Upper component for creating a component connection with an overlap joint, arrangement, and method for producing an arrangement

Abstract

The invention relates to a superstructure (12) for creating a component connection with an overlap joint (18), comprising at least one first welding area (20) for creating a first weld connection (22) between the superstructure (12) and at least one further component (14), wherein the further component (14) faces a bottom surface (24) of the superstructure (12), and wherein the superstructure (12) has a second welding area (28) for creating a second weld connection with the further component (14), which has a raised area (34) relative to a surface (32) of the superstructure (12). The invention further relates to an arrangement (10) and a method for manufacturing an arrangement (10).

Description

[0001] The invention relates to an upper component for producing a component connection with a lap joint according to the applicable patent claim 1. Furthermore, the invention relates to an arrangement and a method for producing an arrangement.

[0002] According to the current state of the art, component joints with overlapping joints and a larger gap between the components cannot be welded flawlessly using I-beams, as the gap cannot be sufficiently filled with molten metal during the process. Particularly in applications with curved superstructures, the curvature of the component creates a gap next to an originally welded fillet weld, meaning that if the initial weld is faulty, the joint cannot be repaired with a second, adjacent weld.

[0003] DE 10 2021 005 274 A1 relates to a method for producing a welded joint of at least three components by means of energy radiation, wherein a first lower edge of an upper component of the at least three components is arranged on at least one first lower component of at least two lower components of the at least three components in such a way that the first lower edge of the upper component rests on a first contact surface of the at least one first lower component and thereby at least one first connection region is formed, wherein one of the first lower edges in the connection direction of the at least two lower components opposite the second lower edge of the upper component is arranged on at least one second lower component of the at least two lower components in such a way,that the second lower edge of the upper component rests on a second contact surface of the at least one second lower component, thereby forming at least one second connecting region, wherein the upper component is arranged on the at least one first lower component and on the at least one second lower component such that a concave boundary surface of the upper component arranged between the first lower edge and the second lower edge faces the at least one first lower component and the at least one second lower component, wherein the upper component is subjected to an energy beam in the at least one first connecting region and in the at least one second connecting region, wherein the energy beam is displaced in a weld seam direction at least in regions along the first lower edge of the upper component and at least in regions along the second lower edge of the upper component,so that in the at least one first connecting region, the first lower edge of the upper component is welded to the at least one first lower component by forming at least one first weld seam, and in the at least one second connecting region, the second lower edge of the upper component is welded to the at least one second lower component by forming at least one second weld seam.

[0004] DE 10 2022 000 445 A1 relates to a welded joint between two components, wherein a second component is positioned on a surface of the first component and welded to the first component. The weld seam runs along or parallel to an edge of the second component, with the second component having a chamfer in the region of the edge, so that it tapers at an acute angle to the edge touching the first component.

[0005] The object of the present invention is to provide an upper component, an arrangement and a method by means of which a reliable mechanical connection between the upper component and another component can be formed.

[0006] This object is achieved by an upper component, an arrangement, and a method according to the independent patent claims. Advantageous embodiments are specified in the subclaims.

[0007] One aspect of the invention relates to an upper component for producing a component connection with a lap joint, with at least one first welding region for producing a first welded connection between the upper component and at least one further component, wherein the further component faces an underside of the upper component.

[0008] It is provided that the upper component has a second welding area for producing a second welded connection with the further component, which has an elevation relative to a surface of the upper component.

[0009] In particular, the upper component thus has a material thickening as an elevation with a predetermined height, which, in particular, depends on the expected gap, which can fill the missing volume in the gap by melting it during the welding process, so that an I-beam can be reliably applied in the area of ​​the material thickening. The first weld is to be considered in particular as the initial weld and is therefore carried out in particular before the second connection. Particularly in the case of the previously faulty first weld, which can be carried out, for example, using laser welding, the component forming with material thickening according to the invention offers a process-reliable solution for supplementary or repair welding.

[0010] The welding can be carried out as a linear weld or as a laser weld with superimposed beam oscillation in order to melt and melt the material thickening well.

[0011] This makes it possible, in particular, to compensate for larger gaps in overlap joints by melting in the material thickenings. The material thickenings can be integrated directly into the production process of the upper component, for example, by manufacturing and cutting an extruded profile. This makes it possible to achieve good weld seam quality in I-seams by avoiding seam collapse and constrictions. Furthermore, the exclusion of connections with faulty arrangements can be reduced. The upper component according to the invention can be used in particular in an application for the electrical contact of battery cells by means of cell connectors to one another and busbars. The upper component can particularly preferably be joined by laser welding. This design is also possible using conventional plant technology and is therefore particularly cost-neutral.Furthermore, the material thickening can be detected using optical measuring systems, for example, so that reliable weld seam positioning in the area of ​​the material thickening can be achieved. Furthermore, the application can be realized particularly with metallic materials, particularly preferably with aluminum and aluminum alloys and / or copper and copper alloys and / or their mixed compounds.

[0012] According to an advantageous embodiment, the upper part is formed with at least one curved underside. The curved underside is, in particular, concave. This has the particular advantage of enabling a reliable connection between, for example, the upper component, the further component, and yet another component, for example, in the form of two battery cells. The upper component then serves, in particular, as a cell connector.

