Contact assembly with frictionally engaging contact elements and modular connector

Abstract

The invention relates to a contact assembly for a module connection, wherein the contact assembly comprises a contact element, a busbar and a fastening for fastening the contact assembly to a counterpart of the module connection, the contact element having an introduction opening for insertion of the fastening, a contact portion extending in a tubular manner along the introduction opening and having a contact surface for a counter contact of the module connection, and a collar portion adjoining the contact portion and extending the introduction opening in a sleeve-like manner, wherein the busbar comprises a receiving opening for receiving at least the collar portion, wherein the contact element is configured to be frictionally fixed to the busbar in the receiving opening at a first friction surface, wherein the contact element is configured to be frictionally fixable to the busbar in the receiving opening or to the fastening in the introduction opening at a second friction surface, and wherein the first friction surface and the second friction surface are offset relative to one another at least in a radial direction relative to the introduction opening.

Description

TECHNICAL FIELD

[0001] The present invention relates to an electrically conductive contact assembly for the connection of modules, for example battery modules, for example but not exclusively in the automotive and energy technology sector. Furthermore, the invention relates to a module connector, a connection assembly, a battery cell and a battery module having at least one such contact assembly. BACKGROUND

[0002] In order to transmit electrical currents in the order of magnitude of several hundred amperes between electrical modules, for example battery modules and electric motors or other consumers, busbars made of copper, aluminum or alloys containing copper and / or aluminum are often used in automotive and electrical engineering. In order to be able to connect electrical modules to one another, the busbars are usually provided with contact portions which protrude from the remaining busbar, provide a defined contact surface and are pressed together by means of fastening elements. In this case, the protruding contact portions represent a discontinuity in the shape of the respective busbar, which often leads to challenges in manufacturing.

[0003] If the busbar is manufactured integrally with the contact portion, for example by forging or extrusion, the remaining part of the busbar can usually not be configured completely freely, but is structurally limited, since the entire busbar cannot be manufactured otherwise or can only be manufactured with great effort. In other words, a busbar manufactured integrally is limited in its geometry and therefore cannot have a complex route. Modern battery applications in the field of electromobility, however, require busbars with complex contours in particular, especially since battery modules and electric motors are increasingly distributed in a decentralized manner in vehicles in order to save installation space.

[0004] If the contact portion is welded to the busbar as a previously separate component during the manufacturing process, limitations also arise here, since the weldability must be superior to other properties of the material and structure. This can mean that particularly weight-saving materials or material combinations cannot be used, since they are not suitable for welding. SUMMARY

[0005] The underlying problem of the present invention is therefore to provide a modular connection which can be configured more freely in terms of geometry and material selection and which can therefore be manufactured more easily.

[0006] This problem is solved by an electrically conductive contact assembly for a module connection, wherein the contact assembly comprises a contact element, a busbar and a fastening for fastening the contact assembly to a counterpart of the module connection, which is configured complementary to the fastening, wherein the contact element has an introduction opening for insertion into the fastening, a contact portion which extends in a tubular manner along the introduction opening and has a contact surface for a counterpart contact of the module connection, and a collar portion which adjoins the contact portion and extends the introduction opening in a sleeve-like manner, wherein the busbar comprises a receiving opening for receiving at least the collar portion, wherein the contact element is configured to be frictionally fixed to the busbar in the receiving opening at a first friction surface, wherein the contact element is configured to be frictionally fixable to the busbar in the receiving opening or to the fastening in the introduction opening at a second friction surface, and wherein the first friction surface and the second friction surface are offset relative to each other at least in a radial direction relative to the introduction opening.

[0007] The invention is preferred because the contact portion with the contact surface is provided on the contact element and thus on a component separate from the busbar. The busbar can thus be manufactured completely independently of the contact element with a complex process and then fitted to the contact element. Due to the fixability achieved via the first friction surface, welding together is not necessary, so that the contact element and the busbar can be made of materials which would otherwise not be possible or very difficult to weld. As will be explained in more detail below, the second friction surface, which is radially offset from the first friction surface, is also advantageously used to provide fixability.

[0008] In summary, this means that in the contact assembly according to the invention, the geometry and the choice of materials are not limited or at least less limited than with the busbar welded together or manufactured integrally as described at the beginning. An overall improved manufacturability is thus achieved.

[0009] The invention can be further improved by the following configurations, each of which is advantageous in itself and can be combined with each other as desired.

[0010] According to a first exemplary embodiment, the contact element can have a nickel-containing and / or silver-containing coating in order to improve its contact properties. In particular, the contact element can be completely coated, since the contact element is provided as a separate component before being fixed to the busbar and does not have to withstand the thermal stress of a welding process. This is preferred, in particular because a complete coating can be obtained, for example by means of an electroplating dip process, which eliminates the need for time-consuming sealing and bonding steps, which are necessary in selective coating processes for manufacturing a busbar welded together or manufactured integrally.

