Method for material-lockingly contact-connecting components in an electrical system, energy storage unit and use of its energy

Abstract

A method for material-locking contact connection of components in an electrical system, the method comprising the steps of: - providing a plurality of components, wherein the components have contact elements for electrical contact connection; - connecting the component contacts through the contact elements to generate a current path; - generating a current in the current path for material-locking connection of the contact elements by heat generated therethere.

Description

Technical Field

[0001] This invention relates to a method for material-locking ground contacts to connect components in an electrical system, an energy storage unit, and the application of energy from the energy storage unit. Background Technology

[0002] It is generally known that, for example, two electrical conductors can be screwed together to make contact. To reduce contact resistance at the contact points, a preferred method of material locking, such as brazing, is to make the contacts or connect them. For high-voltage storage devices, such as those used in partially or fully electrified motor vehicles, this means that the cables or module connectors used to connect the various battery modules are often too large to keep the contact resistance at their contact points as small as possible and to keep heat dissipation within limits. However, material locking at all contact points, for example by brazing, becomes costly and therefore expensive in mass production. This makes the accessibility of the brazing or contact points a problem. Summary of the Invention

[0003] Therefore, the objective of this invention is to provide a method for material-locking contact connection of components in an electrical system, an energy storage unit, and an application of energy from the energy storage unit, wherein known methods or schemes for material-locking contact connection should be optimized and simplified.

[0004] This task is accomplished by the method for connecting components in an electrical system using material-locking ground contacts according to the invention, by the energy storage unit according to the invention, and by the application according to the invention.

[0005] According to the present invention, a method for connecting components in an electrical / electronic system using material-locking ground contacts includes the steps of:

[0006] - Provides multiple components, wherein the components have contact elements for electrical contact connection;

[0007] - The component contacts are connected via the contact element to generate a current path;

[0008] - A current is generated in the current path to be used to lock the contact element in place by a thermal material generated there.

[0009] Advantageously, current is generated in the current path in such a way that the contact elements are materially locked at the contact positions by the heat or thermal energy generated there. That is, the aforementioned "contact closure of the component" is particularly understood as the pre-positioning or pre-contact closure of the component. This contact closure should be implemented such that the components are fully connected so that a current path can be formed in general, or current can be allowed to pass through. By introducing energy into the current path to generate current, the pre-positioned or pre-contact closed contact positions are automatically material-locked. Here, the loss generated by the contact resistance present at the contact positions leads to heat dissipation, which is advantageously used to generate the material-locked connection.

[0010] Preferably, a corresponding medium is provided at the contact position, which enables or assists in the formation of a material-locking connection. Typically, for example, brazing material is provided at the contact position.

[0011] Energy can be introduced from the outside or through components that are part of the electrical system. For example, a resistor is used to control / regulate the current.

[0012] In a preferred embodiment, at least one component is an energy storage unit, particularly an electric energy storage device. The method preferably includes the following steps:

[0013] - Introduce (load) resistance, especially electronic load, into the current path;

[0014] - The energy storage device is used to generate current.

[0015] The electronic load is an instrument or structural assembly that can be used as a spare for a conventional load resistor. The current in the current path can be adjusted to a desired level via the resistor, or electronic load.

[0016] Advantageously, the energy storage unit, or the electric energy storage device that is itself a component of the electrical system, is used to connect the contacts of the electrical system. That is, it is advantageous to apply the energy for brazing through the electric energy storage device itself.

[0017] Alternatively, the energy can also be introduced into the current path via an external energy source, i.e., the external energy source is not part of the electrical system to be connected by the contacts. The main advantage of this method is also retained here: the individual contact positions do not require sequential material-locking or brazing of the contacts; instead, this is done directly and simultaneously in a single method step.

[0018] In one embodiment, the energy storage device is charged when energy is introduced through an external energy source.

[0019] According to a particularly preferred embodiment, the method includes the steps of:

[0020] - Offers multiple battery modules;

[0021] - The battery module is connected to the high-voltage storage contact via a power cable, wherein the high-voltage storage forms a current path;

[0022] - By means of the high-voltage memory, current is generated in the current path such that the power cable is brazed at the contact point.

