancing unit.

[0006] To ensure a sufficiently long battery module lifespan, it is crucial to achieve electrically and mechanically stable connections, even during everyday use, where vibrations, shocks, and other factors can impose mechanical stress on the connections. The connection between the cables and the battery cell connection system is achieved through ultrasonic welding.

[0007] Therefore, automakers impose stringent requirements on connection reliability. A well-known 90° peel tension test is performed, and the connection must withstand a force of at least 7N before breaking. During the 90° peel tension test, the previously connected cable is bent at 90° perpendicular to the contact surface. The force at the point of disconnection is then measured. Machine performance characteristic value: Cmk should be greater than 1.67.

[0008] Therefore, a second objective of the present invention is to improve mechanical reliability and thus improve electrical condition and electrical connection, thereby improving the possibility of battery monitoring.

[0009] This first objective is achieved by an apparatus having electrical contact between the electrical conductor of a conductor cable, particularly the electrical conductor of a flexible flat conductor cable, and an electrical coupling. The conductor is embedded in the insulating sheath of the conductor cable within the contact plane. At least on one contact side of the electrical conductor, at a predetermined contact section, the insulating sheath is stripped from the conductor. The contact section of the conductor is bent out of the contact plane, particularly beyond the insulating sheath. The contact side of the contact section of the conductor rests on the electrical coupling and establishes direct electrical contact with it. Furthermore, the contact side of the electrical conductor is connected to the electrical coupling in the region of the contact section.

[0010] This connection can be achieved through welding, particularly laser welding or ultrasonic welding.

[0011] The connecting mating parts can be, for example, electrical conductor strips, electrical conductor plates, or any other type of contact element.

[0012] In the contact section region, the insulation sheath of the conductor cable is not bent in the direction of the electrical connection mating member. The conductor cable can be configured, for example, to be planar in the contact section region, and to transition longitudinally in a planar manner into adjacent regions of the conductor cable before and after the contact section. This prevents additional mechanical stress on the conductor cable and other conductors of the conductor cable in the contact section region. Because in this embodiment only the electrical conductor is configured to be bent in the direction of the electrical connection mating member, the amount of processing work, especially mechanical processing work, required to establish electrical contact is reduced. Furthermore, since the conductor cable does not need to bend in the direction of the electrical connection mating member, this allows multiple electrical contacts of adjacent conductors to be offset relative to each other in the longitudinal direction of the conductor cable. The conductor cable can be configured to be flat and smooth in the contact section region. Therefore, overall planar support of the conductor cable on the connection mating member can be obtained.

[0013] In one embodiment, the contact section of the electrical conductor is bent such that the contact side protrudes beyond the outer side of the insulating sheath from the contact plane in a first direction. The contact side of the contact section of the electrical conductor is then placed on and directly connected to the electrical connector. The conductor cable is bent in a second direction in the region of the contact section, i.e., the insulating sheath of the conductor cable is just outside the contact section, such that the second direction points in the opposite direction to the first direction. Due to the deflection of the conductor cable in the direction opposite to the bending of the electrical conductor, a preload is applied to the electrical conductor. Therefore, the constricted section of the electrical conductor is preloaded in the direction toward the connector and can be pressed onto the electrical connector with a higher pressing force. Thus, an electrical connection can be established between the electrical conductor and the electrical connector with higher quality and a simpler method. In particular, it is not necessary to press the electrical conductor itself onto the electrical connector with a mechanical tool in the region of the contact section. For example, in the case of laser welding or ultrasonic welding connections, the electrical and mechanical connections between the electrical connector and the electrical conductor can be further improved in this manner. Furthermore, in this embodiment, there is more free space in the contact area of ​​the conductor during assembly. Therefore, it is easier to establish a connection between the conductor and the connecting mating member.

[0014] In another embodiment, the contact segment can be bent so that the conductor is not stretched in the bent region. This prevents a reduction in cross-sectional area. Therefore, mechanical damage to the contact segment can be prevented.

[0015] In another embodiment, the contact side of the contact segment is connected to the electrical connector via multiple contact points. This improves the mechanical connection between the electrical conductor and the electrical connector. Furthermore, it also improves the electrical connection between the electrical conductor and the electrical connector. For example, the contact points can be manufactured by laser welding. In this embodiment, the contact points can be manufactured by a laser weld that is spirally formed. However, other shapes and / or methods, such as ultrasonic welding, can also be used to achieve the contact points.

[0016] In another embodiment, the contact segment of the electrical conductor is divided into two partial segments perpendicular to the longitudinal direction of the conductor cable. In this embodiment, at least one partial segment of the electrical conductor is placed on the electrical connection mating member with its contact side facing out, and is mechanically and electrically connected to the electrical connection mating member.

[0017] In another embodiment, at least a portion of the contact segment of the electrical conductor is embedded in an insulating material, particularly in an electrically insulating potting material. This achieves both electrical insulation and mechanical protection of the contact segment of the electrical conductor.

[0018] In another embodiment, the electrical connector and the electrical conductor are formed of different conductive materials, wherein, in particular, the electrical connector may be formed of aluminum and the electrical conductor of copper. Even when using different conductive materials, especially when using copper and aluminum, good electrical contact can be achieved between the conductor and the connector using the device of the present invention described herein. Laser welding or ultrasonic welding is particularly suitable for establishing good electrical connections and sufficient mechanical connections between aluminum and copper.

[0019] In one embodiment, the electrical connection mating element is a contact of the electrical terminals of a battery, particularly a vehicle battery. The battery may be, for example, part of an arrangement of multiple batteries, wherein voltage measurements are performed on the battery, for example, using electrical conductors.

[0020] In another embodiment, the contact segment can be at least partially imprinted into the connecting mating parts. The advantage of imprinting is that the two parts can be joined during production without additional clamping steps to hold them together. Therefore, a more efficient manufacturing process can be used, while simultaneously achieving sufficiently high mechanical strength.

[0021] In another embodiment, the interface between the contact segment and the electrical connection mating member can be located below the surface of the connection mating member immediately adjacent to the interface, particularly at most about 0.1 to 0.5 mm below the surface, and more particularly at most about 0.2 to 0.3 mm. This further improves mechanical strength.

[0022] In another embodiment, the surfaces of the contact segment and the electrical connection mating member may include mating surface area enhancement features at the interface. Using an embossing die with a structured surface, such as a plurality of regularly arranged pyramidal protrusions on its surface, this pattern is transferred onto the contact segment and extends to the surface side of the contact segment that engages with the connection mating member. This can further improve adhesion before the final connection step, such as using welding.