[0011] According to another exemplary embodiment, the contact element can be frictionally fixed to the busbar by means of the first friction surface, thereby fitting onto the busbar. Thus, the contact element is advantageously held captive and the manageability of the contact assembly according to the application is increased. For example, the contact element can be configured as a cylindrical contact ring which is at least partially, in particular with the collar portion, frictionally inserted into a receiving opening of the busbar. The contact surface can be formed by an end face of the contact portion facing away from the collar portion and is accessible for the counter contact.

[0012] In order to be able to maintain or repair the module connection, the fastener of the contact assembly is preferably configured to be detachably fixed to a counterpart of the module connection which is complementary to the fastener. Thus, the module connection is preferably a detachable module connection. To this end, the fastener can for example comprise a threaded portion. In particular, the fastener can be configured as a screw having an external thread on the threaded portion. Alternatively, the fastener can be configured as a threaded sleeve having an internal thread on the threaded portion. The counterpart of the module connection which is configured to be complementary to the fastener can in each case have a corresponding mating thread. In this case, the use of a threaded connection is particularly preferred, since it allows an axial force to be exerted which presses the contact surface of the contact element onto the aforementioned counter contact. The surface pressure generated on the contact surface increases the contact force, thereby reducing the contact resistance.

[0013] The fastener can have a support portion which extends radially outward. For example, the support portion can protrude circumferentially from the remaining portion of the fastener in a plate-like manner. The support portion can for example be formed by a screw head of the fastener configured as a screw or by an annular widening of the fastener configured as a threaded sleeve. In the assembled state of the contact assembly, the support portion of the fastener and the contact portion of the contact element are opposite each other with respect to the busbar, so that the accessibility of the contact surface of the contact portion is not restricted.

[0014] The contact element configured as a contact ring can have a circular cross section in the axial direction. This simplifies the insertion process in the receiving opening, since the contact element can be inserted into any rotational position with respect to the busbar. Of course, the contact ring can also have a non-circular cross section at least locally, in particular an oval, elliptical, square, rectangular or polygonal cross section, for example at the collar portion, in order to prevent an unintended twisting of the contact element in the receiving opening.

[0015] To prevent the contact element from being inserted too deep into the receiving opening of the busbar, in addition to the already described frictional connection, the contact element and the busbar can be configured to form at least a one-sided form fit with one another. Preferably, the form fit connection is in the axial direction relative to the introduction opening. To this end, the contact element can have a preferably circumferential shoulder between the contact portion and the collar portion, wherein the contact element abuts against the busbar by means of the shoulder. In particular, the contact portion can have a larger outer diameter than the collar portion, and the shoulder can form a shoulder-like transition between the contact portion and the collar portion.

[0016] To produce the aforementioned one-sided form fit between the contact element and the busbar, the receiving opening of the busbar can optionally have several different inner diameters along its depth. In particular, the receiving opening can have a narrower region with a smaller inner diameter and a wider region with a larger inner diameter. Preferably, the outer diameter of the collar portion is too large relative to the inner diameter dimension of the narrower region, and the outer diameter of the contact portion is too large relative to the inner diameter dimension of the wider region. The busbar can have a step in the receiving opening between the narrower region and the wider region. A step surface of the step facing the wider region forms the transition between the smaller and larger inner diameters. The shoulder of the contact element can rest on this step surface. To this end, the receiving opening can be configured as a stepped bore, for example, appropriately dimensioned.

[0017] In this embodiment with a stepped receiving opening, at least a portion of the contact portion can also be received in the receiving opening in addition to the collar portion. This produces an increased contact area between the contact element and the busbar, in particular if, as already mentioned, the outer diameter of the contact portion is larger than the outer diameter of the collar portion. Advantageously, this provides a large conductor cross section for current transmission. Furthermore, the contact element can thus also be secured to the busbar with a second friction surface. In other words, both the first and the second friction surfaces can be formed on the outer surface of the contact element and serve to provide a frictional connection between the contact element and the busbar. Preferably, the first and the second friction surfaces are offset from one another in the axial direction relative to the introduction opening and are arranged coaxially. In particular, the first friction surface can be arranged on the collar portion, and the second friction surface can be arranged on the contact portion. The shoulder of the contact element can be located between the first and the second friction surfaces.

[0018] Optionally, the receiving opening of the busbar can have at least one material recess in its periphery. In particular, the at least one material recess can be located on the circumference of the wider region of the stepped receiving opening. The at least one material recess advantageously increases the local deformability of the busbar, so that the fitting of the contact element and the busbar can be achieved with less force.