[0023] Therefore, the components currently in particular include battery modules and power cables or module connectors that provide connections or contact points for the battery modules. These module connectors or power cables are typically copper cables or metal and / or copper busbars. These module connectors or power cables can currently be advantageously sized significantly smaller because the contact resistance at the contact points is low due to the material-locked connection. This saves structural space, weight, and cost.

[0024] According to one embodiment, the method includes the steps of:

[0025] - To connect the contact elements to form-locking and / or force-locking contacts.

[0026] The contact closure of the form-locking and / or force-locking contacts is suitably designed such that the contact elements are fully closed so that a current path can be formed in general.

[0027] According to one embodiment, the method includes the steps of:

[0028] - A clamping force is applied by a clamping device to make the contacts of at least two contact elements connected.

[0029] Such a clamping device can, for example, connect two contact elements, i.e., a contact position, to each other, especially temporarily. Suitably, a material-locking connection is then formed, or the clamping device is removed after the material-locking connection is formed. Advantageously, the clamping device is configured such that multiple contact positions can be connected or pre-connected, thereby significantly reducing costs.

[0030] According to one embodiment, the method includes the steps of:

[0031] -In particular, prestress is applied to at least one contact element by deformation to enable force-locked contact closure.

[0032] Suitably, whenever possible, the suitably constructed component is at least partially deformed to induce, for example, (pre)stress, which can be used to achieve contact closure by force-locking between two contact elements or components. This approach is particularly effective when the component is a conductor in the form of a tab or similar material.

[0033] According to one embodiment, the method includes the steps of:

[0034] - Provide soldering material on the contact elements.

[0035] As already mentioned, brazing materials are used, in particular, for material-locking connections. That is, the material-locking connection is understood, in particular, as a brazing method. The melting point of brazing materials is typically between 180°C and 260°C. To achieve this temperature at the contact point, the current in the current path is adjusted accordingly for a short time. Suitablely, the material-locking connection is made over the thermal durability load of the component, particularly a module connector or power cable.

[0036] According to one embodiment, the method includes the steps of:

[0037] - Especially by using adhesives to lock the contact points of the component materials together.

[0038] In one embodiment, an adhesive is provided at the contact location to pre-connect or pre-position the contact element.

[0039] According to one embodiment, the method includes the steps of:

[0040] - Embed the brazing material into the adhesive.

[0041] In one embodiment, the corresponding material mixture can be applied to at least one component of the assembly or at least one contact element of the contact element.

[0042] In one embodiment, at least one contact element has a solder pouch or is configured to have such a solder pouch. The solder pouch is suitably configured to provide solder deposits, i.e., a certain amount of solder material, required for subsequent connection. The solder pouch can also be configured such that identically configured contact elements can be provided in a form-locking and / or force-locking manner, or particularly inserted, for pre-contact engagement. In one embodiment, the solder pouch is configured as a gap, recess, opening, or hole in the corresponding component or in the corresponding contact element. Suitably, the component is further configured as a power cable, wherein the power cable end is configured with a solder pouch.

[0043] As a further alternative, the pre-contact engagement for form-locking and / or force-locking can also use a fastening mechanism, such as a screw, which can be left in the contact position or removed again.

[0044] According to one embodiment, the method includes the steps of: adjusting, in particular increasing, the contact resistance at the contact position of at least two contact elements, especially by introducing a corresponding material into or onto the contact position.

[0045] The aforementioned materials are suitably selected such that the contact resistance is modified, particularly increased, to specifically achieve heat dissipation for forming a material-locked connection. Alternatively, the contact resistance can be specifically achieved by partially or completely withdrawing material from the conductor, for example, by reducing its cross-sectional area. In one embodiment, a gas resistance (Lufttasche) is specifically provided, which can then be filled with brazing material.

[0046] In one embodiment, the aforementioned adhesive can be configured as a material that increases contact resistance.

[0047] At rated voltages in the range of 300V to 500V, the typical rated current for achieving material-locked connections is, for example, in the range of 1200 to 1600A. The rated current for high-voltage batteries used in hybrid vehicles may also be significantly lower. And the rated voltage may very well be higher in the future, for example, in the range of 800V to 1000V.

