Connection device and method for connecting a connection device with a component

Abstract

The invention relates to a connection device having a metallic flat conductor having a cross-sectional profile which is at least quadrangular and at least two mutually opposite surfaces which extend parallel to one another in the longitudinal direction at least in an end region, a first through-opening between the surfaces in the end region, wherein the first through-opening forms a receptacle for a pin, at least one second through-opening between the surfaces in the end region, wherein the second through-opening forms a receptacle for a metallic connection bracket, wherein the connection bracket is formed as a flat piece and lies against one of the surfaces of the flat conductor in the end region in a surface-like manner by means of a contact surface.

Description

TECHNICAL FIELD

[0001] The present application relates to a connection device having a metallic flat conductor and a connection carrier and to a method for connecting the connection device with a component. BACKGROUND

[0002] For the distribution of electrical energy in automotive applications, in particular in motor vehicles, whether passenger cars or lorries, flat conductors are increasingly used. Flat conductors are particularly suitable for energy distribution, since from a certain conductor cross-section they have a greater surface than round conductors and thus an improved current-carrying capacity. In particular, flat conductors are used in order to transmit electrical energy between a battery, a starter and / or an electrical generator. In electrically driven vehicles, flat conductors are used as so-called energy backbones for distributing electrical energy from the battery to a plurality of consumers and between the drive battery and the drive motor. In all cases the flat conductors have a large conductor cross-section. Due to the large conductor cross-section, aluminium is often used as the metallic material of the flat conductors, since it has a smaller weight compared to copper.

[0003] However, when distributing electrical energy in a vehicle, the flat conductors need to be electrically connected to the consumers, which requires an electrical transfer point which must be stable over a long period of time in terms of mechanical and electrical properties. The contact resistance at the transfer point must be small in order to keep the electrical losses small there and in order to avoid overheating. In particular, very high currents flow in the drive train of a vehicle, which, if the contact resistance is too high, can lead to high ohmic losses at the transfer point.

[0004] In particular in cases where use in a dynamic environment over a longer period of time is envisaged, the contact resistance can increase over time. This can in particular occur when the contact surface between the flat conductor and the connection piece is reduced due to dynamic loads. Thus, in particular in the case of aluminium, plastic deformations occur in a dynamic environment because of the ductility of aluminium. It must therefore be ensured that the aluminium does not plastically deform or only slightly plastically deform as a result of mechanical loads at the contact location, so that no adverse effects on the contact resistance result therefrom. SUMMARY

[0005] It is therefore an object of the present application to provide a connection carrier for a flat conductor which ensures a consistently small contact resistance over a long service life when used in a dynamic environment.

[0006] The connection device in particular comprises a metallic flat conductor. Here, the metallic flat conductor is in particular formed from aluminium or an aluminium alloy. This can be, for example, E-aluminium or aluminium 99.5. The aluminium here can in particular be soft annealed.

[0007] The flat conductor can be at least partially surrounded by an electrical insulator, for example by plastic, for example silicone or PVC. In the end region, the flat conductor can be free of an insulation. The flat conductor can also be free of an insulation in the middle region. The end region or the middle region can be regarded as a connection region.

[0008] The flat conductor has a polygonal cross-sectional profile, in particular at least a quadrangular cross-sectional profile. Here, in particular a rectangular or square cross-sectional profile is preferred. This cross-sectional profile is characterized in that the flat conductor has at least two mutually opposite surfaces which extend parallel to one another in the longitudinal direction at least in the connection region.

[0009] In the connection region, the flat conductor has a first through-hole. Here, the through-hole can be, for example, drilled, punched, sawn, milled or shaped in any other way. The through-hole extends between the surfaces which extend parallel to one another in the connection region. The through-hole forms a receptacle for a pin which is inserted through the through-hole in order to arrange the connection device on the component, as will still be described below.

[0010] In addition to the first through-hole between the two surfaces, the flat conductor has at least one second through-hole between the surfaces in the connection region. This second through-hole serves to receive a metal connection bracket. In particular, as will be described below, a projection of the connection bracket is inserted into this second through-hole.

