Contact device and power module assembly

Abstract

The invention relates to a contact device for electrically contacting at least two electrical functional components of an electrical and / or electronic circuit and / or sub-circuit in at least one connection interface, comprising at least one bus bar extending from a first contact region to a second contact region. The bus bar may form a current path within the bus bar between the first and second contact regions when the functional member is in electrical contact with respective different contact regions of the bus bar. Electrical contact between the at least one contact region and the at least one external contact surface of the functional component is formed by means of a material closure. Each contact region has at least one contact connection tab for the cohesive connection to an outer contact surface of the functional component. The material closure is formed between the outer edge edges of the at least one contact web transversely to the direction of extension of the contact web in the direction of extension of the bus bar and is interrupted by the at least one through-opening in order to form at least two contact elements, which have only sub-sections of the formed material closure.

Description

Technical Field

[0001] The invention relates to a contact device and a power module assembly having at least one power module and at least one contact device which is in electrical contact with the power module in a connection interface, in particular for supplying a phase current to an electric machine. Background Art

[0002] Power module assemblies are known from the prior art, for example for motor vehicles, in which a first connection interface between at least one power module and a capacitor assembly comprising at least one capacitor or a second connection interface between at least one power module and a phase connection to an electric machine is realized by a welded connection.

[0003] The service life of electric drives of motor vehicles is generally assumed to be at least 15 years or more. During this period, the mentioned welded connections must withstand moisture, temperature changes, mechanical stress, salt contact, etc. without losing electrical conductivity.

[0004] In particular, mechanical stresses act as negative amplifiers for other influencing factors, so that there is a risk of cable breakage. This risk is even greater if the cable connection is subject to specific vibrations and / or torsion that results in unfavorable stresses, for example due to a specific installation position in a motor vehicle. Summary of the invention

[0005] The object of the present invention is to provide a cost-effective and technically easy-to-implement electrical contact of at least two electrical functional components of an electrical and / or electronic circuit and / or a subcircuit within at least one connection interface, wherein stress-related negative influences that affect the connection interface and that have an impact on the service life are reduced.

[0006] This object is achieved by a contact device and a power module assembly in combination with the features of an exemplary embodiment of the invention, which comprises at least one power module and at least one contact device which is in electrical contact with the power module in a connection interface, in particular for providing a phase current to an electric machine.

[0007] The present invention relates to a contact device for electrical contact of at least two electrical functional components of an electrical and / or electronic circuit and / or subcircuit in at least one connection interface. The two functional components to be electrically contacted are, for example, a power module and a capacitor as part of a rectifier circuit for the control of an electric motor. In this case, the contact device comprises at least one busbar (Stromschiene), which extends from at least one first contact connection piece to a second contact connection piece. Therefore, the contact connection piece (Kontaktanschlusslasche) comprises a connection surface for electrical contact. The at least one busbar is formed so that when the functional component is electrically contacted with different contact connection pieces of the busbar, a current path between the first contact connection piece and the second contact connection piece can be formed in the busbar. The busbar bridges the local interval between the two functional components to be contacted. Preferably, the busbar is formed in a straight line, so that the two contact connection surfaces are opposite to each other along a straight line. In this case, the direction of the busbar between these contact connection pieces can also deviate from the straight line and, for example, have a certain L-shaped or S-shaped direction direction. However, other directions can also be conceivable. In contrast to the straight-line implementation of the busbar, these contact connecting pieces are arranged opposite to each other in an offset manner. In this case, usually a contact connecting piece transitions linearly to the remaining direction of the busbar before the direction of the busbar deviates from the straight-line implementation. Each contact connecting piece is assigned to be used for electrical contact with the external contact surface of each functional component. Here, the electrical contact of at least one contact connecting piece with at least one external contact surface of one of these functional components is formed by means of a material lock (Stoffschluss), in particular by means of a welded connection. The material lock (in particular at an angle of 45° to 90°, preferably at a right angle) is formed transversely to the extension direction of the contact connecting piece in the extension direction of the busbar between the outer edge edges of the at least one contact connecting piece. In addition, the material lock is interrupted by at least one through-opening in the contact connecting piece so that at least two contact elements are formed on the contact connecting piece, which contact elements only have a sub-section (Teilabschnitte) of the formed material lock. Advantageously, subsections of the material connection are formed by one or more through-openings, which together result in a shorter contact length of the material connection that is effective for connection than if the material connection were formed through the contact web without a through-opening. In this simple manner, a mechanical decoupling of the material connection is achieved in the contact region. As a result, the influence of mechanical and / or thermomechanical stresses on such a connection mentioned is significantly reduced. In particular, such a mechanical decoupling leads to a compliance in the contact region, whereby stresses that would otherwise occur can be eliminated. Overall, the operational safety of such a contact assembly described can be ensured in the simplest manner over a defined service life.In contrast to the case of different contact webs of the at least one busbar, the contact elements K of a contact web are in electrical contact with the same, continuous, bare external contact surface.