[0019] The at least one material recess can for example be formed by a recess extending on the inner surface of the receiving opening in axial and radial direction relative to the receiving opening. Preferably, the recess extends through or flush with the step surface of the receiving opening. For example, the at least one material recess can be formed by an axial bore and / or a radial notch. The axial bore is preferably created before the step bore, while the radial notch can be milled after the step bore has been created. Optionally, the receiving opening can have several such material recesses distributed around its circumference. Advantageously, this allows for a visual or measuring check to determine whether the shoulder of the contact element is actually resting completely on the step surface of the receiving opening. In particular, it can thus be excluded that dust, debris or other contaminants are unintentionally included between the step of the receiving opening and the shoulder of the contact element.

[0020] As an alternative to the stepped receiving opening, the receiving opening can also merely have a continuously constant inner diameter along its depth, wherein the outer diameter of the collar portion has an oversize relative to this constant inner diameter. The contact element having the second friction surface can instead be fixed to the fastener, rather than to the busbar. Thus, the first friction surface can be formed on an outer surface of the contact element, and the second friction surface can be formed on an inner surface of the contact element. In particular, the second friction surface can serve to fix the contact element and the fastener to each other, in particular in a rotationally fixed manner. This embodiment is for example preferred if a twist receiving portion is required on the fastener.

[0021] The method of assembling a contact assembly according to the application also solves the basic problem introduced above, wherein the method comprises the steps of providing a contact element, a busbar and a fastener, frictionally locking the contact element at a first surface to the busbar, and frictionally locking the contact element at a second friction surface to the busbar or the fastener. In particular, the last two method steps of frictionally fixing can be performed successively or simultaneously. A mounting machine configured to perform the above method, preferably automatically, in particular fully automatically, also solves the underlying problem introduced above.

[0022] In embodiments of the contact assembly with a stepped receiving opening of the busbar, the outer diameter of the support portion of the fastener is at least larger than the smaller inner diameter of the stepped receiving opening. In embodiments with a constant receiving opening, the outer diameter of the support portion is larger than the inner diameter of the constant receiving opening. Thus, the fastener with the support portion can rest circumferentially on the busbar. Preferably, the support portion is arranged opposite to the threaded portion, wherein the distance between the threaded portion and the support portion is larger than the length of the receiving opening of the busbar.

[0023] Thus, when the threaded portion of the fastener is inserted into the introduction opening of the contact element accommodated in the receiving opening of the busbar, the fastener can rest on the busbar at the opposite side relative to the threaded portion. The support portion thus provides a support surface for the fastener, which is specifically configured as a screw or a threaded sleeve. This support surface is advantageously used to transmit the axial force already mentioned above, which is transmitted from the busbar via the shoulder to the contact element and thus can act as a surface pressure on the contact surface.

[0024] According to another possible embodiment, the collar portion can have the same length as the receiving opening of the busbar. In other words, the height of the collar portion measured in axial direction relative to the introduction opening can correspond to the length of the receiving opening. Thus, the collar portion is flush with the busbar over its circumference, and the support portion of the fastener can rest on the busbar and the collar portion. This embodiment provides the fastener with enhanced support stability and is particularly suitable for low thermal load applications or when the busbar and the contact element are made of the same material or at least have similar coefficients of thermal expansion, such that the flush fit between the busbar and the collar portion is not disturbed by the thermal expansion of the components.

[0025] For applications with expected high thermal loads and / or strongly varying thermal expansion behavior, the collar portion can alternatively be configured shorter than the receiving opening of the busbar. In other words, the height of the collar portion measured in axial direction relative to the introduction opening can be smaller than the length of the receiving opening. This ensures, among other things, that the collar portion does not protrude on the outside from the receiving opening of the busbar and thus ensures that the support portion of the fastener rests only on the busbar. In particular, this creates a gap between the collar portion of the contact element and the support portion of the fastener. This gap is preferred in two respects:

[0026] On the one hand, if the contact element expands thermally more than the busbar and the fastener during operational heating, the gap can serve to prevent the collar portion from protruding from the receiving opening and the fastener from coming loose from the busbar.

[0027] On the other hand, due to the gap between the shoulder of the contact element and the support portion of the fastener, the busbar can be clamped. In the case of a greater thermal expansion of the busbar than of the contact element and the fastener, the frictional connection between the busbar and the contact element will be offset, in particular because the increase in the outer diameter of the collar portion cannot compensate for the increase in the inner diameter of the receiving opening. Above a certain thermal expansion, the excessive size of the outer diameter relative to the inner diameter required for the frictional connection will no longer exist. However, the fixation and contact of the contact element to the busbar will continue, as the thermal expansion of the busbar will also inevitably lead to an increase in said clamping.

[0028] In order to intensify the frictional connection between the contact element and the fastening element, the fastening element can have a knurled portion. The knurled portion is preferably arranged between the threaded portion and the support portion and is oversized with respect to the introduction opening of the contact element. For example, the knurled portion can have ribs which project radially, extend axially and are distributed in the circumferential direction on the knurled portion. In particular, the knurled portion can have axially parallel serrations. The knurled portion can be produced by knurling a rotationally symmetrical portion of the fastening element, however, the knurled portion is not limited to a circular cross section, but can also produce a non-circular cross section, in particular an oval, elliptical, square, rectangular or polygonal cross section, by other shaping processes, such as stamping, machining processes, such as milling, and / or one-off shaping processes, such as casting, wherein a surface structure is obtained as in knurling.

