Sprayed high-voltage bus for vehicle, in particular electric vehicle

Abstract

The present disclosure relates to a method of manufacturing a high voltage bus bar for current transfer in a vehicle, in particular in an electrically driven vehicle, the method comprising: providing a bus bar body made of a copper metal or an aluminum metal as a metal forming an oxide layer, the busbar body has a first contact region and at least one further contact region spatially separated from the first contact region, each contact region being designed to have a corresponding contact surface for establishing an electrical contact with the busbar body; and spraying at least one of the contact areas with a material stream of a molten corrosion-resistant metal, thereby constructing a contact surface, to provide a method for producing a permanently reliable high-voltage bus bar, which is resource-saving, particularly environmentally friendly, flexible and easy to operate, and a high-voltage bus bar produced by such a method.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a high-voltage busbar for transmitting current in a vehicle, particularly in an electrically driven vehicle. The method includes providing a busbar body made of copper or aluminum metal, which is an oxide-layer-forming metal, the busbar body having a first contact area and at least one further contact area spatially separated from the first contact area, each contact area having a corresponding contact surface for establishing electrical contact with the busbar body and thus with the busbar. Background Art

[0002] In vehicles, especially electrically driven vehicles, large currents occur despite high voltages. This is the case, for example, during fast charging. Therefore, busbars, i.e., solid power lines made of solid material, are increasingly replacing traditional braided lines used as power lines in vehicles and are becoming more and more popular.

[0003] One problem is that the contact surfaces of the busbar are prone to corrosion due to operating conditions. To avoid this problem, the busbar is coated, generally by electroplating during conveyor belt transport or as a rack product in a dipping bath. The entire busbar is usually coated with gold, silver, palladium, nickel, and tin, as well as alloys based on or containing these metals.

[0004] Tin contact surfaces can also be produced using a hot dip tinning process, in which the busbar is completely or partially tinned in a dipping bath. However, it is difficult to achieve defined contact surface properties in this way. Therefore, electrochemical processes are the most common. The problem with electrochemical processes is that they require a large amount of resources, for example, consuming large amounts of chemicals, energy, and water, as well as a significant amount of coating material.

[0005] As an alternative to electrochemical processes, other methods are known, but these methods have not been widely accepted.

[0006] For example, EP 3719932B1 discloses a contact insert made of a material different from the busbar.

[0007] EP3091617 describes a method for generating at least one functional area limited to a partial surface of a contact element. A material coating in the form of a paste, powder, wire, or film is mechanically applied to the contact element, and then high-energy thermal radiation is used to change the mechanical and chemical properties of the material coating.

[0008] DE 102022105707A1 proposes a surface structure that can penetrate the oxide layer of the busbar, thus overcoming the oxidation problem of the contact surface.

[0009] Therefore, the technical problem to be solved is to provide a more resource-efficient, especially more environmentally friendly, flexible and easy-to-use process for manufacturing permanently reliable (high-voltage) busbars. Summary of the Invention

[0010] This problem is solved by the subject matter of the independent claims. Advantageous embodiments are apparent from the dependent claims, the description and the drawings.

[0011] One aspect relates to a method for producing a high-voltage busbar (which can also be referred to as a conductor rail) for transmitting current in a vehicle, in particular for transmitting current in an electric vehicle. The vehicle can be a land vehicle (such as a motor vehicle, for example a passenger car, a truck or a motorcycle), an air vehicle (such as a quadcopter drone) or a water vehicle (such as a boat). An electric vehicle can be understood as a vehicle having an electric drive motor, such as an electric car. The high voltage can be, for example, a voltage of at least 60 V, preferably at least 200 V, particularly preferably at least 380 V, and most preferably at least 780 V.