[0008] The contacting device according to the invention can be advantageously improved and perfected by the measures given in the preferred exemplary embodiments.

[0009] In a preferred embodiment of the contact device, the through-opening is designed in the form of an elongated hole, wherein the longitudinal axis of the elongated hole is oriented in the direction of the extension of the busbar and / or in the direction of the axis of symmetry of the outer contact surface of the electrical contact of the functional component. The elongated hole makes the flexibility in the contact area significantly greater than, for example, the case with only a round hole. In addition, the notch effect is reduced by the cross section of the material connection extending laterally from the longitudinal section of the elongated hole.

[0010] In principle, the through-opening can be produced by a material removal method, for example by sawing, milling, drilling or the like, or by means of a punching method, for example. Preferably, the through-opening has rounded corners, whereby notch effects are additionally reduced under stress.

[0011] In one embodiment of the contact arrangement, the subsections of the material connection are arranged along a common axis on all contact elements, which is particularly advantageous. In the case of a weld seam connection as a material connection, the imaginary extensions of the subsections thus merge into one another in an overlapping manner. This ensures that the material expansion in the contact region caused by the effects of temperature does not lead to asymmetrical deformations that could cause unnecessary thermomechanical stresses.

[0012] Preferably, in one embodiment of the contact device, the subsections of the material connection formed on the contact element extend substantially from the outer edge of the contact web to the outer edge of the through-opening, or from one outer edge of each of two through-openings, between which a contact element is formed. These edge edges are usually oriented substantially in the direction of extension of the busbar behind the contact web. Advantageously, the entire remaining cross section of the connection surface is thus utilized in the region of the through-opening for material-locked electrical contact. Thus, the possible current-carrying capacity of the busbar can be utilized to the maximum extent. Under due consideration of the trade-off between flexibility and the maximum current-carrying capacity required of the busbar in the contact region, it is conceivable that the dimensions of the through-opening are set so that the cross section of the connection surface of the contact web available for material connection remains at 50% to 80%, preferably 50% to 75%, in particular 50% to 65%. However, it should be noted in principle that, in general, a remaining cross section of the connection surface is retained in the contact region, which has the current-carrying capacity required in relation to the application.

[0013] Depending on the application and on which side of the contact web the mechanical and / or thermomechanical stresses are mainly present, preferred embodiments of the contact assembly may differ from one another. In the case where the stresses are introduced via a functional component which is in electrical contact with the contact web, an embodiment of the contact assembly is particularly suitable in which at least one (in particular all) through-openings of the at least one contact web extend up to a terminal edge of the at least one contact web, which also forms one of the terminal edges of the busbar, and the at least one (in particular all) through-openings extend beyond the adjacent subsection of the material connection on the side facing away from the terminal edge in the direction of extension of the busbar by a distance of 1 mm to 30 mm, in particular 1 mm to 20 mm. In this respect, the through-openings are formed open toward the terminal edge.

[0014] If, in contrast, the mechanical stresses are introduced by a functional component which is in materially bonded electrical contact with an opposing contact lug, an embodiment of the contact assembly is preferably provided in which at least one (in particular all) through-openings of the at least one contact lug extend to a position with a distance dimension of 1 mm to 30 mm (in particular 1 mm to 20 mm) relative to the terminal edge, which also forms one of the terminal edges of the busbar, and the at least one (in particular all) through-openings extend on the side facing away from the terminal edge in the extension direction of the busbar to a position with a distance dimension of 1 mm to 30 mm (in particular 1 mm to 20 mm) in front of the other contact lug. Compared to the previously described embodiments, the through-openings are thus formed closed at the edge, but extend further toward the opposing contact lug.

[0015] A particularly advantageous embodiment of the contact device is that the contact device comprises at least two busbars electrically insulated from one another, which can be loaded with different potentials (elektrischenpotentialen) from the assigned functional components. The electrical insulation can be achieved by the minimum distance between the two busbars by means of an air gap between them. In order to exclude the possibility of accidental contact between the two busbars, an electrically insulating material, such as an insulating protective film or an insulating spacer element or the like, can also be arranged between the two busbars. For example, two or more busbars of the contact device are embedded in a common electrically insulating sheath (Umhüllung), wherein at least the contact connection piece protrudes from the sheath. The sheath advantageously forms a contact protection for the contact device, so that during the operation of the contact device, even in the case of high currents and / or voltages and in normal use, there is no direct danger to people and the environment. The sheath material can be provided, for example, by a casting material (for example by ceramic) or by a particularly polymer injection molding material (for example a molding compound). The electrical insulation can also be used advantageously to connect the two busbars together in a fixed manner in the form of an assembly, so that a connection diagram tailored to the application is produced by the spatially correct arrangement of the contact lugs and then used to make electrical contact with the assembly to the functional component.