[0029] The oversize of the knurled portion is optionally selected such that, after insertion of the fastening element into the introduction opening, the collar portion of the contact element is deformed, in particular plastically deformed, by the knurled portion. Since this deformation, which depends on the material thickness of the collar portion, also affects the outer surface of the collar portion which forms the first friction surface, the knurled portion can also serve to intensify the frictional connection between the contact element and the busbar.

[0030] According to another possible embodiment, the knurled portion is shorter than the receiving opening of the busbar. In other words, the knurled length, measured in the axial direction, is smaller than the material thickness of the busbar around the receiving opening. Preferably, the knurled portion is also shorter than the collar portion of the contact element, however, the knurled portion and the collar portion together are longer than the receiving opening. Thus, when the knurled portion is inserted, the collar portion of the contact element does not deform over its entire height, but only in the region facing away from the contact portion. In particular, the collar portion widens in a conical or wedge-shaped shape. Depending on the deformability of the busbar, the collar portion can expand radially in the receiving opening like a pin and generate an increased frictional connection and, in some cases, a form fit between the inner surface of the receiving opening and the deformed collar portion.

[0031] If a torsion accommodation is inconvenient, or if the torsion accommodation is arranged in the mating portion of the fastening means, the fastening means itself can also be arranged rotatably, preferably freely rotatably, in the introduction opening of the contact element. This rotatability allows and simplifies the formation of the above-mentioned threaded connection by means of the fastening element.

[0032] The receiving opening can be located in particular in an end portion of the busbar. Furthermore, the busbar can have at least one further end portion in which a further receiving opening is optionally arranged. Thus, the contact assembly can have at least one further contact element which is fixed in this further receiving opening.

[0033] The busbar can be a busbar extending between at least two electrical modules or a busbar segment being part of an electrical module. The busbar segment is preferably in electrically conductive connection with an electrode or an electrical pole of the electrical module, thereby forming a connection of the electrical module. In the case of a busbar, as already mentioned, the contact assembly according to the application can have at least one further contact element. Accordingly, at least one further receiving opening for the contact element of the contact assembly according to the application can be provided on the busbar. In particular, the busbar can have a receiving opening for the contact element of the contact assembly according to the application for each electrical module connected therewith.

[0034] The basic problem introduced at the outset can also be solved by a module connector having at least one contact assembly and a contact protection housing according to the application, wherein the contact protection housing is configured to accommodate the at least one contact assembly. Here, the modular connector according to the application benefits from the advantages of the contact assembly already mentioned. In particular, the increased constructional freedom with regard to the geometry and the choice of materials contributes to an improved manufacturability of the entire modular connector. Furthermore, the module connector according to the application is characterized by an increased electrical safety. This greatly expands the possible field of application.

[0035] The contact protection housing is preferably made of an electrically insulating material. Optionally, the contact protection housing can have at least one contact protection cap arranged on the fastening element. This at least one contact protection cap can for example surround the support portion of the fastening element. Alternatively or additionally, a further contact protection cap can be connected to the threaded portion of the fastening element. The introduction opening of the contact element can be configured at least partially to accommodate a counterpart complementary to the fastening element, in particular a counterpart having a contact protection cap complementary thereto. For this purpose, the inner contour of the introduction opening can be larger than the outer contour of the contact protection cap of the counterpart.

[0036] The connection assembly having two or more contact assemblies, each having a complementary fastening element, also solves the above-mentioned problems. The advantages already mentioned above are also utilized in the connection assembly according to the application. Furthermore, the connection assembly according to the application can be used directly for establishing a module connection. For this purpose, the contact elements of the two contact assemblies are frictionally secured to the respective busbars with their contact surfaces pressed against each other and held together by the fastening elements, which are configured in a complementary manner to each other.

[0037] The battery cell having at least one battery terminal configured as a contact assembly according to the application also benefits from the advantages already mentioned above and solves the potential problems mentioned in the introduction due to the resulting improvement in manufacturability. The battery cell can further comprise at least one electrode, wherein the busbar of the battery terminal configured as a contact assembly is in electrically conductive connection with the at least one electrode.

[0038] For reasons of electrical safety, the connection assembly according to the application can optionally comprise two contact protection housings, each of which is configured to accommodate a contact assembly. The battery cell according to the application can also have a contact protection housing for the at least one battery terminal.

[0039] The basic problem introduced above is also solved by a battery module having at least one battery cell according to the application and at least one module connector according to the application, wherein the fastening of the battery terminal of the battery cell configured as a contact assembly is configured to be complementary to the fastening of the contact assembly of the module connector. The battery module according to the application can be connected to further battery modules and / or to a consumer unit.