[0012] The process comprises a series of process steps. One process step is: providing a busbar body made of copper metal or aluminum metal, which is a metal that forms an oxide layer. The busbar body is preferably flat, so the busbar is preferably flat. Thus, at least in sections (i.e., in sections or over the entire busbar), the thickness measured in the thickness direction transverse to the main extension direction of the busbar (along its route) is less than the width of the busbar measured in a thickness direction transverse to the thickness direction and transverse to the main extension direction. For example, the width can be at least twice the thickness. The width can also vary along the busbar. For example, the width can be at least five times the thickness, preferably the width is at least ten times the thickness (at least in some sections). Any tabs (which may be provided for fastening) can be neglected. The busbar can have minimum dimensions, where the overall length is at least 150 mm, and / or the thickness is at least 3 mm, and / or the width is at least 20 mm.

[0013] The copper or aluminum metal is preferably copper or aluminum, but can also be a copper alloy or an aluminum alloy. In principle, further elements, such as fastening elements, such as eyelet inserts, etc., can be provided on the busbar body. Compared with a power cord based on wire braiding, the busbar body has a solid structure, i.e., a continuous cross-sectional area in the corresponding metal. Preferably, the busbar body has a substantially rectangular cross-section (i.e., especially apart from rounded edges). Compared with common flexible power cords based on wire braiding, the busbar is a rigid power cord.

[0014] The busbar body has a first contact area and at least one further contact area spatially separated from the first contact area, i.e., one or more further contact areas spatially separated from the first contact area and / or from each other. The contact areas each correspond to a first contact surface or a further contact surface for establishing electrical contact with the busbar body, thereby serving to conduct current through the busbar. When the busbar is used as intended, the contact surfaces will be in electrical contact with other current-carrying components in the vehicle, such that current can flow between different contact surfaces and thus between different contact areas. For example, a charging current of more than 10 A or even more than 100 A can be conducted through the busbar. Therefore, the busbar is preferably designed to carry high currents of more than 10 A, more preferably more than 100 A. Each contact surface can be assigned to a current-carrying component, and / or each current-carrying component can be assigned to a contact surface. Corresponding through-holes can be provided in one, several, or all of the contact areas. This allows the busbar, or more precisely, the associated contact surface, to be pressed particularly firmly against another current-carrying component, for example by using screws. However, this can also be achieved in other ways and / or without through-holes. Thus, the contact surfaces are designed for clamping contact.

[0015] A further process step is to spray at least one of the contact areas in the contact region with a molten flow of a corrosion - resistant and thus contact - maintaining metallic material, thereby establishing (in particular, forming) a contact surface by means of the corrosion - resistant metal or by coating the contact area with the corrosion - resistant metal. The corrosion - resistant metal prevents corrosion, in particular the oxidation of the busbar body, and is thus contact - maintaining in the sense that it contributes to the durability of the electrical contact established via the contact area and / or the contact surface. The corrosion - resistant metal itself may also oxidize, but in a way that does not damage the electrical contact or does so to a lesser extent than the metal of the busbar body. For example, in the case where the corrosion - resistant metal is tin, it forms a thin and brittle oxide layer that breaks under the contact pressure of the contact surface on the current - carrying component, thus still allowing the current - carrying component to come into contact with the unoxidized, softer tin that was previously beneath the oxide layer. The unoxidized, softer tin adapts to the shape of the mating contact surface of another current - carrying component under pressure, thereby ensuring a particularly low contact resistance. The same applies to silver. As a transport protection, the contact surface sprayed with metal may also be provided with a volatile layer (such as a wax layer) that evaporates under the contact pressure during contact.

[0016] Spraying can also be referred to as partial or area - by - area spraying because it can (essentially) be limited to the respective contact areas. Compared to known electrochemical processes, in this example only a partial area of the busbar body is coated, i.e., sprayed. Thus, the main part of the busbar body is not sprayed, and only a small part of the total surface of the busbar body, which is at least less than 50%, preferably less than 25%, and particularly preferably less than 10%, is sprayed. The main part of the busbar body that is not sprayed and thus not coated with the corrosion - resistant metal (i.e., not coated) can be correspondingly referred to as the central area. In particular, the uncoated central area separates at least two, more than two, or all of the contact areas. In particular, spraying can thus be carried out only in the contact areas (especially excluding possible transition areas that may result from spatially blurred spraying between the contact area and the central area). For better material savings, the central area can thus be covered with a spraying mask to prevent spraying into the central area. This allows for the creation of clearly defined and delimited contact areas.