[0023] A second objective of the present invention is achieved by a battery cell connection system for vehicle battery modules, particularly for electric or hybrid vehicles, according to claim 13. This battery cell connection system includes the apparatus described above—wherein the electrical connection mating member includes a contact element for receiving electrodes of at least one battery cell, and the conductor cable, particularly a flexible flat conductor cable, includes a sensing cable. The sensing cable includes wires that electrically and mechanically connect the battery monitoring unit and the contact element. The characteristic feature is that the surfaces of the wires and / or the contact element include an increased surface area feature in the areas where they contact each other. Compared to a smooth surface, by increasing the surface area, the mechanical contact force can be improved due to the larger interacting surface. According to this embodiment, the first and second objectives of the present invention are achieved.

[0024] A second object of the invention is also achieved by a battery cell connection system for a vehicle battery module, particularly for a battery module for an electric or hybrid vehicle, according to claim 14. The battery cell connection system includes contact elements for receiving electrodes of at least one battery cell, and a sensing cable including wires electrically and mechanically connected to a battery monitoring unit and the contact elements. The characteristic feature is that the surfaces of the wires and / or contact elements include an increased surface area in the areas where they contact each other. Compared to a smooth surface, by increasing the surface area, the mechanical contact force can be improved due to the larger interacting surface.

[0025] According to a variation of the invention, the surface area increasing feature may include a plurality of bumps. By forming bumps on the surface, the contact surface area can be easily increased.

[0026] According to a variation of the invention, the bump can extend linearly, particularly parallel to the longer side of the contact area. This configuration is readily achievable.

[0027] According to a variation of the invention, the bump can have a pyramid shape, particularly a pointed pyramid shape. Such a design further increases the surface area and provides contact sides in different directions.

[0028] According to a variation of the invention, the pyramid shape can have a rectangular, particularly square, base shape, and a side angle of approximately 30° to 60°, particularly 45°. According to a variation of the invention, the bumps have a maximum height of 0.5 mm, particularly a maximum height of 0.2 mm, and more particularly a maximum height of 0.1 mm. According to a variation of the invention, the distance between the apexes of directly adjacent bumps can be a maximum of 5 mm, particularly a maximum of 0.2 mm. These dimensions improve contact force compared to a flat, smooth surface.

[0029] According to a variation of the invention, the wires and contact elements can be welded together, particularly by ultrasonic welding. The increased surface area allows for higher and more stable welding forces because greater material transfer can occur between the welded components.

[0030] According to variations of the invention, the contact element and the wire can be made of different materials, particularly aluminum and copper, respectively. The invention even allows for the combination of two different materials and the attainment of a satisfactory connection. When using a material having a thin electrically insulating oxide layer on its surface, it is preferable to achieve an increased surface area feature at least on that material.

[0031] According to a variation of the invention, the battery cell connection system may have a plurality of contact elements arranged in two rows, thereby allowing series electrical connection of battery cells, wherein one of the contact elements opposite to each other is electrically and mechanically connected to the conductor of the sensing cable.

[0032] According to a variation of the invention, the sensing cable may include multiple parallel conductors, particularly flat conductors, embedded in an electrical insulator, wherein each conductor connected to a contact element is electrically connected and mechanically connected to another contact element, and wherein the electrical insulator is removed in each contact area.

[0033] Furthermore, according to a first objective of the invention, claim 25, a method is provided for manufacturing an apparatus having electrical contact between the electrical conductors of a conductor cable, particularly a flexible flat conductor cable, and an electrical connecting mating member. To this end, a conductor cable, particularly a flexible flat conductor cable, is provided, comprising at least one, particularly multiple, electrical conductors embedded in a contact plane within an insulating sheath of the conductor cable. At least one electrical conductor has its insulating sheath stripped at a predetermined contact segment on at least one contact side. For example, the electrical conductor in the contact segment may also have its insulating sheath stripped on all sides. The method comprises the steps of: a) bending the contact side of the contact segment of the electrical conductor outside the contact plane, to at least one outer side of the insulating sheath; step b) placing, particularly after the conductor has been bent out of the contact plane, the conductor cable, particularly the flexible flat conductor cable, onto the connecting mating member; step c) placing the contact side of the contact segment of the electrical conductor onto the electrical connecting mating member; and then step d) connecting the contact side of the contact segment of the conductor to the electrical connecting mating member. In one embodiment of step d), the contact side of the electrical conductor is welded to the electrical connecting mating member.

[0034] Advantageous in this method is that the insulating sheath does not bend in the direction toward the connecting mating member in the contact section region. This allows for more space for the connection between the conductor and the connecting mating member. The insulating sheath of the conductor cable can be arranged in the contact section region as a plane relative to the upper side of the electrical connecting mating member, or it can have a bend away from the electrical connecting mating member. Both embodiments allow for a simple and reliable electrical contact between the electrical conductor and the electrical connecting mating member.

[0035] In one embodiment, the contact side of the electrical conductor is welded to the electrical connection mating member by means of a laser. For example, one or more contact points or weld points can be formed between the electrical conductor and the electrical connection mating member. In particular, the laser can form a laser seam, which is, for example, spiral-shaped and forms the contact point. Alternatively, ultrasonic welding can be used.

[0036] According to an embodiment, the method may include the following steps: prior to welding, pressing the contact side of the electrical conductor downward toward the electrical connection mating member using a pressure wave (particularly from a liquid or solid phase to a gaseous phase, and / or an explosion) formed by inducing a phase change in a pressure-generating material. Forming such a pressure wave to push the contact segment onto the electrical connection mating member has the advantage that the manufacturing process can be achieved without clamping or with minimal clamping, since at most clamping is required to achieve the first weld point. The pressure-generating material can be the same material used to achieve the connection, such as welding material or adhesive. In variations, it can be a flammable material, such as CH3NO2.

[0037] According to an embodiment, the pressure wave forming step may include the following steps: striking a pressure-generating material with one or more laser pulses, particularly using the same laser used for welding. Therefore, the same laser used for welding can be used to generate the pressure wave. A first jet can be used to ignite droplets of combustible material, or one or more pulses can be used to evaporate small droplets of a phase-change material, such as a weldment or adhesive. A subsequent pulse can then be used to weld the contact segment and the electrical connection mating element.

[0038] According to an embodiment, the pressure-generating material can be disposed on or above the contact segment in the form of droplets or a coating. By disposing of the pressure-generating material near the contact segment, the downward pressure effect after the generation of a pressure wave can be optimized.

[0039] In one embodiment, before placing the electrical conductor onto the electrical connector and before soldering the conductor to the connector, the conductor cable is bent in a second direction in the region of the contact section, i.e., the insulating sheath of the conductor cable is just outside the contact section. This second direction is opposite to the first direction in which the electrical connector is bent. By creating a bend in the conductor cable in a direction opposite to the bending direction of the conductor, a preload is generated on the conductor, which facilitates and improves electrical contact between the conductor and the electrical connector. This means that at least part or even all of the use of a special clamping system is no longer necessary.

