Connection assembly, in particular for use in electric or hybrid vehicle
By designing a flat contact head of a stamping structure in an electric vehicle, protruding the edges and breaking the foreign body layer, the problem of high contact resistance in high current connection is solved, low and stable resistance connection is achieved, and heat generation and voltage are reduced. drop.
Patent Information
- Application Number
- CN202380045647.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2022-06-08
- Filing Date
- 2023-05-25
- Publication Date
- 2025-01-17
AI Technical Summary
In electric vehicles or hybrid vehicles, when high current electrical and electronic components are connected, the prior art is difficult to effectively reduce contact resistance, resulting in heat generation and voltage drop, and foreign matter layers such as oxide layers will increase contact resistance.
A connection assembly is designed to project at the edges of the flat contact head and press into the second contact surface through stamping technology to break the foreign body layer and achieve a low contact resistance connection. The assembly includes a flat contact head with a flat contact surface and a second contact surface, and when fastened by a connecting element such as a threaded member, the edge breaks the foreign body layer in relative motion, ensuring a low and stable resistance.
A low contact resistance between two flat contact heads is achieved, which avoids high heat generation and voltage drop, and breaks the foreign body layer by local high force to ensure a stable electrical connection.
Smart Images
Figure CN119325670A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to a connection assembly having the features of the preamble of independent claim 1 , in particular for use in an electric vehicle or a hybrid vehicle. Background Art
[0002] In power electronics, for example in electric vehicles or hybrid vehicles, electrical and / or electronic components that conduct high currents are connected to one another. Due to the high currents, the current-carrying elements, by which the electrical and / or electronic components are connected to one another, must have a correspondingly low resistance and therefore a large cross section and / or a material with high electrical conductivity. In such an arrangement, the current is therefore conducted, for example, via busbars (also referred to as busbars), and the electrical and / or electronic components are connected to one another via the busbars.
[0003] In order to connect electrical and / or electronic components to one another, flat connecting contacts, such as busbars, which form electrical connections of the electrical and / or electronic components, are electrically connected to one another. Here, the flat connecting contacts overlap and are connected to one another, such as screwed, in the region where they overlap. If high currents flow through the connection, the electrical material resistance and the electrical contact resistance must be kept low in order to minimize the total electrical power loss. Summary of the invention
[0004] According to the invention, a connection assembly is proposed, in particular for use in electric vehicles or hybrid vehicles. 1. The connection assembly comprises: a first flat connection contact having a flat first contact surface for electrically contacting a first electrical and / or electronic component and a second flat connection contact having a second contact surface for electrically contacting a second electrical and / or electronic component, wherein the first flat connection contact and the second flat connection contact overlap in an overlapping area, wherein the first contact surface faces the second contact surface, wherein the first flat connection contact and the second flat connection contact are connected by means of a connecting element and the first contact surface is pressed against the second contact surface by the connecting element. According to the invention, a structure is stamped into the first flat connection contact so that an edge of the first flat connection contact protrudes from the plane of the first contact surface, wherein the edge protruding from the plane of the first contact surface is pressed into the second contact surface of the second flat connection contact by the connecting element.
[0005] Advantages of the present invention:
[0006] Compared with the prior art, the connection assembly with the features of the independent claim has the following advantages: an advantageously low contact resistance is achieved in the connection between the two flat connection contacts. This advantageously prevents otherwise high levels of heat generation and high voltage drops at the contact point between the two flat connection contacts. When the flat connection contacts are mechanically fastened to each other, for example when tightening, the edge of the first flat connection contact pressed into the second contact surface of the second flat connection contact is pressed through the foreign body layer on the second contact surface. This foreign body layer can be, for example, an oxide layer caused by corrosion of the second flat connection contact, which can lead to high contact resistance at the contact point between the two flat connection contacts. When the flat connection contacts are fastened to each other, the edge penetrates the foreign body layer on the second contact surface. During the fastening of the flat connection contacts to each other, for example when tightening the screw connection, the stamped structure is flattened. In this way, a relative movement of the edge on the second contact surface occurs, wherein the edge moves on the second contact surface. By this relative movement, the foreign body layer on the second contact surface is broken by the edge, and at the same time the foreign body layer is removed at the edge. As a result, the foreign matter layer, which can be, for example, an oxide layer, at the two flat connecting contacts is broken open by the relative movement. For example, when tightening the threaded connection, it is ensured by tightening the flat connecting contacts that the areas with the open foreign matter layer subsequently overlap each other, and that no foreign matter layer can be formed on this overlapping area. This advantageously achieves a low and stable resistance between the two connecting contacts. At the beginning of the screwing process, there is a line contact between the first flat connecting contact and the second flat connecting contact. Advantageously, the surface pressure in the line contact area is advantageously higher during the screwing process because the pressure-bearing area is very small (surface pressure=force / area). This makes it possible to very well break the foreign matter layer by locally very high forces.