[0016] Generally speaking, it is advantageous if at least one busbar (or all busbars) of the contact device is formed from a plate-shaped substrate having a plate thickness d between two opposing outer surfaces. Therefore, at least one busbar (or all busbars) of the contact device is preferably formed from a sheet metal material as the sheet material, further preferably from copper or a copper alloy. Advantageously, in this way such busbars can each be embodied as a stamped and bent part, thereby enabling cost-effective mass production.

[0017] The present invention also relates to a power module assembly, which has at least one power module, which includes a plurality of semiconductor switches and at least one external contact surface. The power module assembly also has at least one connection interface, which includes at least one contact device according to one of the aforementioned embodiments, wherein at least one contact connecting piece of at least one bus bar is connected to the external contact surface of the power module in a material-locked manner, in particular by means of a weld.

[0018] In another preferred embodiment of the power module assembly, the first connection interface comprises the first previously described contact device and is designed to electrically connect at least one first (or second) external contact surface of the at least one power module to a first power supply connection (Versorgungsanschluss), and to electrically connect at least one third external contact surface of the at least one power module to a second power supply connection. Via the first connection interface, the corresponding power module can be electrically connected to these power supply connections in one working step, which are provided, for example, by the capacitor assembly. Preferably, the plurality of busbars contained in the first contact device can be arranged at a certain distance electrically insulated from each other. The second connection interface can include another external contact device and is designed to electrically connect at least one fourth external contact surface of the at least one power module to a load connection. Via the second connection interface, the corresponding power module can be electrically connected, for example, to a phase connection (Phasenanschluss) of an electric machine.

[0019] In a further preferred configuration, the power module assembly may include three power modules. Here, at least one fourth external contact surface of the first power module may be electrically connected to a load connection terminal implemented as a first phase connection terminal and provide a first phase current for the motor. At least one fourth external contact surface of the second power module may be electrically connected to a load connection terminal implemented as a second phase connection terminal and provide a second phase current for the motor. At least one fourth external contact surface of the third power module may be electrically connected to a load connection terminal implemented as a third phase connection terminal and provide a third phase current for the motor. In addition, the three power modules may respectively have a first connection interface, which electrically connects the corresponding power module to the first power supply connection terminal and to the second power supply connection terminal, and the three power modules may respectively have a second connection interface, which electrically connects the corresponding power module to the corresponding load connection terminal. The power module assembly having these three power modules can preferably be used as a power output stage of a three-phase motor. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The embodiments of the present invention are shown in the drawings and explained in detail in the following description. In the drawings, the same reference numerals represent components or elements that implement the same or similar functions.

[0021] Further advantages, features and details of the present invention are apparent from the following description of preferred embodiments and from the accompanying drawings. In the drawings:

[0022] Figure 1 A schematic top view of one embodiment of a power module assembly is shown.

[0023] Figure 2 Shown for Figure 1A schematic top view of one embodiment of a power module of a power module assembly is shown.

[0024] Figure 3 Shows Figure 1 A schematic cross-sectional view of a power module assembly is shown.

[0025] Figure 4a The perspective view schematically shows Figure 1 One embodiment of a contact arrangement within a power module assembly is shown.

[0026] Figure 4b The top view shows Figure 4a Two bus bars within the contact arrangement are shown.

[0027] Figure 4c The arrangement of the current sensor device in the region of the through-opening of the contact lug is shown.

[0028] In the figures, components with the same function are respectively denoted by the same reference numerals. DETAILED DESCRIPTION