[0040] In another embodiment, the contact segment of the electrical conductor is divided into first and second partial segments perpendicular to the longitudinal direction. At least one first partial segment of the electrical conductor is bent out of the contact plane. According to the chosen embodiment, the electrical conductor may also be bent out of the contact plane first, and then the electrical conductor may be divided into two partial segments in the region of the contact segment. At least one first partial segment is placed on the electrical connection mating member and soldered to the electrical connection mating member via a contact side. Depending on the chosen embodiment, both partial segments may be placed on the electrical connection mating member and electrically connected to the electrical connection mating member.

[0041] Dividing the conductor into two local segments in the contact section offers the following advantages: the actual conductor cable can extend in a planar manner, and the conductor with the insulation stripped can be configured as a spring element with virtually no tension. Therefore, it is easier to achieve conductor flexing from the contact plane without reducing the cross-section, and this can be achieved with minimal mechanical stress applied to the conductor. This allows even thick conductors to bend out of the contact plane with very little pressure. Even with a thick insulation sheath, corresponding bending in the local segments can be guided out of the conductor cable's insulation material with minimal mechanical deformation. This reduces mechanical stress on the conductor in the contact section region, especially with thicker insulation sheaths. This reduces mechanical stress and conductor deformation, thus improving electrical contact in terms of long service life. In particular, the mechanical connection of the conductor can be protected in this way, and its damage is less when it bends out of the contact plane. This also improves the long-term stability of the electrical contact. Furthermore, the impact on the conductor's cross-section is minimal in the contact section region. In this way, parameters for connection, particularly for welding electrical conductors to electrical connectors, can be set more precisely. This also improves the quality of both the electrical and mechanical contact between the conductors and connectors. Furthermore, it also enhances the long-term stability of the electrical contact between the conductors and connectors. This is particularly advantageous for applications in the automotive sector, where vehicles are subjected to mechanical vibration stresses during operation and under thermal loads, especially during high-temperature fluctuations. The quality of the mechanical and electrical connection between the conductors and the battery's electrical connectors is especially important when establishing contact with the battery's electrical contacts.

[0042] According to an embodiment, steps a) and c) can be performed simultaneously by imprinting contact segments into the electrical connection mating member. Therefore, a conductor cable with contact segments is placed on the electrical connection mating member, and then a stamping machine is used to bend the contact segments toward the surface of the electrical connection mating member and imprint them into the surface of the electrical connection mating member. Thus, the two parts can be held together in one step, eliminating the need for additional clamping of the two parts before welding.

[0043] Depending on the variant, a stamping press with a flat or structured surface can be used. Using a structured surface, such as multiple regularly arranged pyramidal shapes, a surface pattern can be obtained on the surface side of the actual facing electrical connection mating parts of the contact segment. This surface pattern will be imprinted in the same manner to form a mating pattern on the surface of the mating parts. A larger surface area can improve the bonding strength between the two parts.

[0044] The second objective of the invention, in conjunction with the first objective, is achieved by the method described above, which provides a battery cell connection system according to the second objective of the invention, wherein the surface area increase feature is achieved using a stamping machine, a scraping tool, or by laser structuring. Therefore, electrical contact is improved at the moment of achieving the electrical connection between the two parts.

[0045] A second object of the invention is also achieved by the method of claim 35, which is used to attach a sensing cable to a contact element of a battery cell monitoring system according to the above embodiments. The method includes steps of achieving a surface area increase feature using a stamping machine or a scraping tool or by laser structuring. Compared to connections on smooth surfaces, this method allows for improved connection strength. Simultaneously, surface structuring can disrupt the thin oxide layer on the surface of the wires and / or contact elements. Therefore, electrical contact is improved at the moment of achieving electrical connection between the two parts.

[0046] According to a variation of the invention, stamping, scraping, or laser structuring is applied to one side of the wire and / or the contact element on which electrical and mechanical connections will be established.

[0047] According to a variation of the invention, electrical and mechanical connections can be achieved by welding, particularly ultrasonic welding. The increased surface area allows for higher and more stable welding forces because greater material transfer can occur between the welded components.

[0048] According to other variations, any embodiment and its variations relating to the first inventive objective may be combined with any one or more variations relating to the second inventive objective. Attached Figure Description

[0049] The invention can be understood by referring to the following description taken in conjunction with the accompanying drawings, wherein reference numerals denote features of the invention.

[0050] Figure 1 A schematic perspective view of a flexible flat conductor cable on an electrical contact is shown;

[0051] Figure 2 It shows according to Figure 1 A schematic partial cross-sectional view of a flexible flat conductor cable and its electrical contacts;

[0052] Figure 3 It shows Figure 1 Longitudinal cross-sectional view of a flexible flat conductor cable;

[0053] Figure 4 An embodiment of a flexible flat conductor cable with bent electrical conductors is shown;

[0054] Figure 5 It shows according to Figure 4A top view of a flexible flat conductor cable, wherein the electrical conductor is placed on an electrical connection mating piece;

[0055] Figure 6 A partial top view of a flexible flat conductor cable is shown, in which the electrical conductor is connected to an electrical connection mating member via contact points or solder points;

[0056] Figure 7 A schematic diagram of another embodiment of a flexible flat conductor cable is shown, wherein the electrical conductor is connected to an electrical connection mating member in two partial segments;

[0057] Figure 8 The view showing the underside of the flexible flat conductor cable is a perspective view of two partial sections of the flexible flat conductor cable, wherein the two partial sections of the electrical conductor extend from the insulating sheath;

[0058] Figure 9 A perspective view of a flexible flat conductor cable is shown, in which two partial segments of the electrical conductor are placed on an electrical connection mating piece;

[0059] Figure 10 It shows having Figure 7 A perspective view of two partial sections of the arrangement;

[0060] Figure 11 It shows according to Figure 7 A partial cross-sectional view of a flexible flat conductor cable and its electrical contacts;

[0061] Figure 12 It shows Figure 11 The arrangement in which a portion of the electrical conductor of the flexible flat conductor cable is embedded in an insulating material;

[0062] Figure 13 A schematic diagram of a battery is shown, with its electrical terminals in contact with the conductor of a flexible flat conductor cable.

[0063] Figures 14a to 14e A schematic diagram of a method for bending a contact segment onto an electrical connection mating element according to an embodiment of the present invention is shown.

[0064] Figures 15a to 15c A schematic diagram of a method for imprinting contact segments into an electrical connection mating element according to an embodiment of the present invention is shown.

[0065] Figure 16 A battery cell connection system for a vehicle battery module according to the present invention is shown.

[0066] Figures 17a to 17c A variation of the surface area increase feature according to the invention is illustrated schematically.

[0067] Figure 18 A stamping press with a pointed pyramid shape is shown to form a surface area-increasing feature in a conductor.