[0007] Further advantageous embodiments and improvements of the invention are possible by means of the features specified in the dependent claims.
[0008] According to an advantageous embodiment, a first gap is formed in the overlapping region in the first connecting contact, wherein the edge is formed by the edge of the first connecting contact surrounding the first gap, wherein the connecting element protrudes through the first gap in the first flat connecting contact. Therefore, a connection with a lower contact resistance is established by using the edge around the connecting element. The gap, for example, a hole for receiving a screw, is used at the same time to use the edge around the gap as an edge to establish a connection with an advantageous low contact resistance. The edge extending around the gap for the connecting element can be advantageously pressed into the second contact surface in a circumferential manner and establish an advantageous low transition resistance between the two flat connecting elements. Here, when tightening the connecting element, the head of the connecting element, for example, the head of the screw, can, for example, press the surrounding edge, for example, annularly into the second contact surface of the second flat connecting element. Due to the annular contact portion around the first gap, a connection with an advantageous low resistance can be established even with the aid of a small screw.
[0009] According to an advantageous embodiment, a funnel-shaped structure is formed in the first connecting contact, which is punched around the first recess. Such a structure is advantageously easy to produce and is particularly suitable for bringing about a good relative movement of the edge on the second contact surface when fastening the flat connecting elements to one another, for example when tightening the connecting element, which is designed, for example, as a screw. In this case, the funnel-shaped structure flattens during tightening and the edge breaks the foreign body layer in the radial direction.
[0010] According to an advantageous embodiment, the connecting element is configured as a threaded connection, and the first flat connecting contact and the second flat connecting contact are connected to each other and pressed against each other via the threaded connection. A particularly simple and at the same time good mechanical connection is established between the flat connecting contacts via the threaded connection. In addition, by tightening the screw, a force can be applied to the flat connecting contact, which force presses the edge firmly into the second contact surface, and sufficient force can be introduced to flatten the structure and break open the foreign body layer located at the second contact surface and the edge. In this case, the head of the screw can, for example, be pressed onto a funnel-shaped structure around the first gap, and the edge is thus pressed into the second contact surface around the first gap. The edge moves radially away from the connecting element on the second contact surface, and thus breaks open the foreign body layer on the second contact surface in an annular manner.
[0011] According to an advantageous embodiment, a second recess is formed in the second flat terminal contact, through which the connecting element protrudes, wherein the edge around the first recess is pressed into the second contact surface, in particular in an annular manner surrounding the second recess. The connecting element can thus be arranged through both recesses and the two flat terminal contacts can be easily connected to one another.
[0012] According to an advantageous embodiment, it is provided that the first flat terminal contact is designed as a busbar and / or the second flat terminal contact is designed as a busbar. The busbars can be connected to one another particularly well in the manner shown; the busbar can be punched and stamped particularly easily and inexpensively. The first recess in the busbar can advantageously be produced easily by punching. The punched recess then has, for example, particularly sharp edges, which can advantageously penetrate the foreign body layer on the second contact surface well. The punched structure can be produced particularly easily on the first flat terminal contact designed as a busbar.
[0013] Furthermore, a method for producing a connection assembly is proposed. The method comprises: a step for providing a first flat connection contact, in particular a busbar, with a flat first contact surface; a step for providing a second flat connection contact with a second contact surface; a step for punching a structure in the flat connection contact, wherein the edge of the first flat connection contact is pressed out of the plane of the flat first contact surface by punching the structure; a step for arranging the first contact surface of the first flat connection contact on the second contact surface of the second flat connection contact; a step for fastening the first flat connection contact to the second flat connection contact by a connecting element, wherein the first contact surface of the first flat connection contact is pressed against the second contact surface of the second flat connection contact and the edge of the first flat connection contact is pressed into the second contact surface of the second flat connection contact. In this way, a connection assembly with an advantageously low contact resistance between the flat connection contacts can be produced in a simple and cost-effective manner. The foreign material layer on the two flat connection contacts is broken at the contact point and a stable contact with a low contact resistance is formed between the two flat connection contacts.
[0014] According to an advantageous embodiment, a first recess is formed in the first flat terminal contact, wherein the edge of the first flat terminal contact surrounding the first recess forms an edge, wherein when the first flat terminal contact is fastened to the second flat terminal contact, a connecting element, in particular a screw connection, is plugged through the first recess. Thus, a mechanically stable connection can be produced in a simple manner with a low contact resistance.