[0048] In a preferred embodiment, the method for contacting the material-locking contacts is implemented immediately after the production or manufacture of the electrical system, such as a high-voltage storage device. That is, the brazing process advantageously occurs directly after production is completed.

[0049] This invention also relates to an energy storage unit, particularly a high-voltage storage unit, which is contact-connected or manufactured according to the method of the invention. Such a high-voltage storage unit preferably comprises multiple battery modules assembled into a high-voltage storage unit. The battery modules suitably each have multiple accumulator cells, particularly energy storage units. Preferred types or kinds of accumulator cells are, for example, lithium-ion cells, lithium-sulfur cells, or iron phosphate cells. Typical housing structures of accumulator cells are circular cells and, particularly, prismatic cells, i.e., housings comprising a robust body. However, accumulator cells with flexible housings can also be used, and these cells are also known as pouch cells. Accumulator cells can also be capacitors or supercapacitors. Energy storage units of this type are particularly used as energy storage units in partially and / or fully electrically operated motor vehicles. The energy storage unit is also referred to as a traction or drive battery.

[0050] This invention also relates to the application of energy from energy storage units, particularly electrical energy storage units such as high-voltage storage devices, in a current path for material-locking connections at contact points within the current path. That is, energy is suitably applied by the energy storage unit itself for material-locking connections, preferably for brazing. It has proven advantageous, for example, to use power cables including solder pouches disposed at the ends, wherein the solder pouches can be used both for pre-positioning or pre-contacting of the power cable and for providing the brazing material required for brazing.

[0051] In one implementation, the energy from the energy storage unit is used for re-brazing. This means that maintenance brazing can be appropriately performed when needed during the operation of the energy storage unit. Using the current generated during operation for resoldering, or operating the energy storage unit briefly in this way, allows resoldering to occur at the contact points. This is particularly advantageous because it ensures optimized connections at the contact points throughout the lifespan of the energy storage unit, or generally the electrical system. Attached Figure Description

[0052] Further advantages and features will be revealed in the following descriptions of different implementations of the components or methods, with reference to the accompanying drawings. (See the drawings.)

[0053] Figure 1 Multiple contact elements are shown, which form contact positions through clamping device contacts;

[0054] Figure 2 Another implementation of the contact location is shown;

[0055] Figure 3 Two implementations of the component together with the contact elements are shown;

[0056] Figure 4 This illustrates another implementation of the contact location. Detailed Implementation

[0057] Figure 1 A schematic view of a clamping device 22 is shown, having two tabs connected by a fastening mechanism 30, currently outlined as dashed lines. The fastening mechanism 30 may be a threaded connection. Two components 10 are visible, each having a contact element 20 at its end. A brazing material 24 is applied to one of each contact element 20. The clamping device 22 presses the corresponding contact elements 20 together, with the brazing material 24 positioned between them. If a sufficiently high current now flows through the components 10, or contact elements 20, brazing automatically occurs at the contact position 21. The clamping device 22 can then be removed.

[0058] Figure 2 A schematic illustration of an embodiment of contact position 21 is shown, in which one component 10 is currently configured, for example, as a power cable or module connector having contact elements 20 at the ends, with insulating material 26 disposed on the contact elements. The insulating material is preferably used to increase, or particularly specifically and locally increase, the contact resistance to additionally generate heat. The insulating material 26 can also function as an adhesive. Another component 10 is currently conceived as an energy storage device or battery module 40 including voltage taps 42, which currently constitute a second contact element. Soldering material 24 is disposed on the second contact element. The power cable 44 is schematically deformed. This deformation introduces stress into the component, which can be connected to form a current path by making the two contact elements 20 contact each other, particularly by force-locking contact.

[0059] Figure 3 Two schematic embodiments of component 10 are shown. In the left half of the image, component 10 is depicted as, for example, a conductor element having a contact element 20 at its end, wherein the contact element has an adhesive into which solder material 24 is embedded. In the right half of the image, component 10, for example, a conductor element having a contact element 20 at its end, has a solder pouch 28. Solder material for subsequent soldering can be provided or disposed in such a solder pouch 28. Additionally, such a solder pouch can be used to provide, form-locking and / or force-locking, equally configured (not shown here) contact elements for pre-positioning or pre-contact connection.