[0068] Figure 19 Peeling forces according to four embodiments of the present invention are shown compared to a comparative example with a smooth surface. Detailed Implementation

[0069] Figures 1 to 1 5. Embodiments relating to the first objective of the present invention.

[0070] Figure 1 A schematic diagram of a conductor cable 1 placed on an electrical connection mating member 2 is shown. In this embodiment and the following embodiments, a flexible flat conductor cable is used; however, the invention is not limited thereto, and any type of conductor cable with at least one electrical conductor embedded in an insulating sheath can be used.

[0071] The flexible flat conductor cable 1 includes a plurality of electrical conductors 3, 10 embedded in an insulating sheath 4. In the illustrated embodiment, the flexible flat conductor cable 1 includes nine electrical conductors 3, 10 embedded in the insulating sheath 4. In the contact section 5, the insulating sheath 4 of the electrical conductors 3 is stripped. This means that the electrical conductors 3 have no insulating sheath 4 material on any side of the contact section 5. Furthermore, the electrical conductors 3 are placed on the electrical connection mating member 2 with one contact side of their contact section.

[0072] Figure 2 A schematic partial cross-sectional view is shown. Figure 1 The arrangement extends along the electrical conductor 3. It can be clearly seen that the electrical conductor 3 no longer has an insulating sheath 4 in the contact section 5. Furthermore, the electrical conductor 3 is placed on the contact section 5 with one contact side positioned on the upper side of the electrical connection mating member 2. The remaining electrical conductors 10 of the flexible flat conductor cable 1 are completely embedded in the insulating sheath. Depending on the chosen embodiment, additional electrical conductors 10 may also be stripped from the insulating material of the insulating sheath in the contact section and placed on the electrical connection mating member 2 with one contact side. Viewed from the longitudinal direction of the flexible flat conductor cable 1, the contact section with the stripped additional electrical conductors 10 may be arranged at the same height as the flexible flat conductor cable 1 or in a different longitudinal section.

[0073] Figure 3 It shows Figure 1 A schematic cross-section of the arrangement. The insulating sheath 4 includes a recess 9 in the area of ​​the contact section 5.

[0074] from Figure 3As shown in the diagram, the flexible flat conductor cable 1 is placed on the side of the contact section 5, and an insulating sheath 4 is provided on the upper surface side 8 of the electrical connection mating member 2 of the electrical contact. However, in the region of the contact section 5, the flexible flat conductor cable 1 bends upward from the upper surface side 8 of the electrical contact 2 along a second direction 11. Additionally, the conductor 3 bends downward from the contact plane 13 of the insulating sheath 4 in the region of the contact section 5 along a first direction 12 toward the electrical connection mating member 2. The contact plane 13 is typically formed at the center of the insulating sheath 4, in which the conductors 3 and 10 of the flexible flat conductor cable are arranged. The bending of the conductor 3 toward the connection mating member 2 secures the contact side 7 of the conductor 3 firmly on the upper side 8 of the electrical contact 2. Furthermore, the cable section 14 bending upward in the second direction 11 can be used to apply a preload force to the contact section 5 of the conductor 3 in the direction of the electrical connection mating member 2. This also makes it easier for the conductor 3 to bend in the direction of the connection mating member 2 without deforming it.

[0075] According to the selected embodiment, the flexible flat conductor cable 1 can also be placed planarly on the connecting mating member 2 in the area of ​​the contact section 5. However, in this embodiment, the conductor 3 is deformed, particularly stretched, to allow flexing in the direction toward the connecting mating member 2.

[0076] Figure 4 Another embodiment of the flexible flat conductor cable 1 is shown in perspective. The flexible flat conductor cable 1 has an electrical conductor 3 that is bent outwards into an insulating sheath 4 along a first direction 12. Meanwhile, in the contact section 5, the cable section 14 has a shape that is bent relative to the rest of the flexible flat conductor cable 1 that extends in a planar manner along a second direction 11 that is arranged opposite to the first direction 12.

[0077] Figure 5 It shows Figure 4 The flexible flat conductor cable 1 is placed on an electrical connection mating member 2. Here, the contact segment 5 of the conductor 3 is placed on the upper side 8 of the electrical connection mating member 2. In this embodiment, the flexible flat conductor cable 1 includes six conductors 3, 10, shown in dashed lines. The conductors 3 are not mechanically connected to the electrical connection mating member 2 via their contact segments 5, but are simply placed on the upper side 8 of the electrical connection mating member 2. In subsequent method steps, the contact segments 5 of the conductors 3 are connected to the upper side 8 of the electrical connection mating member 2. For this purpose, for example, welding, adhesive bonding, or brazing can be used. In particular, laser welding can be used as a welding connection. The welding of the contact segments 5 of the conductors 3 to the upper side 8 of the electrical contact member 2 is completed by a laser beam. Depending on the chosen embodiment, one or more welding points 15 can be used, such as... Figure 6As shown. Ultrasonic welding can also be used as an alternative to laser welding.

[0078] Figure 6 Shown in enlarged illustration Figure 5 The details of the arrangement include the use of two solder points 15 and 16 to solder the electrical conductor 3 to the electrical connection mating member 2. Depending on the chosen embodiment, only one solder point may be used, or more than two solder points may be used. Alternatively, elongated, rectangular, or serrated solder joints may be chosen instead of circular solder points. For example, the solder joint may be established by means of a laser beam guided in a spiral shape from the center point of the solder joint to the edge region of the solder joint.

[0079] Figure 7 A perspective view of another device is shown, which has electrical contact between the electrical conductor 3 and the electrical connection mating member 2 of the flexible flat conductor cable 1. Figure 7 The illustration is a schematic diagram of a flexible flat conductor cable 1 as seen from above, shown placed on an electrical connection mating member 2. A recess 9 is introduced into the insulating sheath 4 of the flexible flat conductor cable 1, causing the contact segment 5 of the conductor 3 to peel off from the insulating material of the insulating sheath 4. Furthermore, the contact segment 5 of the conductor 3 is divided into a first partial segment 17 and a second partial segment 18. The first and second partial segments 17 and 18 extend downwards from the contact plane of the insulating sheath 4 relative to the flexible flat conductor cable 1 and are placed on the upper side 8 of the electrical connection mating member 2. Additionally, each partial segment 17 and 18 is electrically and mechanically connected to the electrical connection mating member 2 via two corresponding solder points 15 and 16. The solder points 15 and 16 can be created, for example, by laser welding.