[0015] According to an advantageous embodiment, a funnel-shaped structure is stamped around the first recess, wherein an edge is pressed out in an annular manner from the plane of the first contact surface. Such a structure is particularly suitable when the head of a screw element presses the first flat connecting contact against the second flat connecting contact. In this case, the structure is evenly flattened when the connection is tightened, and the edge moves in the radial direction away from the connecting element, which is designed as a screw element, on the second contact surface and breaks up the foreign body layer on the second contact surface in an annular manner around the connecting element.
[0016] According to an advantageous embodiment, when the first flat terminal contact is fastened to the second flat terminal contact, the edge is pressed into the second contact surface of the second flat terminal contact in an annular manner, in particular surrounding the second recess in the second flat terminal contact, thereby producing an advantageously good contact with low contact resistance. BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Embodiments of the invention are shown in the drawings and are explained in detail in the following description.
[0018] Figure 1 shows an embodiment of a first flat connecting contact,
[0019] Figure 2 shows a further view of an embodiment of a first flat connecting contact,
[0020] Figure 3 shows a cross section through an exemplary embodiment of a first flat connecting contact,
[0021] Figure 4 shows a cross section through an embodiment of a connecting assembly before fastening a first flat connecting contact to a second flat connecting contact,
[0022] Figure 5 shows an enlarged cross section of an exemplary embodiment of a connecting assembly when a first flat connecting contact is fastened to a second flat connecting contact,
[0023] Figure 6 A cross section through an exemplary embodiment of a connecting assembly is shown after fastening of a first flat connecting contact to a second flat connecting contact. DETAILED DESCRIPTION
[0024] Figures 1 to 3 Different views of an exemplary embodiment of a first flat connecting contact 11 are shown. Figures 4 to 5 Shows that there is Figures 1 to 3 The present invention relates to an embodiment of a connection assembly 1 with an embodiment of a first flat connecting contact 11 in FIG. The connection assembly 1 can be used in all applications where high currents must be conducted via the contact connection and power losses must be kept low. The connection assembly 1 can be used, for example, in systems that conduct high currents, such as in power electronics in electric vehicles or hybrid vehicles. For example, the connection assembly 1 can be used in power electronics, converters or batteries.
[0025] The connection arrangement 1 comprises a first flat connection contact 11, which can be, for example, an electrical connection of a first electrical and / or electronic component. Furthermore, the connection arrangement 1 comprises a second flat connection contact 21, which can be, for example, an electrical connection of a second electrical and / or electronic component. The electrical and / or electronic component can be or comprise, for example, an inverter, a converter, a DC / DC converter, a capacitor (for example an intermediate circuit capacitor), a battery or other electronic and / or electrical components, for example, for use in electric vehicles or hybrid vehicles.
[0026] The first electrical and / or electronic component is electrically conductively connected to the second electrical and / or electronic component. The electrically conductive connection between the first electrical and / or electronic component and the second electrical and / or electronic component is established via the flat terminal contacts 11, 21. For this purpose, the first flat terminal contact 11 is electrically conductively connected to the second flat terminal contact 21. For this purpose, the first flat terminal contact 11 is placed flatly, in particular directly, on the second flat terminal contact 21.
[0027] The flat connecting contacts 11, 21 are made of an electrically conductive material, for example, a metal, for example, copper. Copper has an advantageously low material resistance. The first flat connecting contact 11 can be made of the same material as the second flat connecting contact 21. However, the first flat connecting contact 11 and the second flat connecting contact 21 can also be made of different materials. The flat connecting contacts 11, 21 are substantially flat at least in their overlapping regions. The flat connecting contacts 11, 21 have flat contact surfaces 12, 22 in the overlapping region 5, at which the flat connecting contacts 11, 21 abut against each other, thereby establishing an electrically conductive connection between the flat connecting contacts 11, 21. The flat connecting contacts 11, 21 are arranged parallel to each other with respect to their flat extension planes. In the illustrated embodiment, the flat connecting contacts 11, 21 are designed as busbars 11, 21. In the context of the present application, busbars 11, 21 are understood to be electrically conductive flat conductors, for example electrically conductive sheet metal strips or electrically conductive strips. Thus, the busbar can be, for example, a busbar. The busbars 11, 21 can be, for example, bent or arched, or can also extend in a curved or stepped manner. The busbars 11, 21 are made of an electrically conductive material, for example, a metal, such as copper. The busbars 11, 21 are, for example, constructed in one piece. The busbars 11, 21 are, for example, made continuously from the same material. The busbars 11, 21 are, for example, constructed as blanking parts. For example, each of the busbars 11, 21 has a constant busbar 11, 21 thickness within the longitudinal extension of the busbars 11, 21, for example, perpendicular to the current direction. For example, each of the busbars 11, 21 can have a constant busbar 11, 21 width within the longitudinal extension of the busbars 11, 21, for example, perpendicular to the current direction. A first gap 12 is constructed in the first flat connecting contact 11. A second gap 22 is constructed in the second flat connecting contact 21. The first recess 12 in the first flat terminal contact 11 has, for example, a greater surface extent than the second recess 22 in the second flat terminal contact 21 .