[0040] Of course, the battery cell can also have two battery terminals, each of which is configured like a contact assembly according to the application. Thus, the battery cell can have two electrodes, wherein one busbar of each of the contact assemblies is in each case in electrically conductive connection with one electrode. Furthermore, the battery module can also have a plurality of battery cells and a plurality of module connectors, the fastenings of which are respectively configured in pairs to be complementary to one another. BRIEF DESCRIPTION OF DRAWINGS

[0041] In the following, the application is explained in more detail by means of a few exemplary embodiments with reference to the drawings, the individual features of which can be combined with one another as desired in accordance with the above explanations. In particular, individual features can be added to the described embodiments in accordance with the above explanations if the effect of the individual features is necessary for a particular application. Conversely, individual features can be omitted from the described embodiments if the technical effect of these features is not important in a particular application. In the drawings, similar, identical and functionally identical elements are given, where appropriate, the same reference signs.

[0042] In the drawings:

[0043] Figure 1 A schematic perspective exploded view of a contact assembly according to a first exemplary embodiment is shown;

[0044] Figure 2 A schematic perspective view of the rear side of a contact assembly according to Figure 1 is shown;

[0045] Figure 3 A schematic perspective cross-sectional view of a contact assembly according to a second exemplary embodiment is shown in exploded view;

[0046] Figure 4 A schematic perspective view of the rear side of a contact assembly according to Figure 3 is shown;

[0047] Figure 5a schematic perspective view of a contact assembly according to a third exemplary embodiment; and

[0048] Figure 6 a schematic cross-sectional view of a connection assembly according to an exemplary embodiment. DETAILED DESCRIPTION

[0049] Based on Figures 1 to 5 the exemplary embodiments described below, a schematic structure of a contact assembly 1 according to the present application is described. Furthermore, reference is made to Figure 6 a schematic structure of a connection assembly 2 according to the present application is briefly explained.

[0050] As can be taken from Figure 1 the contact assembly 1 in the exemplary embodiments comprises a contact element 4, a busbar 6 and a fastener 8. The contact element 4 and the busbar 6 can be provided as separate parts (see Figure 1 and can be frictionally fitted together (see Figure 2 ) as will be explained in more detail below. As a result, the contact element 4 can be completely coated with a nickel- and / or silver-containing coating.

[0051] The contact element 4 comprises an introduction opening 10 for the insertion of the fastener 8. Along the introduction opening 10, a contact portion 12 of the contact element 4 extends in a tubular manner. A collar portion 14 of the contact element 4 adjoins the contact portion 12 and extends the introduction opening 10 in a sleeve-like manner.

[0052] The busbar 6 has a receiving opening 16 for receiving at least the collar portion 14. The receiving opening 16 is located, for example, in an end portion 18 of the busbar 6. The busbar 6 can be a busbar extending between at least two electrical modules (not shown) or a busbar segment being part of an electrical module.

[0053] The fastener 8 serves to fasten the contact assembly 1 to a counterpart 20 (see Figure 3 ) which is complementary to the fastener 8. The fastener 8 can also be frictionally fitted to the contact element 4 (see Figure 2 ) or freely rotatably arranged in the introduction opening 10 of the contact element 4.

[0054] In the exemplary embodiments shown in Figure 1 and 2 the fastener 8 of the contact assembly 1 is configured as a threaded sleeve 22 having an inner thread 24. The inner thread 24 is located on a threaded portion 26 of the fastener 8. In Figure 3 the fastener 8 is shown as a screw 28 having an outer thread 30 on the threaded portion 26. In Figure 4 and 5 in each case, the contact assembly 1 is shown without a fastener.

[0055] In all embodiments shown, the fastener 8 has a support portion 32 extending radially outward, wherein the support portion 32 protrudes circumferentially from the rest of the fastener 8 in a plate-like manner. In Figure 1 and 2 the fastener 8 is configured as a threaded sleeve 22, the support portion 32 is formed by an annular widening 34. Figure 3 The fastener 8 of Fig. 3 is configured as a screw 28 having a screw head 36 forming the support portion 32. In the assembled state of the contact assembly 1, the support portion 32 is located opposite the contact portion 12 of the contact element 4 with respect to the busbar 6 (see Figure 2 ). Furthermore, the support portion 32 is located outside the busbar 6 with respect to the threaded portion 26 of the fastener 8 when the threaded portion 26 of the fastener 8 is inserted into the through-hole 10 of the contact element 4 accommodated in the receiving opening 16 of the busbar 6.