[0080] Figure 8 The image shows the part placed on the electrical connection mating piece 2. Figure 7 The flexible flat conductor cable 1 is shown in the figure. Here, the partial sections 17 and 18 of the conductor 3, bent out from the insulating sheath 4 of the flexible flat conductor cable 1, can be easily identified. Partial sections 17 and 18 are respectively divided into a first section 19 and a second section 20. The first section 19 extends from the contact plane 13 of the insulating sheath 4 and is inclined at a predetermined angle relative to the contact plane 13. The first section 19 transitions to the second section 20 via a bend 21. The second section 20 has a smaller inclination relative to the contact plane 13 and can be arranged, for example, parallel to the plane of the flexible flat conductor cable 1. The first and second partial sections 17 and 18 can be shaped identically, such that the first section 19 each has the same angle relative to the plane of the flexible flat conductor cable 1, and the second section 20 is arranged parallel to each other. This shape of the partial sections 17 and 18 simplifies and improves the realization of electrical contact between the conductor 3 and the electrical connection mating member 2.

[0081] Due to the shapes of the partial segments 17 and 18, when the flexible flat conductor cable 1 is placed on the electrical connection mating member 2, the second segment 20 of the partial segments 17 and 18 has a relatively large contact surface with the upper side 8 of the electrical contact member 2. Therefore, the second segment 20 of the partial segments 17 and 18 contacts the electrical connection mating member 2 over a large area. This provides a large contact surface. Furthermore, a large surface is provided for forming the connection between the connection mating member 2 and the partial segments 17 and 18.

[0082] Figure 9 It shows Figure 8 A flexible flat conductor cable 1 is placed on an electrical connection mating member 2, such that partial sections 17 and 18 and a second section 20 rest on the upper side 8 of the electrical connection mating member 2.

[0083] Figure 10 This shows the process after the partial segments 17 and 18 are welded to the electrical connection mating part 2 using welding points 15. Figure 9 The arrangement.

[0084] Figure 11 It shows Figure 10 A schematic partial cross-sectional view of the arrangement, in which the formation of the first segment 19 and the second segment 20 of partial segments 17 and 18 is clearly visible. Figure 11 In one embodiment, two welding points 15 and 16 are formed in the second segment 20 of the partial segments 17 and 18, and the partial segments 17 and 18 are connected to the electrical connection mating member 2.

[0085] Figure 12 It shows Figure 7 A schematic partial cross-section of another embodiment. In this embodiment, the first partial segment 17 and the second partial segment 18 are embedded in an insulating material 22. The insulating material 22 may be formed of, for example, an electrically insulating potting material, such as a plastic material. For example, the partial segments 17 and 18 after peeling off the insulating sheath 4 may be at least partially, and in particular completely, covered by the insulating material 22. This achieves safe and reliable electrical insulation of the partial segments 17 and 18.

[0086] In a similar way, Figures 1 to 6 In the embodiment, the contact portion 5 can also be covered with insulating material, especially with electrically insulating potting material.

[0087] Depending on the chosen embodiment, the electrical connection mating member 2 and the electrical conductor 3 can be formed of different materials. For example, the electrical connection mating member 2 can be made of aluminum. Alternatively, the electrical conductor 3 can be formed of copper.

[0088] Figure 13A schematic diagram illustrates the arrangement of a battery system having multiple batteries 23, 24, and 25, each battery having an electrical terminal, some of which are schematically shown as rectangular terminals 26, 27, and 28. Additionally, a flexible flat conductor cable 1 passes through the batteries 23, 24, and 25. The flexible flat conductor cable 1 includes an electrical conductor 3, another electrical conductor 10, and an additional electrical conductor 29. Electrical conductors 3, 10, and 29 are shown schematically only in partial sections, but they are formed along the entire flexible flat conductor cable 1. In the illustrated embodiment, according to... Figures 1 to 12 In one of the aforementioned embodiments, electrical conductor 3 is electrically connected to the first terminal 26 of the first battery 23, another electrical conductor 10 is connected to the second terminal 27 of the second battery 24, and an additional electrical conductor 29 is connected to the third terminal 28 of the third battery 25. For example, the batteries are arranged in a vehicle. The battery terminals 26, 27, and 28 represent electrical contacts. Depending on the chosen embodiment, only one battery may be provided with an electrical terminal connected to the conductor of a flexible flat conductor cable. The electrical contacts of the battery terminals can be used to detect the battery voltage to balance their and / or the battery temperature. The battery has two terminals, which are not shown in this schematic diagram.

[0089] Figures 14a to 14e Another embodiment of the invention is shown. Features having the same reference numerals as those used in the above description will not be described in detail but will be labeled accordingly.

[0090] Figure 14a A schematic side cross-sectional view of the conductor cable is shown, here in an exemplary form where a flexible flat conductor cable 1 is positioned with its insulating sheath 4 on an electrical connection mating member 2. The conductor 3 lies within the contact plane 13 along its entire length. The contact segment 5 is not yet bent toward the surface 8 of the electrical connection mating member 2. Droplets 31 of welding material or adhesive of explosive or flammable material are positioned on the surface side 33 opposite to the contact side 7. Instead of liquid materials, suitable solid materials, such as materials in the form of an explosive coating, may also be used on the surface side 33 opposite to the contact side 7.

[0091] Figure 14b The image shows a laser pulse 35 emitted by a pulsed laser 37 striking a droplet 31.

[0092] Depending on the material used, droplet 31 will immediately evaporate, burn, or explode due to energy transfer. For this, a single laser pulse may be sufficient. In some applications, multiple pulses may be required.

[0093] After the phase transition, a pressure wave 39 is formed. This pressure wave 39 rapidly expands and presses the contact side 7 of the contact segment 5 downwards against the surface 8 of the electrical connection mating member 2. This... Figure 14c As shown in the image.

[0094] Subsequently, as Figure 14d As shown, while the contact segment 5 is still pressed down by the pressure wave 39, the laser 37 emits another laser pulse 41, which strikes the contact segment 5 to weld it to the electrical connection mating part 2 in the welding area 42.

[0095] Figure 14e The final result is shown. The contact segment 5 bends out from the contact plane 13 and is electrically and mechanically connected to the electrical connection mating member 2. A high-quality weld 43 can be obtained by pressing down the contact segment 5 at the moment of interaction with the laser.

[0096] Figures 15a to 15c Another embodiment of the invention is shown. Features having the same reference numerals as those used in the above description will not be described in detail but will be labeled accordingly.

[0097] Figure 15a A schematic side cross-sectional view of a conductor cable is shown, here in an exemplary form where a flexible flat conductor cable 1 is positioned with its insulating sheath 4 on an electrical connection mating member 2. The electrical conductor 3 lies within the contact plane 13 along its entire length. The contact segment 5 is not yet bent toward the surface 8 of the electrical connection mating member 2. A stamping press 51 is located directly above the contact segment 5. The embossed surface 53 may be a flat surface with or without chamfered edges.

[0098] A variation of the embodiment is shown in magnified region 55. Here, the embossing surface 57 has a structured surface 59, for example, a plurality of pyramid-shaped portions 61 regularly arranged on the embossing surface 57.