[0028] The recesses 12, 22 are used to receive a connecting element 30, which is used to mechanically connect the flat connecting contacts 11, 21 to each other. The connecting element 30 is inserted through the recesses 12, 22. The connecting element 30 is screwed and thus presses the contact surfaces 12, 22 of the flat connecting contacts 11, 21 against each other. The connecting element 30 establishes a mechanical connection between the first flat connecting contact 11 and the second flat connecting contact 21. The connecting element 30 can be configured, for example, as a screw 31. The screw 31 passes through the connecting contacts 11, 21 in the overlapping region 5 in which the connecting contacts 11, 21 overlap. For this purpose, a first recess 12 is configured in the first flat connecting contact 11, and a second recess 22 is configured in the second flat connecting contact 21. The screw 31 protrudes through the first recess 12 of the first flat connecting contact 11 and through the second recess 22 of the second flat connecting contact 21. The screw 31 is spaced apart from the first flat connection contact 11 and the second flat connection contact 21 in the recesses 12, 22 and does not contact them. A screw head 32 is formed at the first end of the screw 31. At the second end of the screw 31 facing away from the first end of the screw 31, the screw 31 is screwed into a mating screw 33. The mating screw 33 is formed in another component 35, such as a screw bushing, a nut or a housing. The screw head 32 covers the first recess 12 in the first flat connection contact 11, and therefore when the screw 31 is screwed into the mating screw 33, the following force acts on the first flat connection contact 11, which forces the first contact surface 15 of the first flat connection contact 11 against the second contact surface 25 of the second flat connection contact 21. The screw head 32 has, for example, a larger diameter than the first recess 12. Therefore, the first contact surface 15 of the first flat connection contact 11 is pressed against the contact surface 25 of the second flat connection contact 21 by the screw 31. The two flat connecting contacts 11, 21 are arranged between the screw head and the counter screw 33. The connecting element 30 can be made of metal, for example steel.
[0029] exist Figures 1 to 3, an embodiment of a first flat connecting contact 11 is shown. In this embodiment, the first flat connecting contact 11 is designed as a busbar, also called a busbar. The first flat connecting contact 11 is made of an electrically conductive material, for example, a metal, such as copper. The first electrical connecting contact 11 is, for example, punched and / or bent and / or stamped out of a sheet metal. The first flat connecting contact 11 has a first contact surface 15. The first contact surface 15 is flatly configured and therefore extends in a plane. A first recess 12 for receiving a connecting element 30 is configured in the first connecting contact 11. In this embodiment, the first recess 12 is punched out in the first connecting contact 11. The first recess 12 can be, for example, a hole for receiving a screw as a connecting element 30. In addition, a structure 17 is punched into the first connecting contact 11 around the first recess 12. The structure 17 is funnel-shaped. By means of the funnel-shaped structure 17, the edge of the first connecting contact 11 is bent out of the plane of the first contact surface 15 around the first recess 12 and protrudes from the first recess. This results in an edge 16 which is pressed into the second contact surface 22 when the first flat terminal contact 11 is fastened, in particular screwed together, to the second flat terminal contact 21 .
[0030] exist Figures 4 to 6 2 shows how an electrically conductive and mechanical connection is established between flat terminal contacts 11 , 21 of a connection assembly 1 . Figure 4 A cross section through an exemplary embodiment of the connecting arrangement 1 is shown before the first flat connecting contact 11 is fastened to the second flat connecting contact 21 .
[0031] Figure 5 An enlarged cross section of an embodiment of the connection assembly 1 is shown when the first flat connecting contact 11 is fastened to the second flat connecting contact 21. When the screw 31 is tightened, the edge 16 of the first flat connecting contact 11 rests sharply on the second contact surface 25 of the second flat connecting contact 21. The edge 16 points in the direction of the second contact surface 25. If the screw 31 is tightened further, the structure 17 punched into the first flat connecting contact 11 is flattened and the edge 17 penetrates the foreign layer, for example an oxide layer, on the second contact surface 25. The arrow shows the direction of movement of the edge 17 on the second contact surface 25 when the screw is tightened and the structure 17 is flattened.