[0029] from Figure 1 , Figure 2 , Figure 3 , Figure 4a and Figure 4b as well as Figure 4c As can be seen, the illustrated embodiment of the power module assembly 1 according to the invention comprises at least one power module 2, 2A, 2B, 2C, and at least one connection interface 10, 10A, 10B, the power module comprising a plurality of semiconductor switches not shown in detail and at least one external contact surface 2.1, 2.1A, 2.1B, 2.1C, 2.1D, the connection interface comprising at least one contact device 12, 12A, 12B. The at least one connection interface 10, 10A, 10B electrically connects the at least one external contact surface 2.1, 2.1A, 2.1B, 2.1C, 2.1D of the power module 2 to at least one first further external contact surface 2.2, 2.2A (e.g. first or second supply connection 32, 32A, 32B) or to at least one second further external contact surface 2.2, 2.2B (e.g. load connection 34). The at least one external contact device 12, 12A, 12B is electrically connected to the at least one external contact surface 2.1, 2.1A, 2.1B, 2.1C, 2.1D of the power module 2. Figure 1 Only simplified rectangular elements are visualized in FIG. A possible embodiment can be obtained from Figures 4a to 4cThe at least one external contact device 12, 12A, 12B comprises at least one, two or more busbars 14, 14A, 14B, each of which has at least one first contact region 16, which is electrically contacted with at least one external contact surface 2.1, 2.1A, 2.1B, 2.1C, 2.1D of the power module 2, 2A, 2B, 2C by means of at least one contact connection piece 16.1, 16.2, and each of which has at least one second contact region 18, which is contacted with the at least one other external power supply connection terminal 32 or the at least one other external load connection terminal 34 by means of at least one contact connection piece 18.1. At least one contact terminal 16.1, 16.2 of the at least one first contact area 16 of each busbar 14, 14A, 14B, 14C and at least one contact terminal 18.1 of the at least one second contact area 18 are electrically contacted or connected to the corresponding external contact surfaces 2.1, 2.1A, 2.1B, 2.1C, 2.1D of the power module 2, 2A, 2B, 2C or to the at least one other external contact surface 2.2, 2.2A, 2.2B (for example, one of the power supply connections 32, 32A, 32B or the load connection 34) by means of a material connection 17 (for example, a weld connection, a soldered connection or an adhesive connection).

[0030] As from Figures 1 to 3It can be further seen that the illustrated embodiment of the power module assembly 1 includes three power modules 2, 2A, 2B, 2C. In the illustrated embodiment of the power module assembly 1, the three power modules 2, 2A, 2B, 2C each include a first circuit carrier not shown in detail, on which at least two semiconductor switches not shown in detail are arranged. Here, at least one first semiconductor switch is electrically connected between a first or second external contact surface 2.1A, 2.1B and a fourth external contact surface 2.1D, the first semiconductor switch is also called a high-side switch, the first or second external contact surface 2.1A, 2.1B is connected to a first (or positive) external power supply connection terminal 32A, and the fourth external contact surface 2.1D is connected to the at least one external load connection terminal 34. At least one second semiconductor switch is electrically connected between the third external contact surface 2.1C and the fourth external contact surface 2.1D, the second semiconductor switch is also called a low-side switch, the third external contact surface 2.1C is connected to the second (or negative) external power supply connection terminal 32B, and the fourth external contact surface 2.1D is connected to the at least one external load connection terminal 34. The control connection terminals of the at least two semiconductor switches are respectively electrically connected to at least one external contact element 2.2 arranged on the second circuit carrier, and the external contact element 2.2 can be contacted with at least one control line of the external control contact device. The second circuit carrier is connected to the first circuit carrier by a solder connection, a sintering connection, a welding connection, or an adhesive connection.

[0031] As from Figures 1 to 3 It can be further seen that each power module 2, 2A, 2B, 2C is enclosed by a covering 3, which has a gap 5 in the region of the external contact surface 2.1, 2.1A, 2.1B, 2.1C, 2.1D, so that the external contact surface 2.1, 2.1A, 2.1B, 2.1C, 2.1D is contactable. In the region of the external contact surface 2.1, an exposed portion 7 is provided in the covering 3, so that the contact surface 2.1 is exposed and contactable.

[0032] Especially from Figures 1 to 3It can be further seen that each power module 2A, 2B, 2C includes a first and a second external contact surface 2.1A, 2.1B connected to the first (or positive) external power supply connection terminal 32A through the first connection interface 10A, a third external contact surface 2.1C connected to the second (or positive and negative) external power supply connection terminal 32A through the first connection interface 10A, and two fourth contact surfaces 2.1D connected to the external load connection terminal 34 through the second connection interface 10B. Therefore, the three power modules 2A, 2B, 2C respectively have a first connection interface 10A, which electrically connects the corresponding power module 2A, 2B, 2C to the first (or positive) power supply connection terminal 32A and to the second power supply connection terminal 32B, and the three power modules 2A, 2B, 2C respectively have a second connection interface 10B, which electrically connects the corresponding power module 2A, 2B, 2C to the corresponding load connection terminal 34. Here, the two fourth external contact surfaces 2.1D of the first power module 2A arranged at the top in the figure are electrically connected to the load connection terminal 34 implemented as the first phase connection terminal 34U, and provide the first phase current for the motor. The two fourth external contact surfaces 2.1D of the second power module 2B arranged in the middle in the figure are electrically connected to the load connection terminal 34 implemented as the second phase connection terminal 34V, and provide the second phase current for the motor. The two fourth external contact surfaces 2.1D of the third power module 2C arranged at the bottom in the figure are electrically connected to the load connection terminal 34 implemented as the third phase connection terminal 34W, and provide the third phase current for the motor.