[0099] Figure 15b The result is shown after the press 51 has moved downwards and pressed against the surface 8 of the contact segment 5 and the electrical connection mating member 2. Under the pressure of the press 51, at least a portion 63 of the contact segment 5 has been bent and imprinted into the surface 65 of the electrical connection mating member 2. The height 67 of the imprint's interface plane 69 is 0.1 to 0.5 mm, preferably 0.2 to 0.4 mm, compared to the surface 8 immediately adjacent to the imprinted area 71.

[0100] Enlarged area 73 shows when using a device with, for example Figure 15a The interface 75 of the structured surface 59 shown is located at the stamping machine 51. Here, the contact segment 5 and the electrical connection mating member 2 have an increased mating surface area feature 77 at the interface 75.

[0101] The advantage of embossing is that the two parts are positioned relative to each other without the need for additional clamping devices, thus simplifying the manufacturing process.

[0102] Subsequently, as Figure 15c As shown, a laser 79 is used to weld the contact segment 5 to the electrical connection mating member 2. Similar to the embodiment described above, one or more welding points 81 can be formed in the imprinted area 71. Alternatively, ultrasonic welding can be used.

[0103] Therefore, in this embodiment, bending and pacing of the contact side on and therein on the surface 8 of the electrical connection mating member 2 are achieved in one step.

[0104] Figure 16 A battery cell connection system 100 for a battery module related to the second objective of the present invention is shown.

[0105] Such a battery cell connection system 100 is used in electric or hybrid vehicles. It receives battery cells connected in parallel and series to provide energy to the vehicle's electric motor.

[0106] The battery cell connection system 100 includes a support 103, typically made of plastic, which, for example, uses a snap-fit ​​connection to mount a plurality of contact elements 109 and 111, typically made of aluminum, in two rows of 105, 107. The contact elements 109, 111 correspond to the electrical connection mating elements 2 in the above embodiment.

[0107] In this embodiment, each contact element 109 and each contact element 111 respectively includes two contact element segments 109a, 109b and 111a, 111b. The two contact element segments 109a, 109b are electrically connected to each other. The contact element segments 111a, 111b are also electrically connected to each other.

[0108] In use, the positive and negative terminals of the battery cells are positioned on opposite contact sections. Therefore, one battery cell is on contact element sections 109a and 111a, and another battery cell is on contact element sections 109b and 111b. Thus, the battery cells are arranged in parallel. In variations, fewer or more than two battery cells can be arranged in parallel. The battery cells are typically welded to the contact element sections to ensure reliable electrical and mechanical connections.

[0109] In row 105, adjacent contact elements 113 are electrically isolated from contact element 109 by an isolation element 115, which is typically integrally formed with the support. In the opposite row, adjacent contact elements 117 are electrically connected to contact element 111. Therefore, the battery cells mounted on contact elements 113 and 117 are mounted in series with respect to the battery cells mounted on contact elements 109 and 111. A parallel arrangement of paired battery cells connected in series with adjacent battery cells is achieved throughout rows 105 and 107. Therefore, the paired electrically connected contact elements are separated from subsequent paired electrically connected elements by the isolation element 115. In this embodiment, only contact element 109 in row 105 and contact element 149 in row 107 are not electrically connected to adjacent contact elements.

[0110] The battery cell connection system 100 is connected to an adjacent battery cell connection system or motor via busbars 119 and 121.

[0111] The battery cell connection system 100 also includes a printed circuit board (PCB) 123 having a battery cell monitoring unit 125. The monitoring unit 125 on the PCB 123 is electrically connected to at least some of the contact elements 109, 111, 113, and 115 to monitor battery cell parameters, such as temperature and capacitance, for example, to balance the capacitance or its state of charge. The connection is achieved using sensing cables, referred herein as flexible flat cables 127, 129, 131, and 133, and also as flexible flat conductor cables in the above embodiments.

[0112] As can be seen in enlarged view 135, the flexible flat cable 133 comprises multiple, here six, parallel conductors 137a-f, which are copper wires, isolated from each other by electrical insulation 139, and in this embodiment embedded in extruded PVC. Three of the conductors (137c, 137d, and 137e) are electrically and mechanically connected to one and only one contact element, here contact elements 145, 147, and 149. Furthermore, from... Figure 1 As can be seen, each pair of opposing contact elements is connected to only one wire. Here, wire 137d is connected to contact element 147, while the opposing contact elements in row 105 are not connected to flexible flat cable 127 for monitoring battery cell installation. Regarding opposing contact elements 109a and 111a, both elements are connected to their corresponding flexible flat cables 129 and 131.

[0113] The flexible flat cable 133 has an exposed area 141, in which the conductor 143 corresponding to conductor 137c does not have electrical insulation. Conductor 143 is typically welded to contact element 145 by ultrasonic welding. For ultrasonic welding to be performed, such as... Figure 1As shown, the opposite side to the contact element 145 also needs to be free of electrical insulation 139 because the ultrasonic generator used for welding needs to be positioned on the wire. Typically, the surface on which the ultrasonic generator is applied has visible markings of the ultrasonic generator contact surface.

[0114] According to the invention, the exposed area 141 facing the contact element 145 includes, for example, a surface area-increasing feature with bumps. Herein, a surface area-increasing feature refers to a surface having a larger area than the smooth surface of a copper conductor, obtained, for example, after removing the electrical insulation 139 using a CO2 laser and subsequently cleaning, for example, mechanical cleaning using metal and / or plastic brushes (such as circular brushes).

[0115] Figures 17a to 17c Three different variations of the surface area increase feature on the exposed area 141 of the conductor 143 according to the present invention are shown. The surface area increase feature is on the side of the conductor that will contact the contact element 145, such as... Figure 16 As shown.

[0116] Figure 17a The surface of the exposed area 151 of the wire 153 after the application of a scratching tool is shown. The scratches 155 are preferably set across the entire surface of the exposed area and increase the surface area compared to a smooth surface.

[0117] Figure 17b The surface of the exposed area 161 of the conductor 163 after the application of a stamping press is shown, resulting in the formation of a patterned surface area-increasing feature in the form of linear bumps 165 extending along the longer side of the exposed area 161. In another variation, the linear bumps 165 may extend along the shorter side or be angled. In this embodiment, all linear bumps 165 have the same shape. In variations, they may also be different, for example, higher towards the edge. The linear bumps 165 have a maximum height of 0.5 mm, particularly a maximum height of 0.2 mm, and more particularly a maximum height of 0.1 mm. Furthermore, the distance between the tips of directly adjacent bumps is a maximum of 5 mm, particularly a maximum of 0.2 mm.