[0060] Figure 4 Another schematic embodiment of the contact position 21 is shown, in which two components 10, each having a contact element 20 at one end, can abut against each other at the contact position 21. The right-hand contact element 20 has a solder pouch 28 and an interlocking region 32 designed to work in conjunction with a fastening mechanism 30. The two components 10 can be pre-contacted with each other via the fastening mechanism 30. A true material-locked connection is achieved indirectly through solder, which is provided in the solder pouch 28.

[0061] List of reference numerals

[0062] 10 components

[0063] 20 Contact elements

[0064] 21 Contact position

[0065] 22 Clamping equipment

[0066] 24 Brazing materials

[0067] 26 Insulation materials

[0068] 28 Solder bags

[0069] 30 Fastening mechanism

[0070] 32 Interlocking Area

[0071] 40 Battery Module

[0072] 42 Voltage taps

[0073] 44 Power Cable

Claims

1. Method for material-lockingly contact-connecting components (10) in an electrical system, the method comprising the steps of: - providing a plurality of components (10), wherein the components (10) for electrical contact-connection having contact elements (20); - contact-connecting the components (10) by means of the contact elements (20) for the purpose of creating a current path; - generating a current in the current path for the purpose of material-lockingly connecting the contact elements (20) by means of the thermal energy generated there, wherein the components (10) are battery modules (40) and power cables (44) which are provided for connecting or contact-connecting battery modules (40) and which have contact elements (20) at the end sides, respectively, wherein the method comprises the steps of: - providing a plurality of battery modules (40); - contact-connecting the battery modules (40) by means of power cables (44) to a high-voltage storage, wherein the high-voltage storage forms a current path; - generating a current in the current path by means of the high-voltage storage, so that the power cables (44) are brazed.

2. The method of claim 1, wherein, the method comprising the step of: - introducing a resistance into the current path.

3. The method of claim 2, wherein, the method comprising the step of: - introducing an electronic load into the current path.

4. The method according to one of claims 1 to 3, wherein the method comprising the step of: - contact-connecting the contact elements (20) positively and / or force-lockingly.

5. The method of claim 4, wherein, the method comprising the step of: - exerting a clamping force by means of a clamping device (22) for the purpose of contact-connecting at least two contact elements (20).

6. The method of claim 4, wherein, the method comprising the step of: - exerting a prestress on at least one contact element (20) for the purpose of force-locked contact-connection.

7. The method of claim 6, wherein, the method comprising the step of: - exerting a prestress on at least one contact element (20) by means of deformation for the purpose of force-locked contact-connection.

8. The method according to one of claims 1 to 3, wherein the method comprising the step of: - providing a brazing material (24) on the contact elements (20).

9. The method of claim 8, wherein, the method comprising the step of: - material-lockingly contact-connecting the components (10).

10. The method of claim 9, wherein, the method comprising the step of: - material-lockingly contact-connecting the components (10) by means of an adhesive.

11. The method of claim 10, wherein, the method comprising the step of: - embedding the brazing material (24) in the adhesive.

12. The method according to one of claims 1 to 3, wherein the method comprising the step of: - adjusting the contact resistance at the contact locations (21) of at least two contact elements (20).

13. The method of claim 12, wherein, the method comprising the step of: - increasing the contact resistance at the contact locations (21) of at least two contact elements (20).

14. The method of claim 12, wherein, the method comprising the step of: - adjusting the contact resistance at the contact locations (21) of at least two contact elements (20) by introducing an insulating material (26) into or onto the contact locations (21).

15. Energy storage unit produced according to the method according to one of claims 1 to 14.

16. The energy storage unit of claim 15, wherein, The energy storage unit is a high-voltage storage.

17. Use of the energy of an energy storage unit according to claim 15 or 16 in a current path for the material-locking connection of contact locations (21) in the current path.

18. Use according to claim 17, wherein using the energy for re-brazing.

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