[0056] The receiving opening 16 can have a continuously constant inner diameter 38 along its depth, wherein the outer diameter 40 of the collar portion 14 has an oversized dimension with respect to this constant inner diameter 38. In particular, the contact element 4 is configured to be frictionally fixed to the busbar 6 in the receiving opening 16 at a first friction surface 42. The first friction surface 42 is arranged on an outer surface 44 of the collar portion 14. In Figure 2 , the contact element 4 is frictionally fixed to the busbar 6 by means of the first friction surface 42 and thus appears to be in a state of being connected to the busbar 6. In the exemplary embodiment shown, the contact element 4 is configured as a cylindrical contact ring 46 which is frictionally inserted into the receiving opening 16 of the busbar 6 by means of the collar portion 14. On an end face 48 of the contact portion 12 facing away from the collar portion 14, the contact element 4 has a contact surface 50 for a counter contact 52 (see Figure 3 ).

[0057] Figure 1 The contact ring 46 shown has a circular cross section 54 in an axial direction 64 with respect to the introduction opening 10. Alternatively, the contact ring 46 can also have at least locally a non-circular cross section (not shown), in particular an oval, elliptical, square, rectangular or polygonal cross section, for example at the collar portion 14.

[0058] Figure 2 It is shown that the collar portion 14 is shorter than the receiving opening 16 of the busbar 6. That is, a height 56 of the collar portion 14 measured in the axial direction 64 with respect to the introduction opening 10 is smaller than a length 58 of the receiving opening 16. In order to compensate for the thermal expansion process, an annular gap 60 is provided between the collar portion 14 of the contact element 4 and the support portion 32 of the fastener 8 in the assembled state of the contact assembly 1.

[0059] Alternatively, the collar portion 14 can also be configured to the same length as the receiving opening 16 of the busbar 6. This means that in the connected state, the collar portion 14 is flush with the busbar 6 (see Figure 4 ) and together with the busbar 6 provides the support portion 32 of the fastener 8 with the largest possible support surface.

[0060] Figure 2 It is also shown that the contact element 4 and the busbar 6 additionally form a form fit 62 in the axial direction 64 at least on one side. To this end, the contact element 4 has a circumferential shoulder 66 between the contact portion 12 and the collar portion 14, against which the contact element 4 abuts against the busbar 6. The contact portion 12 has a larger outer diameter 68 (see Figure 1 ) than the collar portion 14, the shoulder 66 forming a shoulder-like transition between the contact portion 12 and the collar portion 14. The busbar 6 can thus be clamped between the contact element 4 and the fastener 8, in particular between the shoulder 66 and the support portion 32.

[0061] Furthermore, Figure 1 The contact element 4 of the contact assembly 1 shown is configured to be frictionally secured to the fastener 8 at a second friction surface 70 in the introduction opening 10, i.e. at an inner surface 71 of the contact element 4. The first friction surface 42 and the second friction surface 70 are offset from one another in a radial direction 72 with respect to the introduction opening 10. Figure 2 The contact element 4 is shown frictionally secured to the second friction surface 70 on the fastener 8. In particular, the contact element 4 and the fastener 8 are fixed to one another in a rotationally fixed manner.

[0062] In Figure 1 and 2 the embodiment shown, the frictional connection between the contact element 4 and the fastener 8 is reinforced by a knurled portion 74 on the fastener 8. This knurled portion 74 has an oversized dimension with respect to the introduction opening 10 of the contact element 4. In the exemplary embodiment shown, the knurled portion 74 has radially protruding, axially extending ribs 76, which are distributed over the knurled portion 74 in a circumferential direction 78. In particular, the knurled portion 74 here has saw teeth 80 parallel to the axis.

[0063] Furthermore, the oversize dimension of the knurled portion 74 is selected such that, after insertion of the fastener 8 into the introduction opening 10, the collar portion 14 is plastically deformed by the knurled portion 74. This deformation affects the outer surface 44 of the collar portion 14 (see Figure 2 ), thus also reinforcing the frictional connection between the contact element 4 and the busbar 6.

[0064] As Figure 2As shown, the knurled portion 74 is shorter than the receiving opening 16 of the busbar 6. That is, the knurled length 82 measured in the axial direction 64 is less than the material thickness 84 of the busbar 6 surrounding the receiving opening 16. Furthermore, the knurled portion 74 is also shorter than the collar portion 14 of the contact element 4; however, the knurled portion 74 and the collar portion 14 together are longer than the receiving opening 16. This ensures that the knurled portion 74 extends to the collar portion 14 when the contact element 4 and the fastener 8 are inserted into the receiving opening 16 from opposite sides of the busbar 6. The region 86 of the collar portion 14 facing away from the contact portion 12 thus widens in a tapered shape and expands in the receiving opening 16 in a manner similar to a pin (see...). Figure 2 Thus, a form fit is formed between the inner surface 120 of the receiving opening 16 and the deformable region 86 of the collar portion 14.

[0065] Figure 3 The contact element 4 of the contact assembly 1 shown is configured to be fixed to the busbar 6 via a second friction surface 70, rather than to a fastener 8. For this purpose, the receiving opening 16 of the busbar 6 has two different inner diameters 90 and 94 along its depth. Specifically, the receiving opening 16 has a narrower region 88 with a smaller inner diameter 90 and a wider region 92 with a larger inner diameter 94. The outer diameter 40 of the collar portion 14 is excessively large relative to the inner diameter 90 of the narrower region 88, while the outer diameter 68 of the contact portion 12 is excessively large relative to the inner diameter 94 of the wider region 92.