[0033] In the illustrated embodiment of the power module assembly 1, a capacitor assembly 30 (comprising a plurality of film capacitors not shown) provides the three power modules 2, 2A, 2B, 2C with a first (or positive) power supply connection 32A and a second (or negative) power supply connection 32B, which are supported by a support element 36 made of plastic. The three phase connections 34U, 34V, 34W are respectively connected to a three-phase motor not shown in detail. In addition, the three power modules 2, 2A, 2B, 2C are respectively thermally coupled to a cooling device 9 via a metal structure 4 arranged on the bottom side of each power module 2, 2A, 2B, 2C, so as to conduct away the heat loss caused by each power module 2, 2A, 2B, 2C.

[0034] As from Figure 3 and Figure 4a or Figure 4bIt can be further seen that the first connection interface 10A of one of these power modules 2, 2A, 2B, 2C comprises in the illustrated embodiment a first external contact device 12A, which electrically connects the first and second external contact surfaces 2.1A, 2.1B of the corresponding power module 2, 2A, 2B, 2C to the first power supply connection terminal 32A, and electrically connects the second external contact surface 2.1B of the corresponding power module 2, 2A, 2B, 2C to the second power supply connection terminal 32B. To this end, the first contact device 12A comprises at least two busbars 14A, 14B, each having at least one first contact area 16 and a second contact area 18.

[0035] The busbars 14A, 14B of the first contact device 12A are preferably each designed as a stamped and bent part made of sheet metal, but can also be, for example, a laser-processed bent sheet metal part.

[0036] The power module 2 and the power supply connection terminals 32, 32A, 32B or the load connection terminals 34 associated with the power module 2 are spaced apart from each other by a bridge distance T in the power module assembly 1. The external contact surfaces 2.1, 2.2 to be electrically contacted by the busbars 14A, 14B are arranged spaced apart in the X direction of the Cartesian coordinate system, for example, so that these external contact surfaces 2.1, 2.2 are respectively oriented parallel to the orientation axis AA pointing in the Z-axis direction. In the embodiment, the corresponding external contact surfaces 2.1, 2.2 are arranged in the same plane or at least in planes parallel to each other. In principle, the corresponding external contact surfaces 2.1, 2.2 can also be arranged in a certain plane position rotated around the orientation axis AA by an angle β.

[0037] The first busbar 14A has at least one contact lug 16.1, 18.1 on one side of its first contact region 16 and its second contact region 18. The two contact lugs 16.1, 16.2 in the first contact region 16 of the first busbar 14A are electrically connected to the first and second spaced-apart external contact surfaces 2.1, 2.1A, 2.1B of the corresponding power module 2, 2A, 2B, 2C. In contrast, the second contact region 18 has only one contact lug 18.1, which is electrically connected to the first additional external contact surface 2.2A. The electrical connection of these contact lugs 16.1, 16.2, 18.1 to the correspondingly assigned external contact surfaces 2.1A, 2.1B, 2.2A is achieved by a material connection 17. In the following, a weld connection 17A is considered by way of example or preferably as a material connection 17, wherein these embodiments can also be applied alternatively to the case of a solder connection or an adhesive connection as a material connection 17. A continuous weld connection 17A is formed in each of the first and second contact webs 16.1, 16.2. In contrast, the weld connection 17A formed on the contact web 18.1 in the second contact region 18 is interrupted multiple times by a through-opening D formed in the contact web 18.1. A plurality of contact elements K are formed in the contact web 18.1 by the through-opening D, which then each have a subsection 17a of the weld connection 17A. In contrast to the case of different contact webs 16.1, 16.2, 18.1, the contact elements K of one contact web 18.1 are in electrical contact with the same, continuous, exposed external contact surface 2.2A. The weld connection 17 is formed transversely (in particular perpendicularly) to the extension direction of the contact connecting pieces 16.1, 16.2, 18.1 between the outer edge edges 16.11, 16.12, 16.21, 16.22, 18.11, 18.12 of the contact connecting pieces 16.1, 16.2, 18.1 in the extension direction of the busbar 14A. In addition, the subsection 17a of the weld connection 17A runs along a common running axis on all the formed contact elements K. Depending on the application, one, two, three or more through-openings D can be set. Each through-opening D is, for example, embodied in the form of a slit with a slit width b. Preferably, the through-opening D is formed in the form of an elongated hole. These through-openings D are open toward the terminal edge 18.13 of the contact connecting piece 18.1. The slot then extends from the terminal edge 18.13 in the direction of the first contact region 16, preferably oriented in the direction of the busbar run that is connected to the contact web 18.1. Additionally or alternatively, the longitudinal axis of the slot as through-opening D extends in the direction of the axis of symmetry S of the respectively electrically contacted external contact surfaces 2.1, 2.2.