[0011] Like the flat conductor, the metal connection bracket can be made of aluminum or an aluminum alloy. It is also possible that the metal connection bracket, like the flat conductor, consists of copper or a copper alloy. The connection bracket is configured as a flat piece and has one planar region which constitutes a contact surface with the flat conductor. The contact surface rests on one of the surfaces of the flat conductor in the connection region. In the connection region, the contact surface and / or the surface of the flat conductor can be metal-coated, in particular nickel-plated and / or tin-plated. Here, a metal coating can alternatively or additionally be provided on the flat conductor or on the connection bracket. By means of the connection bracket, in particular the contact surface of the connection bracket, a large contact surface is provided through which the current can flow with a small contact resistance.

[0012] The object is now to design the connection on the contact surface between the connection bracket and the flat conductor to be stable over a long period of time and to protect the connection, in particular in a dynamic environment, from degradation.

[0013] To this end, it is proposed that the connection bracket has a first through-recess. The through-recess can be shaped in accordance with the through-hole, for example congruently therewith. The through-recess can also be drilled, punched, sawn, milled or shaped in any other way.

[0014] If the connection bracket rests on the flat conductor in the connection region by means of the contact region, the through-hole and the through-recess are aligned with one another.

[0015] The aligned first hole / recess serves to receive a pin, as will be described hereinafter.

[0016] In order to improve the long-term stability, at least one protrusion is formed on the connecting bracket. The protrusion preferably extends essentially perpendicularly from the contact surface.

[0017] If the connecting bracket is placed with its contact surface against the flat conductor in the connection region, not only the first through-recess is placed in alignment against the first through-hole, but the protrusion is additionally arranged in the second through-hole.

[0018] Furthermore, the connecting bracket is materially bonded with its contact surface to the flat conductor in the connection region. By the connecting bracket preferably being made of a different metal than the flat conductor, a long-term stable contact of the flat conductor to the component can be achieved by the connecting device.

[0019] The materially bonded joining of the connecting bracket to the flat conductor is preferably achieved by means of ultrasonic welding, friction welding, friction stir welding, resistance welding, laser welding or the like. The full or partial connection of the contact surface to the flat conductor in the connection region is achieved in particular by friction welding, in particular ultrasonic welding. Resistance welding is also suitable for ensuring a full connection of the contact surface to the flat conductor. Thus, the flat conductor is connected over a large area to the flat conductor by means of the contact surface and is mechanically stably arranged thereon by means of the protrusion.

[0020] According to one embodiment it is proposed that the protrusion extends essentially perpendicularly from the contact surface. The surfaces between which the second through-hole extends are preferably parallel to one another, so that the second through-hole extends perpendicularly to the surfaces. In order to arrange the protrusion in the second through-hole, the protrusion is likewise preferably formed perpendicularly on the contact surface.

[0021] According to one embodiment it is proposed that the protrusion is essentially cylindrical, in particular hollow-cylindrical. The second through-hole can have an inner peripheral surface which coincides with the outer peripheral surface of the protrusion.

[0022] In order to receive clamping forces when the flat conductor is screwed onto the component and to unload the flat conductor, the present application proposes that the protrusion has a longitudinal extension from the contact surface which is equal to the spacing of the surfaces of the flat conductor in the connection region. Thus, the length of the protrusion is equal to the length of the second through-hole (which corresponds to the height of the flat conductor in the connection region), which results in the protrusion completely filling the through-hole in the inserted state. Thus, the flat component can be placed against the protrusion and the protrusion takes up the pressing forces which are exerted onto the flat component and act onto the surfaces of the flat conductor in the connection region, in particular perpendicularly.

[0023] According to one embodiment it is proposed that the protrusion abuts with its outer circumferential surface at least partially, in particular completely, on the inner circumferential surface of the second through-hole. Thereby, the current can flow not only through the contact surface but also through the surface on which the protrusion abuts on the inner circumferential surface of the through-hole. If the protrusion and the second through-hole have an interference fit or an over- fit, a particularly good connection is achieved.

[0024] The protrusion is preferably integrally formed with the connection carrier (flat). Here, the connection carrier can be formed cut or non-cut, in particular by means of punching and / or bending. In preparation of the flat, the protrusion can be pressed out of the material of the flat by means of punching. The integral design of the protrusion with the flat prevents a contact resistance between the protrusion and the flat.

[0025] According to one embodiment it is proposed that the end surface of the protrusion is flush with the surface of the flat conductor. The surface of the flat conductor which is located on the side away from the connection carrier is the surface which is flush with the protrusion.