[0066] In the receiving opening 16, the busbar 6 has a step 96 between the narrower region 88 and the wider region 92. The shoulder 66 of the contact element 4 can rest flat on this step 96 (see...). Figure 5 The step surface 98 of step 96 facing the wider region 92 forms a transition between a smaller inner diameter 90 and a larger inner diameter 94. The receiving opening 16 is configured as a correspondingly sized stepped hole 100.

[0067] like Figure 5 As shown, in this embodiment, in addition to the collar portion 14, at least a portion of the contact portion 12 may also be received in the receiving opening 16 of the busbar 6, wherein the second friction surface 70 is offset from the first friction surface 42 in the axial direction 64 and is formed by the outer surface 101 of the contact portion 12.

[0068] By means of a material recess 104 configured as a radial notch 102 (see Figure 5 This verifies that the shoulder 66 of the contact element 4 actually extends to the stepped surface 98. Furthermore, the material recess 104 makes the end portion 18 of the busbar 6 more easily deformable, allowing the engagement of the contact element 4 and the busbar 6 to be achieved with less force. As an alternative to the notch 102, the axial aperture 106 can also form the material recess 104. This allows for…Figure 3 and Figure 4 are seen in which several axial bores 106 are distributed around the circumference 108 of the wider region 92 of the stepped bore 100.

[0069] For facilitating the mutual insertion, the contact elements 4, the busbars 6 and / or the fasteners 8 can have insertion bevels 110 (see Figure 1 ).

[0070] Figure 2 The contact assembly 1' of Figure 3 together with the contact assembly 1" of Figure 6 form a connection assembly 2. In particular, the fasteners 8' of the contact assembly 1' are configured to be complementary to the fasteners 8" of the contact assembly 1". In other words, the fasteners 8" represent the counterparts 20 of the fasteners 8', and vice versa. For this purpose, the fasteners 8' have inner threads 24 and the fasteners 8" have corresponding counter threads as outer threads 30. The contact surfaces 50', 50" of the contact elements 4', 4" are in face-to-face contact and are pressed together by the fasteners 8', 8".

[0071] Furthermore, the connection assembly 2 has respective contact protection housings 112', 112" for the contact assemblies 1', 1". As part of the respective contact protection housings 112', 112", the fasteners 8', 8" have contact protection caps 114', 114".

[0072] According to the application, Figure 6 the contact assembly 1' shown can represent a battery terminal 116 of a battery cell (not shown), wherein the busbar 6' is conductively connected to an electrode (not shown) of the battery cell. Figure 6 The contact assembly 1" shown together with the contact protection housing 112" can also represent a module connector 118 according to the application. The module connector 118 can form, together with the just mentioned battery cell, a battery module (not shown) which can be connected via the busbars 6', 6" to further battery modules (not shown) and / or to a consumer unit (not shown).