[0038] The second busbar 14B also comprises a first and a second contact region 16, 18. In contrast to the first busbar 14A, the second busbar 14B in this embodiment has only one contact lug 16.1, 18.1 for each contact region 16, 18. In its second contact region 18, the contact lug 18.1 has, for example, two, three or more contact elements K, which are formed by corresponding through-openings D in the contact lug 18.1. The contact lug 16.1 in the first contact region 16 also has a through-opening D, thereby forming two contact elements K. Therefore, in both contact regions 16, 18, a subsection 17a of each weld connection 17A is arranged on the contact lug 16.1 or the corresponding contact element K of the contact lug 18.1. Furthermore, the through-opening D in the contact lug 16.1 in the first contact region 16 does not start from its terminal edge 16.13, but is spaced apart from the terminal edge 16.13 by a distance dimension e.

[0039] The contact web 16 . 1 in the first contact region 16 is electrically connected to the third external contact area 2 . 1C of the power module 2 , 2A, 2B, 2C.

[0040] The two busbars 14A, 14B are arranged in a stacked assembly at a distance dimension a from one another for electrical insulation. In addition, an insulating material is inserted between the two busbars 14A, 14B, for example in the form of a spacer, for example as an injection-molded polymer component. Alternatively, for example, an insulating protective film or the like can also be provided.

[0041] Figure 4b The top view of the electrically connected power modules 2, 2A, 2B, 2C shows a third busbar 14C in addition to the two aforementioned busbars 14A, 14B, which connects the power modules 2, 2A, 2B, 2C to the load connection 34. The third busbar 14C has two contact lugs 16.1, 16.2 in its first contact region 16, which are respectively in electrical contact with the fourth contact surface 2.1D of the power modules 2, 2A, 2B, 2C, and the third busbar 14C has one contact lug 18.1 in its second contact region 18, which is connected to the phase connections 34U, 34V, 34W of the electric motor. All contact webs 16.1, 18.1 have a through-opening D which extends to the end edge 16.13, 18.13 of the respectively associated contact web 16.1, 18.1. In this case, all contact elements K formed by the through-opening D have a corresponding subsection 17a of the weld seam connection 17A.

[0042] Generally speaking, the subsection 17a of the material locking portion 17 or the welded connection 17A formed on the contact element K respectively extends basically from the outer edge edge of the correspondingly assigned contact connecting piece 16.1, 16.2, 18.1 to the outer edge edge of the nearest through-opening D (if it involves the outermost contact element K formed) or from each outer edge edge of the two through-openings D, forming the corresponding contact element K between the two through-openings D.

[0043] In principle, the number of contact pads 16.1, 18.1 and the number of contact elements K formed on each contact pad 16.1, 18.1 depends on the specific application in which the contact device 12 is to be used. In this regard, the invention is only illustrated by way of example with regard to the number of contact pads 16.1, 18.1 and the number of contact elements K and is not to be restricted to the exemplary embodiment shown.