[0026] According to one embodiment it is proposed that the number of second through-holes and protrusions is identical. In particular, more than one second through-hole and protrusion is provided, thereby increasing the number of mechanical connections between the connection carrier and the flat conductor.

[0027] According to one embodiment it is proposed that the geometric arrangement of the protrusions around the through-recesses is identical to the geometric arrangement of the second through-holes around the first through-hole. Thereby, it is achieved that the connection carrier can be inserted with its protrusions into the second through-holes in a manner aligned with the first through-hole.

[0028] According to one embodiment it is proposed that at least two, preferably at least three, second through-holes are arranged around the first through-hole at a mutual, preferably equal, angular distance. In particular, the second through-holes enclose the first through-hole, i.e. the second through-holes are arranged annularly around the first through-hole. Preferably, the second through-holes are located on a circular arc extending around the first through-hole.

[0029] According to one embodiment it is proposed that a second flat, for example in the form of a spacer, is arranged on the surface of the flat conductor opposite the connection carrier. The flat preferably abuts at least on the end surface of the protrusion, but in particular simultaneously on the end surface of the protrusion and on the surface of the flat conductor.

[0030] A peg having a flange-like peg head and a peg shaft extending from the peg head can be inserted into the second flat. The second flat has an accommodation for this peg, for example a hole, a drilled hole or the like.

[0031] In order to secure the connection device to the component, the pin rod is passed through the second flat piece, the first through-hole and the first through-recess and connected with one component such that the second flat piece is clamped between the pin head and the protrusion. By the connection of the pin with the component, a clamping force can be exerted which acts perpendicularly to the second flat piece in the direction of the flat conductor. This can be achieved in particular by screwing when the pin rod is configured as a screw. The pressing force is taken up by the protrusion, thereby reducing the mechanical load of the flat conductor in the connection region, which is helpful in particular for a long-term stable connection.

[0032] According to one embodiment it is proposed that the pin is a screw. The screw can be screwed with the component.

[0033] According to one embodiment it is proposed that the pin presses the second flat piece against the protrusion in the connected state. The protrusion takes up the pressing force, thereby enabling a defined pressing force of the pin on the flat piece.

[0034] According to one embodiment it is proposed that the first through-hole and / or the first through-recess is configured as a round hole or a long hole.

[0035] Another aspect is a method for connecting a component with a connection device as described above. Here, the contact surface of the connection bracket is arranged on the flat conductor. At least one of the protrusions is inserted into at least one of the through-holes, wherein a plurality of protrusions can also be inserted into a plurality of through-holes. In this arrangement, it is ensured that the first through-hole and the first through-recess are aligned with each other so that the pin can be inserted through both. After the connection bracket has been arranged on the flat conductor, the contact surface of the connection bracket engages with the surface of the flat conductor in a material-fit. On the side of the flat conductor opposite the connection bracket, the second flat piece is applied to the first through-hole with the eyelet.

[0036] Then, the pin is inserted into the eyelet, the first through-hole and the first through-recess in order to connect the pin with the component. Here, the second flat piece is clamped between the pin and the protrusion. BRIEF DESCRIPTION OF DRAWINGS

[0037] The application is further explained below with the help of the attached drawings showing embodiments. Therein, it is shown:

[0038] Figure 1a 、 1b A flat conductor with a connection region is shown;

[0039] Figure 2 A top view of a flat conductor with one first through-hole and four second through-holes is shown;

[0040] Figure 3a 、 3b A connection bracket is shown;

[0041] Figure 4A flat conductor is shown with a connection carrier attached;

[0042] Figure 5 A longitudinal section through a connection device of a component is shown. DETAILED DESCRIPTION

[0043] Figure 1a A flat conductor 2 with an insulation 4 is shown. The flat conductor 2 with the insulation 4 can also be referred to as a flat cable. In Figure 1a , the flat cable is deinsulated in an end region, so that the flat conductor 2 is bare in the end region. This end region can be referred to as a connection region 6.

[0044] It can be seen that the flat conductor 2 has a rectangular cross-sectional profile, however, a square or other polygonal cross-sectional profile can also be considered. The flat conductor 2 has two mutually opposite broad surfaces 2a, 2b, which extend parallel to each other in the connection region 6.