[0017] During the spraying process, the molten metal droplets of the material stream are carried by an inert gas stream and / or an (atmospheric) air stream from the spraying device to the contact area, where, for example, they impinge on the busbar body while losing their droplet shape. They cool and adhere to the busbar body, which is thereby coated with the droplets. The coating of the busbar body created in this way from a corrosion-resistant metal can have a thickness of at least 30 μm and / or at least 50 μm. Preferably, the coating of the busbar body has a thickness of at least 10 μm on the contact surface. With this minimum thickness, it is ensured that the busbar body is completely covered and protected against oxidation in the area of the contact surface (i.e., the surface that forms an electrical contact with the corresponding other component when used as intended). This also helps to increase durability, especially after loosening the busbar and reattaching it to the corresponding other component (e.g., during the repair of a vehicle). In particular, the spraying is carried out uniformly so that the coating thickness in the contact area is as consistent as possible. This allows the coating to conform to the contour of the busbar body. The contact resistance is reduced by avoiding oxide inclusions in the coating. This can be achieved depending on the properties of the busbar and / or the contact surface. For example, oxide inclusions can be avoided by adapting the temperatures of the material stream and the busbar body to each other and by adapting the nozzle diameter of the nozzle used for spraying to the intensity of the protective gas stream and / or the (atmospheric) air stream.

[0018] The described method has a series of advantages. First of all, partial spraying reduces the amount of corrosion - resistant metal required, thus also reducing the energy needed for the coating. In addition, spraying is an easy - to - operate technique; unlike electrochemical processes, spraying does not involve any environmentally harmful chemicals. The coating can also be applied locally in the vicinity of other process steps, such as when stamping the busbar body, which saves transportation routes and other resources. Therefore, the manufacturing steps before spraying (such as the aforementioned stamping) can be carried out within the same building and / or the same connected (company) site, and / or within a radius of several kilometers (for example, two kilometers). This saves a significant amount of time and speeds up the production of high - voltage busbars. Since the molten corrosion - resistant metal cools and solidifies almost immediately after contact with the busbar body, for example, by re - orienting the partially sprayed busbar body between two material - flow pulses, it is possible to coat different non - intersecting contact areas (separated by a central area) with only one (pulsed) spraying device. Compared with electroplating, in which the busbar body has to be attached to the frame manually one by one, this step can be completed fully automatically, for example, using a robotic arm. Combining the spraying and fixing (in this case, melting) of the corrosion - resistant metal, i.e., performing them simultaneously in a single process, is highly advantageous. This not only saves time but also ensures that the coating can be carried out independently of the orientation of the surface to be coated in the earth's gravitational field. For example, it is possible to coat from different sides parallel to the earth's surface, which greatly increases the flexibility in terms of the busbar shape and has a shorter process duration.

[0019] In one embodiment, tin and / or zinc and / or nickel and / or silver are used as the corrosion - resistant metal during the spraying process. These metals have proven to be advantageous because they prevent the oxidation of copper or aluminum contact areas, adhere well to the busbar body during spraying, and maintain good electrical contact (despite any oxidation). Softer metals such as tin and zinc are particularly advantageous here because they are deformable under the contact pressure occurring on the contact surface, for example, when the busbar is bolt - connected to other conductive components of a vehicle. This further improves the electrical contact. It is also possible to spray using a mixture of the above - mentioned metals or a material containing the above - mentioned metals.