[0032] Figure 6The cross section of an exemplary embodiment of the connection assembly 1 is shown after the first flat terminal contact 11 has been fastened to the second flat terminal contact 21. After the screw has been tightened, the foreign layer (which can be, for example, an oxide layer) on the two flat terminal contacts 11, 21 can be broken apart in the region of the edge 16 by the relative movement of the edge 17 on the second contact surface 25. The edge 16 is pressed into the second contact surface 25. In this case, the structure 17 is largely or completely flattened by the forces of the screw connection, in particular in the region below the screw head 32.
[0033] Of course, other embodiments and combinations of the embodiments shown are also possible.
Claims
1. A connection assembly (1), in particular for an electric vehicle or a hybrid vehicle, comprising: a first flat connecting contact (11) having a first flat contact surface (15) for electrically contacting a first electrical and / or electronic component; and a second flat connecting contact (21) having a second contact surface (25) for electrically contacting a second electrical and / or electronic component, wherein the first flat connecting contact (11) and the second flat connecting contact (21) overlap in an overlapping region (5), wherein the first contact surface (15) faces the second contact surface (25), wherein the first flat connecting contact (11) and the second flat connecting contact (21) are connected via a connecting element (30) and the first contact surface (15) is pressed against the second contact surface (25) via the connecting element (30), It is characterized in that a structure (17) is stamped into the first flat terminal contact (11) so that an edge (16) of the first flat terminal contact (11) protrudes from the plane of the first contact surface (15), wherein the edge (16) protruding from the plane of the first contact surface (15) is pressed into the second contact surface (25) of the second flat terminal contact (21) via a connecting element (30).
2. The connection assembly according to claim 1, characterized in that: In the overlapping region (5), a first recess (12) is formed in the first terminal contact (11), wherein the edge (16) is formed by an edge of the first terminal contact (11) surrounding the first recess (12), wherein the connecting element (30) protrudes through the first recess (12) in the first flat terminal contact (11).
3. A connection assembly according to any one of the preceding claims, characterized in that A funnel-shaped structure (17) is formed in the first connecting contact (11) and is punched out around the first recess (12).
4. A connection assembly according to any one of the preceding claims, characterised in that The connecting element (30) is configured as a screw (31), and the first flat connecting contact (11) and the second flat connecting contact (21) are connected to each other and pressed against each other via the screw (31).
5. The connection assembly according to any one of claims 2 to 4, characterized in that: A second recess (22) is formed in the second flat terminal contact (21), through which the connecting element (30) projects, wherein an edge (16) surrounding the first recess (12) is pressed into a second contact surface (25), in particular in an annular manner around the second recess (22).
6. A connection assembly according to any one of the preceding claims, characterised in that The first flat terminal contact (11) is designed as a busbar and / or the second flat terminal contact (21) is designed as a busbar.
7. A method for manufacturing a connection assembly, the method comprising the steps of: - providing a first flat connecting contact (11), in particular a busbar, having a flat first contact surface (15); - providing a second flat connecting contact (21) having a second contact surface (25); - stamping the structure (17) into the first flat connecting contact (11), wherein: By stamping the structure (17), an edge (16) of the first flat terminal contact (11) is pressed out of the plane of the flat first contact surface (15); - arranging the first contact surface (15) of the first flat terminal contact (11) on the second contact surface (25) of the second flat terminal contact (21); - The first flat terminal contact (11) is fastened to the second flat terminal contact (21) by means of a connecting element (30), wherein the first contact surface (15) of the first flat terminal contact (11) is pressed against the second contact surface (25) of the second flat terminal contact (21) and the edge (16) of the first flat terminal contact (11) is pressed into the second contact surface (25) of the second flat terminal contact (21).
8. The method according to claim 7, characterized in that A first recess (12) is formed in the first flat terminal contact (11), wherein an edge of the first flat terminal contact (11) surrounding the first recess (12) forms an edge (16), wherein the connecting element (30), in particular the screw (31), is plugged through the first recess (12) when the first flat terminal contact (11) is fastened to the second flat terminal contact (21).
9. The method according to claim 8, characterized in that A funnel-shaped structure (17) is stamped around the first recess (12), wherein the edge (16) is pressed out in an annular manner from the plane of the first contact surface (15).
10. The method according to claim 8 or 9, characterized in that: When the first flat terminal contact (11) is fastened to the second flat terminal contact (21), the edge (16) is pressed into a second contact surface (25) of the second flat terminal contact (21) in an annular manner, in particular around a second recess (22) in the second flat terminal contact (21).