[0118] Figure 17c This shows the application such as Figure 18The surface of the exposed area 171 of the conductor 173 after the stamping press 181 is shown. The stamping application results in a patterned surface area increase feature in the form of a pyramid-shaped array 175 across the entire exposed area 171. In this embodiment, the pyramids 175 are pointed pyramids with a base shape that is substantially rectangular, particularly substantially square, and have a side angle of approximately 30° to 60°, particularly 45°. The pyramids 175 have a maximum height of 0.5 mm, particularly a maximum height of 0.2 mm, and more particularly a maximum height of 0.1 mm. Furthermore, the distance between the apexes of directly adjacent pyramids is a maximum of 5 mm, particularly a maximum of 0.2 mm.

[0119] like Figure 18 As shown, the stamping press 181 includes a regularly arranged array of pyramids 183.

[0120] Instead of imprinting the surface area-enhancing features onto the surface of conductors 163 or 173, laser patterning can also be used.

[0121] The present invention also relates to a method for attaching a sensing cable to a contact element of a battery cell connection system as described above, and includes the steps of: removing electrical insulation 139 from flexible flat cables 127 to 133 to form exposed areas 141, 151, 161, 171 and cleaning the exposed areas. Following this step is a step of forming surface area-increasing features using a stamping machine or scraping tool or by laser structuring to obtain, for example... Figure 17a , 17b Or one of the structures shown in 17c. Subsequently, the electrical and mechanical connections between the exposed areas 141, 151, 161, and 171 of the conductors 143, 153, 163, and 173 are achieved by welding, particularly ultrasonic or laser welding.

[0122] According to the variant, such as Figures 17a to 17c The shape shown can also be or alternatively disposed on the surface of the contact element 145.

[0123] Figure 19 The results obtained after the 90° peel tension test as described above, which satisfies Cmk > 1.67, are shown. Individual measurements and averages are displayed.

[0124] For all samples, aluminum and copper, the same materials, were used as contact elements, and the same ultrasonic treatment process was applied.

[0125] Sample 191 corresponds to the comparison sample with a smooth surface. It can be seen that the peel tension test is satisfactory, as the average level of 8.625 N is higher than the required 7 N (see the horizontal dashed line). One of the test results is less than 7 N.

[0126] Sample 193 corresponds to, for example Figure 17c The surface area of ​​the pointed pyramid shape shown is increased. These are achieved by using features such as... Figure 18 The stamping process shown is used to obtain the spires. The pointed pyramids on the conductors exhibit square bases in both the 0° and 90° directions, with an average distance of 0.4 mm between the spires, a height of 0.2 mm, and a side angle of 45°. The average peel force obtained was 13.154 N when all measurements were above 7 N.

[0127] Sample 195 corresponds to a surface area increase feature in the form of linear bumps, such as Figure 17b As shown, the distance between the apexes is 0.2 mm, the height is 0.1 mm, and the side angle is 45°. When all measurements are above 7 N, the average peel force obtained is 9.482 N.

[0128] Sample 197 corresponds to, for example Figure 17c The surface area of ​​the pointed pyramid shape shown is increased. These are achieved by using features such as... Figure 18 The stamping process shown is used to obtain the spires. The pyramidal fins on the conductors exhibit square bases in both the 0° and 90° directions, with an average distance of 0.2 mm between the fins, a height of 0.1 mm, and a side angle of 45°. The average peel force obtained was 15.56 N when all measurements were above 7 N.

[0129] Sample 199 corresponds to the surface area increase characteristic in the form of scratches. All measurements are above 7 N, and the average peel force obtained is 12.598 N.

[0130] Compared to wires with smooth surfaces, all samples according to the present invention exhibit higher peel strength. Sample 197 achieved the best results, showing an improvement of approximately 80% compared to the control sample.

[0131] Several embodiments of the invention have been described. However, it should be understood that various modifications and enhancements can be made without departing from the appended claims. In particular, further embodiments of the invention are achieved by combining embodiments relating to a first objective of the invention with embodiments relating to a second objective of the invention.

[0132] List of reference numerals

[0133] 1. Conductor cable, here referring to a flexible flat conductor cable.

[0134] 2 Electrical connection mating parts

[0135] 3. Electrical conductors

[0136] 4. Insulating sheath

[0137] 5 contact section

[0138] 7. Contact side

[0139] 8. Upper side of electrical contact

[0140] 9. Recesses in the insulating sheath

[0141] 10 Another electrical conductor

[0142] 11 Second Direction

[0143] 12 First Direction

[0144] 13 Contact plane

[0145] 14 Cable Section

[0146] 15 First welding point

[0147] 16 Second welding point

[0148] 17 First Partial Section

[0149] 18 Second Partial Section

[0150] 19 Part One

[0151] 20 Part Two

[0152] 21. Bend

[0153] 22 Insulation materials

[0154] 23 First Battery

[0155] 24 Second Battery

[0156] 25 Third Battery

[0157] 26 First terminal

[0158] 27 Second terminal

[0159] 28 Third terminal

[0160] 29 Additional electrical conductor

[0161] 31 Droplets

[0162] 33 Surface side

[0163] 35 laser pulses

[0164] 37 Lasers

[0165] 39. Pressure Wave

[0166] 41 Another laser pulse

[0167] 42 Welding area

[0168] 43 Welding

[0169] 51 stamping machine

[0170] 53 Stamped Surface

[0171] 55 Magnified Area

[0172] 57 Stamped Surface

[0173] 59 Structured Surfaces

[0174] 61. Pyramid shape

[0175] 63. Part of contact section 5

[0176] 65 Imprinted surface of electrical connection mating part 2

[0177] 67. Height of the Imprint

[0178] 69. Boundary Plane

[0179] 71 Imprinting Area

[0180] 73 Magnified Area

[0181] 75 interface

[0182] 77. Increased surface area characteristic

[0183] 79 lasers

[0184] 81 Welding

[0185] 100 Battery Cell Connection System

[0186] 103 Support component

[0187] 105th row

[0188] 107 Second row

[0189] 109 Contact elements

[0190] 109a Contact element section

[0191] 109b Contact element section

[0192] 111 Contact element

[0193] 111a Contact element section

[0194] 111b Contact element section

[0195] 113 Adjacent contact elements

[0196] 115 Isolation Element

[0197] 117 Adjacent contact elements

[0198] 119 Busbar

[0199] 121 Busbar

[0200] 123 Printed Circuit Board (PCB)

[0201] 125 Battery Cell Monitoring Unit

[0202] 127 Flexible flat cable

[0203] 129 Flexible flat cable

[0204] 131 Flexible flat cable

[0205] 133 Flexible flat cable

[0206] 135 Enlarged Image

[0207] 137a-f conductor

[0208] 139 Electrical insulation components

[0209] 141 Exposed Area

[0210] 143 Wires in the exposed area

[0211] 145 Contact element

[0212] 147 Contact elements

[0213] 149 Contact element

[0214] 151 Exposed Area

[0215] 153 conductor

[0216] 155 Surface scratches as a feature of increased surface area

[0217] 161 Exposed Area

[0218] 163 conductor

[0219] 165 Linear bumps as a feature of increased surface area

[0220] 171 Exposed Area

[0221] 173 conductor

[0222] 175 Spire pyramids as a feature of increased surface area

[0223] 181 A stamping press with a pointed pyramid shape.