[0020] If the busbar body is made of copper metal and the contact surface during spraying is formed by only one corrosion - resistant metal, especially only by tin (tin layer), it will be particularly advantageous here. This combination has proven to be particularly reliable in spraying. In other processes, such as cold plasma coating, it is not applicable. Therefore, in this case, reliable contact can be achieved even without an additional adhesive layer. It is also possible to perform repeated spraying with different metals and / or different metal mixtures.

[0021] In a further embodiment, the material stream is generated using a corrosion-resistant material or by melting the corrosion-resistant material in a spraying device (in particular in a spray gun). In particular, the spray gun, as a well-known and established technology in painting work, can be used with high quality almost without location restrictions.

[0022] In one embodiment, the metal of the material stream is melted by an electric arc or a flame. Preferably, the melting occurs after the material is provided in the form of a wire. This makes the corrosion-resistant material particularly easy to feed or particularly easy to melt locally (e.g., in a spray gun), and to be sprayed or blown onto the busbar body.

[0023] In another embodiment, it is provided that before spraying, at least one contact area to be sprayed is roughened, preferably by sandblasting. The roughening can alternatively or additionally be carried out in other ways, such as by grinding, and / or glass bead blasting, and / or laser blasting. The advantage is to use easily available techniques to improve the adhesion of the corrosion-resistant metal, thereby improving the long-term performance of the busbar.

[0024] In a further embodiment, it is provided that during spraying, only the sides of the busbar body extending along the main extension plane are sprayed. The main extension plane can be the local main extension plane in the contact area. In particular, only one side of the busbar body is sprayed in each contact area. In this way, the (contact) surfaces of the busbar body that are pressed against the current-carrying components of the vehicle during intended use can be accurately sprayed and coated to save materials. Therefore, the edges of the busbar body and the areas of the busbar body facing the contact surface in the thickness direction are not sprayed, and these edges and areas are not used for transmitting current to the current-carrying components of the vehicle.

[0025] In another embodiment, it is envisaged to spray a plurality of contact areas and spray different contact areas from different directions. Therefore, the contact surfaces formed or constructed during spraying are at least partially oriented differently, especially in opposite directions. At least one contact surface is thus oriented differently from at least one further contact surface. This has the advantage that more complex busbar geometries can be coated in a simple, resource-saving and durable manner, thereby improving their performance. In particular, since the application of the corrosion-resistant metal and its fusion with the busbar body occur in a single step and are independent of the orientation of the earth's gravitational field, the proposed spraying can be used to coat contact areas with different orientations simultaneously or with temporal overlap.

[0026] In one embodiment, several contact surfaces are sprayed, and these contact surfaces extend in different planes (i.e., more than one plane). In particular, this can be done even though the orientation is the same, so that the different planes can extend parallel to each other at one or more different distances from the spraying device. The process can thus be used to coat many different busbar geometries without effort and still achieve a high-quality coating. Thus, there is no need to track the spraying device at an exact distance from the busbar geometry.

[0027] A further aspect relates to a high-voltage busbar for transmitting current in a vehicle, in particular in an electric vehicle. The high-voltage busbar has a first contact surface and at least one further contact surface, the first contact surface being designed to establish electrical contact with the busbar and being arranged in a first contact area of the busbar, and the at least one further contact surface being designed to establish electrical contact with the busbar and being arranged in a respective further contact area of the busbar. The busbar is substantially made of a metal forming an oxide layer, and at least the first contact surface is formed as a partial surface spatially separated from one or more further contact surfaces having a corrosion-resistant metal. At least one contact surface having (i.e., including) a corrosion-resistant metal is formed by spraying molten corrosion-resistant metal onto the corresponding contact. Compared with electrochemical processes and dip-coating processes, this can already be visually confirmed by the naked eye, for example, by the presence or absence of flow marks, the presence or absence of drip tips, and the typical shape of metal droplets hitting and solidifying on the busbar body.

[0028] Another aspect relates to a vehicle having such a high-voltage busbar, and / or one or more current-carrying components for a vehicle having such a high-voltage busbar.