[0044] Figure 4cThe arrangement of the current detection device 40 in the region of the through-opening D of the contact connecting piece 16.1 is shown very schematically in a top view. Only one end of a simplified busbar 14, 14C is shown, wherein the busbar is connected to the external contact surface 2.1D of the power module 2 in a material-locked manner via the contact connecting piece 16.1 formed on its end side, in particular by means of a weld connection. The external contact surface 2.1D is, for example, a provided phase connection end of the AC connection of the power module 2. The current detection device 40 can alternatively also be arranged in the region of the through-opening D of the contact connecting piece 18.1 in the second contact area 18 of the busbar 14C (not shown). In this case, the current detection device 40 includes at least one current sensor 40A, which is at least partially inserted into the through-opening D of the contact connecting piece 16.1. In addition, the current detection device 40 is implemented to detect the AC current in the busbar 14C in a contactless manner. Preferably, the current sensor 40A is configured as a magnetic sensor, which detects the field strength of the magnetic field generated by the alternating current (or phase current) passing through the busbar 14C. Here, the alternating current (or phase current) passing through the busbar 14C can be determined based on the detected field strength of the magnetic field surrounding the busbar 14C. In order to determine the alternating current (or phase current) passing through the busbar 14C, an evaluation and control unit (not shown) can preferably be used, which receives the output signal of at least one current sensor 40A. Based on the output signal received from the at least one current sensor 40A, the evaluation and control unit can calculate the alternating current (or phase current) passing through the busbar 14C. The at least one current sensor 40A can be implemented, for example, as a Hall sensor, a TMR sensor (TMR, Tunnel-Magneto-Resistance: Tunnel Magnetoresistance), a GMR sensor (GMR, Giant-Magneto-Resistance: Giant Magnetoresistance) or an AMR sensor (AMR, Anisotrope-Magneto-Resistance: Anisotropic Magnetoresistance). In addition, other suitable sensor principles can also be used to measure the alternating current (or phase current) passing through the busbar 14C. The at least one current sensor 40A can in principle include two sensor elements, which are arranged mirror-symmetrically with respect to the middle transverse plane of the measuring section of the busbar 14C and can form a sensor pair (Sensorpaar), which can perform differential measurement of the alternating current (or phase current) passing through the busbar 14C. In order to accommodate and / or position the current sensor 40A on the power module 2, a receiving and / or positioning device 40B can be arranged on the power module 2. The receiving and / or positioning device 40B can be, for example, an injection molded part made of an insulating polymer material, which can be fixed to the power module 2 (for example, by force locking and / or form locking).Alternatively, the receiving and / or positioning device 40B is provided as an integrated part of the housing 3 of the power module 2. By accommodating the current sensor 40A in the receiving part 40B (for example, in an opening complementary to the housing of the current sensor 40A), the position of the current sensor 40A relative to the through-opening D (or relative to the existing magnetic field around the busbar 14C) is clearly fixed. The flexible area of ​​the busbar 14C that is present due to the through-opening D is advantageously used as a measuring area for detecting the alternating current (or phase current) through the busbar 14C. In the same way, in the above-mentioned power module assembly 1, the corresponding phase lead-out terminals can be detected in terms of measurement technology. Alternatively, the current detection device described in this way can also be arranged in the contact area 16, 18 of the busbars 14A, 14B on the side of the current supply of the power module 2, for example, in the area where the contact connecting pieces 16.1, 16.2, 18.1 of the busbars 14A, 14B are electrically connected to the external contact surfaces 2.1A, 2.1B, 2.1C of the power module (or to other external contact surfaces 2.2A, 2.2B of the connected electrical functional components), for example, at the current supply connection terminals 32A, 32B of the capacitor assembly 30.

Claims

1. A contact device (12, 12A, 12B) for electrically contacting at least two electrical functional components (2, 2A, 2B, 2C, 30) of an electrical and / or electronic circuit and / or subcircuit in at least one connection interface (10, 10A, 10B), wherein: The contact device (12, 12A, 12B) comprises at least one busbar (14, 14A, 14B, 14C), which extends from at least one first contact area to a second contact area (16, 18) and is formed in such a way that, when the functional component (2, 2A, 2B, 2C, 30) is electrically contacted with respectively different contact areas (16, 18) of the busbar (14, 14A, 14B, 14C), a current path between the first contact area and the second contact area (16, 18) can be formed in the busbar (14, 14A, 14B, 14C), wherein the electrical contact of at least one contact area (16, 18) with at least one external contact surface (2.1, 2.2) of one of the functional components (2, 2A, 2B, 2C, 30) is formed by means of a material connection (17), in particular by means of a weld seam connection (17A), It is characterized in that Each contact region (16, 18) has at least one contact web (16.1, 16.2, 18.1) for connecting to an outer contact surface (2.1, 2.2) of one of the functional components (2, 2A, 2B, 2C, 30) in a materially bonded manner, wherein the materially bonded portion (17) is formed transversely to the extension direction of the contact web (16.1, 16.2, 18.1) in the direction of extension of the busbar (14A, 14B, 14C) between outer edge edges of the at least one contact web (16.1, 16.2, 18.1) and is interrupted by at least one through-opening (D) in the contact web (16.1, 16.2, 18.1), thereby forming at least two contact elements (K) having only subsections (17a) of the formed materially bonded portion (17).

2. The contact device (12, 12A, 12B) according to claim 1, It is characterized in that The through-opening (D) is formed as an elongated hole, wherein the longitudinal axis of the elongated hole is oriented in the direction of extension of the busbar (14A, 14B, 14C) and / or in the direction of the axis of symmetry (S) of the electrically contacted external contact surface (2.1, 2.2) of the functional component (2, 2A, 2B, 2C).

3. The contact device (12, 12A, 12B) according to claim 1 or 2, It is characterized in that The partial sections (17a) of the integral connection (17) are arranged on all contact elements (K) along a common axis.