[0224] 191 Comparison Examples

[0225] 193 The Great Pyramid (stamped)

[0226] 195 Stamped linear protrusions

[0227] 197 Stamped Small Pyramids

[0228] 199. Increased surface area of ​​scratches

Claims

1. A device having electrical contact between an electrical conductor (3) of a conductor cable (1) and an electrical connection mating member (2), said conductor cable (1) being a flexible flat conductor cable, said electrical conductor (3) being embedded in an insulating sheath (4) of the conductor cable (1) in a contact plane (13), wherein, At least on one contact side (7), the electrical conductor (3) is stripped of the insulating sheath (4) in a predetermined contact segment (5), wherein the contact segment (5) of the electrical conductor is bent from the contact plane (13) beyond the insulating sheath (4) along a first direction (12) with the contact side (7), wherein the contact side (7) of the contact segment (5) of the electrical conductor (3) is placed on the electrical connection mating member (2) and directly connected to the electrical connection mating member (2) to form an electrical contact, wherein the conductor cable (1) is bent along a second direction (11) in the region of the contact segment (5), wherein the second direction (11) points in the opposite direction to the first direction (12). The contact segment (5) of the electrical conductor (3) is divided into two local segments, and at least one local segment of the electrical conductor (3) is placed on the electrical connection mating member (2) with the contact side (7) and connected to the electrical connection mating member (2).

2. The apparatus according to claim 1, wherein, The contact side (7) of the contact segment (5) of the electrical conductor (3) is connected to the electrical connection mating member (2) through a plurality of contact points (15, 16).

3. The apparatus according to claim 1, wherein, The contact segment (5) of the electrical conductor (3) is embedded in the insulating material (22).

4. The apparatus according to claim 3, wherein, The insulating material (22) is an electrically insulating potting material.

5. The apparatus according to any one of claims 1-4, wherein, The electrical connection pair (2) and the electrical conductor (3) are formed of different conductive materials.

6. The apparatus according to claim 5, wherein, The electrical connection pair (2) is made of aluminum, and the electrical conductor (3) is made of copper.

7. The apparatus according to any one of claims 1-4, wherein, The electrical connection mating part (2) is a contact of the electrical terminal of the battery, which is a vehicle battery.

8. The apparatus according to any one of claims 1-4, wherein, The electrical conductor (3) is connected to the electrical connection mating part (2) by a welding connection, which is a laser or ultrasonic welding connection.

9. The apparatus according to any one of claims 1 to 4, wherein, The contact segment is at least partially imprinted into the electrical connection mating member.

10. The apparatus according to claim 9, wherein, The interface between the contact segment and the electrical connection mating member is located below the surface of the electrical connection mating member immediately adjacent to the interface.

11. The apparatus according to claim 10, wherein, The interface between the contact segment and the electrical connection mating member is located at a maximum of 0.1 to 0.5 mm below the surface of the electrical connection mating member immediately adjacent to the interface.

12. The apparatus according to claim 9, wherein, The surfaces of the contact section and the electrical connection mating member include a feature at the interface that increases the surface area for mating.

13. A battery cell connection system for a vehicle battery module, comprising the means according to any one of claims 1 to 12, - in, The electrical connection mating member includes a contact element for receiving the electrode of at least one battery cell. - The conductor cable includes a sensing cable, the sensing cable including conductors that are electrically and mechanically connected to the battery cell monitoring unit and the contact element. Its features are: The surfaces of the conductors and / or the contact elements include an increased surface area feature in the areas where they contact each other.

14. The battery cell connection system according to claim 13, wherein, The battery cell connection system is a battery cell connection system for battery modules in electric or hybrid vehicles.

15. A method of manufacturing an apparatus according to any one of the preceding claims, wherein, The method involves embedding the electrical conductor of a conductor cable within the insulating sheath of the conductor cable in a contact plane, the conductor cable being a flexible, flat conductor cable, wherein the insulating sheath is stripped from the electrical conductor in a predetermined contact section on at least one contact side. The method includes the following steps: a) Bend the contact portion of the electrical conductor outside the contact plane, to at least one outer side of the insulating sheath. b) After the electrical conductor has bent out of the contact plane, place the conductor cable on the connecting mating member. c) Place the contact side of the contact segment of the electrical conductor on the electrical connection mating member, and then d) Connect the contact side of the contact segment directly to the electrical connection mating member.

16. The method according to claim 15, wherein, The contact side of the electrical conductor is welded to the electrical connection mating member using laser welding or ultrasonic welding.

17. The method of claim 16, comprising the following steps: Prior to welding, a pressure wave, formed by inducing a phase change in the pressure-generating material, is used to press the contact side of the electrical conductor downward toward the electrical connection mating member.

18. The method of claim 17, wherein the pressure wave is formed during a phase transition from a liquid or solid phase to a gas phase and / or an explosion.

19. The method of claim 17, wherein, The formation of the pressure wave includes the following steps: striking the pressure-generating material with one or more laser pulses.

20. The method of claim 17, wherein, The formation of the pressure wave includes the following steps: striking the pressure-generating material with the same laser used for welding.

21. The method according to claim 17, wherein, The pressure-generating material is disposed on or above the contact segment (5) in the form of droplets or cladding.

22. The method according to any one of claims 15 to 21, wherein, The contact segment of the electrical conductor bends out of the contact plane along a first direction with the contact side extending beyond the outer side of the insulating sheath, wherein the conductor cable then moves toward the electrical connection mating member, and the contact side of the contact segment of the electrical conductor rests on the electrical connection mating member and is directly connected to the electrical connection mating member.

23. The method according to claim 22, wherein, Before the electrical conductor is placed on the electrical connection mating piece and before welding, the conductor cable is bent in a second direction in the region of the contact section, wherein the second direction points in the opposite direction to the first direction.

24. The method according to any one of claims 15 to 21, wherein, The contact segment of the electrical conductor is divided into first and second partial segments, and at least the first partial segment is bent away from the contact plane, wherein the first partial segment is placed on the electrical connection mating member and connected to the electrical connection mating member on the contact side.

25. The method according to any one of claims 15 to 21, wherein, Steps a) and c) are achieved simultaneously by embossing the contact segment (5) in the electrical connection mating member (2).

26. The method of claim 25, wherein, Imprinting is achieved using a stamping press with a flat or structured surface.

27. The method according to any one of claims 15 to 21, for obtaining the battery cell connection system according to claim 13, wherein, The increased surface area is achieved by using a stamping machine or a scraping tool or by laser structuring.

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