[0029] The advantages and advantageous embodiments of the subsequent aspects correspond to the advantages and advantageous embodiments described for the previous aspect, and vice versa.

[0030] The features described and combinations of features (including the features in the introduction section), as well as the features and combinations of features disclosed in the description of the drawings or the drawings, can be used not only individually or in the combinations described, but also in combination with other features or without some of the features disclosed, without departing from the scope of the invention. Thus, embodiments that are not explicitly shown and described in the drawings but can be generated by separately combining the individual features disclosed in the drawings are also part of the invention. Therefore, embodiments and combinations of features that do not include all the features of the initially formulated independent claims will also be considered to be disclosed. In addition, embodiments and combinations of features that deviate from the combinations of features or exceed the combinations of features described by the dependency relationships of the claims are considered to be disclosed.

[0031] In the context of the present disclosure, the term "transverse / along" can be understood as "at least substantially perpendicular / parallel", i.e., "perpendicular / parallel" or "substantially perpendicular / parallel", i.e., perpendicular / parallel except for a predetermined deviation. The predetermined deviation can be, for example, at most 15 degrees, preferably at most 5 degrees, and particularly preferably at most 3 degrees. Correspondingly, "oriented relative to" in the context of the present disclosure can be understood as "at least substantially oriented relative to", i.e., "at least substantially anti-parallelly oriented". The limitation "substantially" can also refer to a maximum allowable deviation specified as a percentage, for example, at most 15%, preferably at most 5%, and particularly preferably at most 3%. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Exemplary embodiments are described in more detail below with reference to the schematic drawings. Among them,

[0033] Figure 1 A first exemplary embodiment of a sprayed high-voltage busbar is shown;

[0034] Figure 2 Another exemplary embodiment of a sprayed high-voltage busbar is shown;

[0035] Figure 3 Yet another exemplary embodiment of a sprayed high-voltage busbar is shown; and

[0036] Figure 4 A schematic representation of a spraying device is shown, by which a method for spraying a contact area of a high-voltage busbar is explained.

[0037] In the drawings, identical or functionally identical features are marked with the same reference numerals. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0038] Figure 1 An exemplary high-voltage busbar is shown in three different directions in different partial images a), b), c). In this case, the busbar 1 is a straight busbar 1, and its main extension direction (i.e., its route) extends in the x direction. The length of the busbar 1 is measured in the main extension direction, the thickness of the busbar 1 is measured in the z direction, and the width of the busbar 1 is measured in the y direction.

[0039] In Figure 1 a, the busbar is shown from the uncoated side A, and the side A is not sprayed, so it is not coated by the described method. In this example, the busbar body 2 is made of copper and has corresponding through holes 4, 4' in the first contact area 3 and at least one (here exactly one) further contact area 3' for screwing the busbar 1 to the current-carrying components in the vehicle.

[0040] In Figure 1In the side view shown in b), the equally non-sprayed edges K of the busbar 1 and / or the busbar body 2 are shown. The busbar body 2 has corresponding coatings 6, 6' in the contact areas 3, 3' (partial coatings 6, 6' of the busbar 1 and / or the busbar body 2), and in this example, the coatings 6, 6' are slightly raised compared to the busbar 1 in the uncoated area on the side B.

[0041] Figure 1 c now shows the side B of the busbar 1 that is partially or locally coated. Here, the contact areas 3, 3' are arranged on the same side B and are separated by an uncoated central area 7. The contact areas 3, 3' can be arranged in the edge area, i.e., at the edge K, but this is not necessary. It would be advantageous if the through-holes 4, 4' were each located in the contact areas 5, 5' and were thus surrounded by the contact areas 5, 5'. Thus, when used as intended, the busbar body 2 is coated in the area of maximum contact pressure on the current-carrying component of the vehicle, and due to the use of the spraying process, this makes the electrical coupling particularly resource-efficient and reliable.