[0045] Figure 1b A flat conductor 2 is shown, in which the connection region 6 is located between two regions with the insulation 4. The flat conductor 2 is also bare here in the connection region 6. Likewise, the broad surfaces 2a, 2b also extend parallel to each other here.

[0046] In order to provide a connection device, it is now proposed that the flat conductor 2 is provided in the connection region 6 with a first through-hole 8 and at least one, in the shown example four, second through-holes 10, as shown in Figure 2 . The through-holes 8, 10 can be punched, milled, drilled or cut from the flat conductor 2. It can be seen that the second through-holes 10 surround the first through-hole 8. In particular, the second through-holes 10 are arranged at an angular spacing from each other around the first through-hole 8. Here, the second through-holes 10 can be located on a circular arc around the first through-hole 8, for example.

[0047] After the connection region 6 with the through-holes 8, 10 has been manufactured, a connection carrier 12, as shown in Figure 3a , 3b , can be attached to the flat conductor 2. Figure 3a A view of the connection carrier 12 is shown. The connection carrier 12 has a through-recess 14. The through-recess 14 can be shaped in correspondence to the through-hole 8. The through-recess 14 in particular has a shape which is congruent or similar to the geometry of the first through-hole 8. This can be a circular hole or a slot, however, other shapes are also possible, in particular angular shapes.

[0048] Furthermore, the connecting bracket 12 has at least one, preferably multiple, protrusions 16. The protrusions 16 are arranged around the through recess 14. The geometric arrangement of the through recess 14 and the protrusions 16 is geometrically consistent with the geometric arrangement of the first through hole 8 relative to the second through hole 10. Therefore, the connecting bracket 12 can be inserted into the second through hole 10 using its protrusions 16. Thus, the first through hole 8 can be aligned with the through recess 14. The connecting bracket 12 has contact surfaces 18 on the sides of the protrusions 16.

[0049] Figure 3b A top view of the contact surface 18 is shown. It can be seen that the protrusion 16 is formed in a hollow cylindrical shape. The protrusion 16 is integrally formed from the connecting bracket 12, particularly by means of stamping, bending, or similar methods. The connecting bracket 12 is particularly made of copper or a copper alloy, while the flat conductor 2 is particularly made of aluminum or an aluminum alloy. Suitable metal coatings, especially zinc plating, nickel plating, etc., can be applied alternatively or additionally to the flat conductor 2 in the connection area 6 and to the connecting bracket 12 on the contact surface 18.

[0050] In order to connect the connecting bracket 12 to the flat conductor 2, the connecting bracket is inserted into the second through hole 10 with its protrusion 16.

[0051] exist Figure 4 The image shows a top view of the surface 2a of the flat conductor 2. It can be seen that the protrusion 16 is inserted into the second through hole 10.

[0052] exist Figure 5 As can be seen in Figure 4 The image shows a cross-section of the flat conductor 2 in the longitudinal direction. It can be seen that the connecting bracket 12 rests against the flat conductor 2 with its contact surface 18. A protrusion 16 is provided in the second through hole 10. The contact surface 18, in particular, engages with the surface 2b of the flat conductor 2 in a material-fitting manner. This can be achieved, for example, by means of ultrasonic welding, resistance welding, or similar methods.

[0053] It can be seen that the protrusion 16 terminates flush with the surface 2a of the flat conductor 2.

[0054] After the flat conductor 2 is engaged with the connecting bracket 12, a washer 20 or other flat piece is placed on the flat conductor 2 and the protrusion 16. Then, a screw having a screw head 22a and a screw pin 22b is screwed into the component 24. Here, the screw head 22a is pressed against the washer 20, and the washer 20 itself is pressed against the end face of the protrusion 16. The protrusion 16 is subjected to a vertical clamping force, causing the washer 20 to be clamped between the screw head 22a, the protrusion 16, and the flat conductor 2.

[0055] The protrusion 16 accepts compressive force, enabling a long-term stable connection between the flat conductor 2 and the component 24.