[0073] Reference signs

[0074] 1, 1', 1" contact assembly

[0075] 2 connection assembly

[0076] 4, 4', 4" contact element

[0077] 6, 6', 6" busbar

[0078] 8, 8', 8" fastener

[0079] 10 introduction opening

[0080] 12 contact portion

[0081] 14 collar portion

[0082] 16 receiving opening

[0083] 18 end portion

[0084] 20 counterpart

[0085] 22 threaded sleeve

[0086] 24 internal thread

[0087] 26 threaded portion

[0088] 28 screw

[0089] 30 external thread

[0090] 32 support portion

[0091] 34 widening

[0092] 36 screw head

[0093] 38 inner diameter

[0094] 40 outer diameter

[0095] 42 first friction surface

[0096] 44 outer surface

[0097] 46 contact ring

[0098] 48 end face

[0099] 50, 50', 50" contact surface

[0100] 52 counterpart contact

[0101] 54 cross section

[0102] 56 height

[0103] 58 length

[0104] 60 gap

[0105] 62 form fit

[0106] 64 axial direction

[0107] 66 shoulder

[0108] 68 outer diameter

[0109] 70 second friction surface

[0110] 71 inner surface

[0111] 72 radial direction

[0112] 74 knurl portion

[0113] 76 rib

[0114] 78 circumferential direction

[0115] 80 sawtooth

[0116] 82 knurl length

[0117] 84 material thickness

[0118] 86 region

[0119] 88 region

[0120] 90 inner diameter

[0121] 92 region

[0122] 94 inner diameter

[0123] 96 step

[0124] 98 step surface

[0125] 100 step bore

[0126] 101 outer surface

[0127] 102 notch

[0128] 104 material recess

[0129] 106 axial bore

[0130] 108 circumference

[0131] 110 insertion bevel

[0132] 112', 112" contact protection housing

[0133] 114', 114" contact protection cap

[0134] 116 battery terminal

[0135] 118 module connector

[0136] 120 inner surface

Claims

1. A conductive contact assembly (1, 1', 1") for module connection, wherein the contact assembly (1, 1', 1") includes contact elements (4, 4', 4"), busbars (6, 6', 6"), and fasteners (8, 8', 8"), the fasteners being used to secure the contact assembly (1) to a mating element (20) of the module connection, the mating element being complementary to the fasteners (8, 8', 8"), in, The contact element (4, 4', 4") includes: an inlet opening (10) for inserting the fastener (8, 8', 8"); a contact portion (12) extending tubularly along the inlet opening (10) and having contact surfaces (50, 50', 50") for mating contacts (52) for module connection; and a collar portion (14) connected to the contact portion (12) and extending sleeve-likely from the inlet opening (10). The busbar (6, 6', 6") includes a receiving opening (16) for receiving at least the collar portion (14). The contact element (4, 4', 4") is configured to be fixed to the busbar (6, 6', 6") in the receiving opening (16) at the first friction surface (42) by frictional engagement. The contact element (4, 4', 4") is configured to be fixed at the second friction surface (70) in the receiving opening (16) to the busbar (6, 6") or in the inlet opening (10) to the fastener (8, 8'). Furthermore, the first friction surface (42) and the second friction surface (70) are offset from each other at least in the radial direction (72) with respect to the introduction opening (10).

2. The contact assembly (1, 1', 1") according to claim 1, wherein, The contact element (4, 4', 4") includes a shoulder (66) between the contact portion (12) and the collar portion (14), and wherein the contact element (4) abuts the busbar (6, 6', 6") through the shoulder (66).

3. The contact assembly (1, 1', 1") according to claim 1 or 2, wherein, The fastener (8, 8', 8") includes a threaded portion (26) and is configured as a screw (28) having an external thread (30) on the threaded portion (26) or as a threaded sleeve (22) having an internal thread (24) on the threaded portion (26).

4. The contact assembly (1, 1', 1") according to claim 1 or 2, wherein, The fastener (8, 8', 8") includes a radially outwardly extending support portion (32), wherein the fastener (8, 8', 8") rests on the busbar (6) via the support portion (32).

5. The contact assembly (1, 1', 1") according to claim 1 or 2, wherein, The collar portion (14) is shorter than the receiving opening (16) of the busbar (6, 6', 6").

6. The contact assembly (1, 1', 1") according to claim 1 or 2, wherein, The fastener (8, 8') includes a knurled portion (74), wherein, after the fastener (8, 8') is inserted into the inlet opening (10), the collar portion (14) of the contact element (4, 4') is deformed by the knurled portion (74).

7. The contact assembly (1, 1', 1") according to claim 6, wherein, The knurled portion (74) is shorter than the receiving opening (16) of the busbar (6, 6').

8. The contact assembly (1, 1', 1") according to claim 1 or 2, wherein, The fastener (8, 8) is rotatably arranged in the inlet opening (10) of the contact element (4, 4).

9. The contact assembly (1, 1', 1") according to claim 1 or 2, wherein, The receiving opening (16) of the busbar (6, 6', 6") is configured as a stepped hole (100).

10. The contact assembly (1, 1', 1") according to claim 1 or 2, wherein, The receiving opening (16) of the busbar (6, 6', 6") has at least one material recess (104) on the circumference (108).

11. The contact assembly (1, 1', 1") according to claim 1 or 2, wherein, The first friction surface (42) is formed on the outer surface (44) of the collar portion (14) of the contact element (4, 4', 4"), and wherein the second friction surface (70) is formed on the outer surface (101) of the contact portion (12) of the contact element (4, 4") or on the inner surface (71) of the contact element (4, 4').

12. A module connector (118) comprising at least one contact assembly (1, 1″) according to any one of claims 1 to 11, and comprising a contact protective housing (112″), wherein, The contact protective housing (112″) is configured to receive at least one contact component (1, 1″).

13. A connecting assembly (2) having two contact assemblies (1, 1', 11") according to any one of claims 1 to 11, wherein, The corresponding fasteners (8, 8', 8") of the two contact components (1, 1', 11") are constructed to be complementary to each other.

14. A battery cell having at least one battery terminal (116) and at least one electrode, wherein the at least one battery terminal is configured as a contact assembly (1, 1') according to any one of claims 1 to 11, and wherein, The busbars (6, 6') of the contact assembly (1, 1') are electrically connected to at least one electrode of the battery cell.

15. A battery module having at least one battery cell according to claim 14 and at least one module connector (118) according to claim 12, wherein, The fasteners (8, 8') of the battery terminals (116) of the battery cell, which are configured as contact components (1, 1'), are configured to be complementary to the fasteners (8, 8") of the contact components (1, 1") of the module connector (118).

Images