[0042] In contrast to Figure 1 similar Figure 2 In subfigures a)-c), a further exemplary embodiment of a high-voltage busbar is shown, which can be produced in a resource-efficient manner using the process.

[0043] Again, the busbar 1 has two contact surfaces 5, 5', however, in this example, these two contact surfaces 5, 5' have opposite orientations, i.e., are arranged on opposite sides A, B of the busbar 1. In the main extension plane (x-y plane) of the busbar, in contrast to Figure 1 the rectangular straight design of the busbar 1 has a curve. The first contact surface 5 extends circularly around the first through-hole 4, while the second contact surface 5' extends in the edge area offset in the z direction from the remaining busbar 1 (i.e., offset in the z direction relative to the remaining busbar 1) and extends as the contact area 3' all the way to the edge K and / or the offset edge of the busbar 1. Thus, the process can be used to coat busbars of various geometries in an extremely flexible, efficient, resource-saving, and durable manner.

[0044] Furthermore, in the example shown, the busbar 1 has a series of additional through-holes 8, and no coatings 6, 6' are applied in the surrounding areas of these additional through-holes 8. Here, for example, smaller consumers can be connected to the busbar 1, or for example, the busbar 1 can be additionally attached to the vehicle, i.e., without an electrical function.

[0045] To illustrate the versatility of the method, Figure 3Further exemplary embodiments of the bus bar 1 with several contact surfaces 5, 5', 5", 5'" are shown in subfigures a) - c). The contact surfaces 5, 5', 5", 5'" are each arranged around corresponding through - holes 4, 4', 4", 4'" and are likewise circular or extend to the next edge K and / or offset edge. The terminal area in which the further contact surface 5' is also arranged is offset in the z - direction relative to the rest of the bus bar 1. Thus, although the further contact surfaces 5' and 5'" have the same orientation, i.e., are arranged on the same side B, they extend in different planes (parallel planes in this example). The first contact surface 5 and the further contact surface 5'" (both arranged on side A of the bus bar and having the same orientation with respect to each other) are oriented in a direction opposite to the further contact surfaces 5' and 5'".

[0046] In the example shown, the bus bar 1 also has a tab 9 which extends mainly in the z - x plane and is thus transverse to the main extension plane of the bus bar 1. The tab 9 has a through - hole 10 for fastening and / or electrical contact, but the tab 9 has no coating and thus no improved contact surface in the sense of the spraying process described. However, the method can be easily used to spray the contact area around the through - hole 10 and thus coat it, i.e., improve it from the perspective of permanently increasing the electrical conductivity. Since spraying is orientation - independent, it can also be carried out simultaneously with the spraying of other contact areas 3, 3', 3", 3'", especially after bending the tab into another plane (i.e., the z - x plane relative to the x - y plane). Thus, the bus bar body 2 completed in the bending - stamping process can be coated so that damage to the coating or contact surface can be avoided compared to applying the coating first and then bending.

[0047] Figure 4 A schematic representation of a spraying device during the manufacture of a high - voltage bus bar for current transmission in a vehicle is shown. Figure 4 It shows the spraying of the contact area 3 of the bus bar body 2 with a material flow 11 of a molten corrosion - resistant metal 12 such as tin after the bus bar body 2 is ready.

[0048] Here, the metal 12 is guided in the form of one or more metal wires 13 into the area of the electric arc in the nozzle area 14 of the spraying device 15 and melted there. By air or an air flow indicated by the arrow 16, the molten metal droplets are carried in the spraying direction S and a material flow 11 is generated. The spraying direction S can be selected largely independently of the earth's gravitational field. The metal droplets burst on the surface of the contact area 3 of the bus bar body 2, the metal 12 solidifies again and then forms the contact surface 5 in the example shown, usually a coating covering the contact surface 5 or an adhesive layer below the contact surface 5.