[0056] Reference Signs List

[0057] 2 flat conductor

[0058] 4 insulation

[0059] 6 connection region

[0060] 8 first through-hole

[0061] 10 second through-hole

[0062] 12 connection bracket

[0063] 14 through recess

[0064] 16 protrusion

[0065] 18 contact surface

[0066] 20 spacer

[0067] 22 screw

[0068] 24 component

Claims

1. A connecting device, comprising: Metal connecting bracket (12) and A flat conductor of metal (2), which has The cross-sectional profile of at least a quadrilateral and at least two opposing surfaces that extend parallel to each other in the longitudinal direction, at least in one connecting region. A first through hole (8) between the surfaces in the connection area, wherein the first through hole (8) is formed for receiving a pin, At least one second through hole (10) between the surfaces in the connection area, wherein the second through hole (10) forms a connection bracket (12) for receiving metal, wherein The connecting bracket (12) is formed as a flat piece and is attached to one of the surfaces of the flat conductor (2) in the connection area via the contact surface (18). in, The connecting bracket (12) has a first through recess (14) which is arranged aligned with the first through hole (8). The connecting bracket (12) has at least one protrusion (16) that protrudes from the contact surface (18) of the connecting bracket (12), and The protrusion (16) is arranged in the second through hole (10). Its features are, The at least one protrusion (16) extends longitudinally from the contact surface (18), the longitudinal extension being equal to the spacing between the surfaces of the flat conductor (2) in the connection area, and The connecting bracket is connected to the flat conductor material at least through the contact surface.

2. The connecting device according to claim 1, Its features are, The protrusion (16) protrudes substantially vertically from the contact surface.

3. The connecting device according to claim 1 or 2, Its features are, The protrusion (16) is substantially cylindrical or hollow cylindrical.

4. The connecting device according to claim 1, Its features are, The protrusion (16) rests at least partially or completely against the inner circumferential surface of the second through hole (10) with its outer peripheral surface.

5. The connecting device according to claim 4, Its features are, The protrusion (16) and the second through hole (10) have a transition fit or an interference fit.

6. The connecting device according to claim 1, Its features are, The protrusion (16) is integral with the flat conductor (2) and is formed by the flat conductor (2).

7. The connecting device according to claim 1, Its features are, The end face of the protrusion (16) is flush with the surface.

8. The connecting device according to claim 1, Its features are, The number of the second through hole (10) and the protrusion (16) is the same.

9. The connecting device according to claim 1, Its features are, The geometric arrangement of the protrusion (16) around the first through recess (14) is consistent with the geometric arrangement of the second through hole (10) around the first through hole (8).

10. The connecting device according to claim 1, Its features are, At least two second through holes (10) are arranged around the first through hole (8) with an angular spacing between them.

11. The connecting device according to claim 10, Its features are, At least three second through holes (10) are arranged around the first through hole (8) with angular spacing between them.

12. The connecting device according to claim 1, Its features are, The pin is arranged in the first through hole. The second flat member is arranged on the surface of the flat conductor (2) opposite to the connecting bracket (12). The pin has a flanged pin head and a pin shank extending from the pin head. The second flat member is formed to receive the pin rod. The pin is guided through the second flat member, the first through hole (8), and the first through recess (14), and connected to the component such that the second flat member is held in a clamping manner between the pin head and the protrusion.

13. The connecting device according to claim 12, Its features are, The pin is a bolt.

14. The connecting device according to any one of claims 12 or 13, Its features are, The pin presses the second flat piece onto the protrusion (16) when the pin is in the connected state.

15. The connecting device according to claim 1, Its features are, The first through hole (8) and / or the first through recess (14) are formed as a round hole or an elongated hole.

16. A method for connecting a component to a connecting device according to any one of the preceding claims, comprising the following steps: The contact surface (18) of the connecting bracket (12) is arranged on the flat conductor (2), wherein, The at least one protrusion (16) is disposed in the at least one second through hole (10), such that the first through hole (8) and the first through recess (14) are aligned with each other, and wherein the at least one protrusion (16) extends longitudinally from the contact surface (18), the longitudinal extension being equal to the spacing between the surfaces of the flat conductor (2) in the connection area. The contact surface (18) of the connecting bracket (12) is connected to the flat conductor (2) material in a mating manner. The second flat piece is placed against the second through hole (10) on the surface of the flat conductor (2) opposite to the connecting bracket (12) with a perforation. Insert the pin into the eyelet, the first through hole (8) and the first through recess (14) to connect the pin to the component, such that the second flat piece is clamped between the pin and the protrusion.

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