4. The contact device (12, 12A, 12B) according to one of the preceding claims, It is characterized in that The subsections (17a) of the material connection (17) formed on the contact element (K) extend substantially from the outer edge of the contact web (16.1, 16.2, 18.1) to the outer edge of the through-opening (D), or from one outer edge of each of the two through-openings (D), between which a contact element (K) is formed.

5. The contact device (12, 12A, 12B) according to one of the preceding claims, It is characterized in that At least one, in particular all, through-openings (D) of at least one contact web (16.1, 16.2, 18.1) extend up to a terminal edge (16.13, 18.13) of the at least one contact web, which terminal edge also forms one of the terminal edges of the busbar (14A, 14B, 14C), and at least one, in particular all, through-openings (D) extend beyond an adjacent subsection (17a) of the material closure (17) on a side facing away from the terminal edge (16.13, 18.13) in the extension direction of the busbar (14A, 14B, 14C) by a distance dimension of 1 mm to 30 mm, in particular 1 mm to 20 mm.

6. The contact device (12, 12A, 12B) according to any one of claims 1 to 4, It is characterized in that At least one, in particular all, through-openings (D) of at least one contact connecting piece (16.1, 16.2, 18.1) extend to a position with a distance dimension of 1 mm to 30 mm, in particular 1 mm to 20 mm relative to the terminal edge (16.13, 18.13), which terminal edge also forms one of the terminal edges of the busbar (14A, 14B, 14C), and at least one, in particular all, through-openings (D) extend on the side facing away from the terminal edge (16.13, 18.13) in the extension direction of the busbar (14A, 14B, 14C) to a position with a distance dimension of 1 mm to 30 mm, in particular 1 mm to 20 mm in front of another contact connecting piece (16.1, 16.2, 18.1).

7. The contact device (12, 12A, 12B) according to one of the preceding claims, It is characterized in that The contact device (12, 12A, 12B) comprises at least two busbars (14A, 14B) which are electrically insulated from one another and can be acted upon by different potentials of associated functional components (2, 2A, 2B, 2C).

8. The contact device (12, 12A, 12B) according to one of the preceding claims, It is characterized in that The at least one busbar (14, 14A, 14B) is formed by a plate-like base material having a plate thickness (d) between two opposite outer surfaces, the plate-like base material being in particular a plate made of copper or a copper alloy.

9. A power module assembly (1), comprising: at least one power module (2, 2A, 2B, 2C), the power module comprising a plurality of semiconductor switches and at least one external contact surface (2.1, 2.1A, 2.1B, 2.1C, 2.1D); and At least one connection interface (10, 10A, 10B), comprising at least one contact device (12, 12A, 12B) according to one of the preceding claims, wherein At least one contact piece ( 16.1, 16.2, 18.1) are connected to the outer contact surface (2.1) of the power module (2, 2A, 2B, 2C) in a materially bonded manner, in particular by means of a weld seam connection (17A).

10. The power module assembly (1) according to claim 9, It is characterized in that The first connection interface (10, 10A) includes a first contact device (12, 12A, 12B) and is implemented to electrically connect at least a first external contact surface (2.1, 2.1A, 2.1B, 2.1C, 2.1D) of at least one power module (2, 2A, 2B, 2C) to a first power supply connection terminal (32A) by means of a first bus bar (14A), and to electrically connect at least a second external contact surface (2.1, 2.1A, 2.1B, 2.1C, 2.1D) of at least one power module (2, 2A, 2B, 2C) to a second power supply connection terminal (32B) by means of a second bus bar (14B).

11. The power module assembly (1) according to claim 9 or 10, It is characterized in that The second connection interface (10, 10B) comprises a further contact device (12, 12A, 12B) according to one of claims 1 to 8 and is embodied to electrically connect at least one fourth external contact surface (2.1D) of the at least one power module (2, 2A, 2B, 2C) to a load connection (34) by means of a further busbar (14C).

12. The power module assembly (1) according to claim 11, It is characterized in that There are three power modules (2), wherein at least one fourth external contact surface (2.1D) of the first power module (2A) is electrically connected to a load connection terminal (34) implemented as a first phase connection terminal (34U) and provides a first phase current for the motor, wherein at least one fourth external contact surface (2.1D) of the second power module (2B) is electrically connected to a load connection terminal (34) implemented as a second phase connection terminal (34V) and provides a second phase current for the motor, and Therein, at least one fourth external contact surface (2.1D) of the third power module (2C) is electrically connected to a load connection terminal (34) implemented as a third phase connection terminal (34U) and provides a third phase current for the motor.

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