Claims

1. A method for producing a high-voltage busbar (1) for transmitting electric current in a vehicle, in particular for transmitting electric current in an electrically driven vehicle, the method comprising the following method steps: A busbar body (2) is provided, the busbar body (2) being made of copper metal or aluminum metal as a metal forming an oxide layer, the busbar body (2) having a first contact area (3) and at least one further contact area (3', 3", 3'"), each contact area having a corresponding contact surface (5, 5', 5", 5'"), the contact surfaces (5, 5', 5", 5'") being used to establish electrical contact with the busbar body (2), wherein: The at least one further contact region (3', 3", 3'") is spatially separated from the first contact region (3); Features: The contact surface (5, 5', 5", 5'") is constructed by spraying at least one of the contact areas (3, 3', 3", 3'") with a material flow (11) of molten corrosion-resistant metal (12).

2. The method according to the preceding claim, characterized in that: Tin, and / or silver, and / or nickel, and / or a mixture thereof are used as the anti-corrosion metal (12) in spraying.

3. The method according to the preceding claim, characterized in that: The busbar body (2) is composed of copper metal; and During spraying, the contact surfaces (5, 5', 5", 5'") are formed using only a corrosion-resistant metal (12), in particular only tin.

4. The method according to claim 1 or 2, characterized in that: The at least one contact area (3, 3', 3", 3'") is sprayed several times with different corrosion-resistant metals (12).

5. The method according to one of the preceding claims, characterized in that: The contact areas (3, 3', 3", 3'") are separated by a central area which is not coated with the corrosion-resistant metal (12) and occupies a large part of the surface of the busbar body (2).

6. The method according to one of the preceding claims, characterized in that: The material flow (11) is produced by melting the corrosion-resistant metal (12) in a spraying device (15), in particular a spraying gun.

7. The method according to one of the preceding claims, characterized in that: The metal (12) for the material flow (11) is melted by means of an electric arc or flame, preferably after the metal (12) for the material flow (11) is provided in the form of a wire (13).

8. The method according to one of the preceding claims, characterized in that: Prior to spraying, the at least one contact area (3, 3', 3", 3'") to be sprayed is roughened, preferably by sandblasting.

9. The method according to one of the preceding claims, characterized in that: During spraying, only the side faces (A, B) of the busbar body (2) extending along the main extension plane are sprayed, in particular only one side face (A, B) of the busbar body (2) is sprayed in each contact area (3, 3', 3", 3'").

10. The method according to one of the preceding claims, characterized in that: Several contact areas (3, 3', 3", 3'") are sprayed, and the spraying of different contact areas (3, 3', 3", 3'") is carried out from different directions, so that the constructed contact surfaces (5, 5', 5", 5'") are at least partially oriented differently.

11. The method according to one of the preceding claims, characterized in that: Multiple contact surfaces (5, 5', 5", 5'") are sprayed, and the contact surfaces (5, 5', 5", 5'") extend in different planes, in particular, although the contact surfaces (5, 5', 5", 5'") have the same orientation, the contact surfaces (5, 5', 5", 5'") also extend in different planes.

12. A high-voltage busbar (1), the high-voltage busbar (1) being used for transmitting electric current in a vehicle, in particular in an electric-drive vehicle, the high-voltage busbar (1) comprising: a first contact surface (5) which is designed to establish an electrical contact with the busbar (1) and is arranged in a first contact region (3) of the busbar; and at least one further contact surface (5', 5", 5'"), the at least one further contact surface (5', 5", 5'") being designed to establish electrical contact with the busbar (1) and being arranged in a corresponding further contact area (3', 3", 3'") of the busbar (1); wherein: The busbar (1) is substantially made of a metal that forms an oxide layer; and At least the first contact surface (5) is formed as a partial surface with a corrosion-resistant metal (12), the partial surface being spatially separated from one or more further contact surfaces (5', 5", 5'"); Features: The at least one contact surface (5) formed with the corrosion-resistant metal (12) is produced by spraying molten corrosion-resistant metal (12) onto the corresponding contact area (3).

13. A vehicle having a high-voltage busbar (1) according to the preceding claim.

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