[0013] It is also advantageous if the height of the raised portion is determined by the radius of curvature of the underside. In particular, a gap is created between the underside of the upper component and the other component, depending on the radius of curvature. The height of the raised portion can thus be determined by the gap, ensuring sufficient material is available to enable a reliable weld between the upper component and the other component.

[0014] It is also advantageous if the width of the raised portion is determined by the radius of curvature of the underside. This also makes it possible, for example, to increase the width of the raised portion so that sufficient material is available for welding.

[0015] A further advantageous embodiment provides for the height of the raised portion to be configured depending on the radius of curvature of the surface. For example, with a concave surface, the center of the surface can be considered the highest point. It can then be provided that the raised portions, which are located in particular at corresponding ends of the upper component, are not higher than the highest height of the surface. This allows, for example, the upper component to be installed with reduced installation space.

[0016] It can also be provided that the width of the raised portion is determined depending on the surface's radius of curvature. In particular, if, for example, the installation space has a specified height and sufficient material is still available, the width of the raised portion can be adjusted instead of increasing the height. This allows sufficient material to be provided for welding while still ensuring a specified height is not exceeded.

[0017] A further advantageous embodiment provides that the upper component is designed as a cell connector for at least two battery cells as additional components. In other words, the upper component is designed to connect at least two components, in particular two battery cells. In particular, the upper component is thus made of metal for electrically connecting the two battery cells.

[0018] It is also advantageous if the upper component has the raised portion at a first end and a further raised portion at a second end opposite the first end. This allows two components to be reliably connected to one another. In particular, a raised portion can be provided on the first component to create a second welded joint, and a raised portion can also be provided on the second component to create a second welded joint. This allows two components, in particular two battery cells, to be reliably connected.

[0019] A further aspect of the invention relates to an arrangement with at least one further component and an upper component according to the preceding aspect, wherein a mechanical connection between the upper component and the further component is established by means of a welded connection.

[0020] The invention also relates to a method for producing an assembly according to the first aspect of the invention. The upper component and the further component are provided. A first welded joint is created between the upper component and the further component. The first welded joint is evaluated. Depending on the evaluation, a second welded joint is created at the elevation between the upper component and the further component. In particular, if the first welded joint is faulty, the second welded joint is created.

[0021] Advantageous embodiments of the superstructure are to be regarded as advantageous embodiments of the arrangement and the method.

[0022] Further advantages, features, and details of the invention will become apparent from the following description of a preferred embodiment and from the drawings. The features and combinations of features mentioned above in the description, as well as the features and combinations of features mentioned below in the description of the figures and / or shown alone in the figures, can be used not only in the respective combinations specified, but also in other combinations or on their own, without departing from the scope of the invention.

[0023] Showing: Fig. 1 is a schematic sectional view according to an embodiment of an arrangement; and Fig. 2 a further schematic sectional view according to an embodiment of an arrangement.

[0024] In the figures, identical or functionally identical elements are provided with the same reference numerals.

[0025] Fig. Figure 1 shows a schematic sectional view of an embodiment of an assembly 10. In the present exemplary embodiment, the assembly 10 comprises an upper component 12. Furthermore, the assembly 10 comprises at least one further component 14 and yet another component 16. In the present exemplary embodiment, the further component 14 and the yet another component 16 are designed, in particular, as battery cells. In the present exemplary embodiment, the upper component 12 is to be understood, in particular, as a cell connector between the two battery cells.

[0026] The upper component 12 is designed to create a component connection with a lap joint 18. For this purpose, the upper component 12 has a first welding area 20 for creating a first welded connection 22 between the upper component 12 and the further component 14. The further component 14 is particularly directed toward an underside 24 of the upper component 12.

[0027] In the Fig. 1 shows, in particular, that the first welded joint 20 between the additional component 14 and the upper component 12 is correct. However, a further first welded joint 26 between the upper component 12 and the yet further component 16 is not correctly formed.

[0028] In order to now carry out a repair of the component connection, in particular the further first welded connection 26 to the further component 16, in particular a second welding area 36 is provided for producing a second welded connection 30 ( Fig. 2) with the further component 16, wherein the second welding area 36 has an elevation 38 relative to a surface 32 of the upper component 12.

[0029] In the following embodiment it is shown in particular that a further second welding area 28 with a further elevation 34 can be provided.

[0030] In particular, it can be provided that a height 39 of the elevations 34 and 38 is formed depending on a gap 40 to be overcome between the further component 14 and the upper component 12. Furthermore, a width 42 can also be formed depending on the gap 14.

[0031] In particular, Fig. 1, the upper component 12 is provided essentially with a curved underside 24. The underside 24 is, in particular, concave. It can be provided that the height 38 of the elevation 34 is determined depending on the radius of curvature of the underside 24. Furthermore, the width 42 of the elevation 34 can also be formed depending on the radius of curvature of the underside 24. In particular, the gap 40 results depending on the radius of curvature.

[0032] Furthermore, it can be provided that the height 38 of the elevation 34 is determined depending on the radius of curvature of the surface 32, and the width 42 of the elevation 34 is also formed depending on the radius of curvature of the surface 32. In particular, it is provided that a corresponding amount of material is provided over the height 38 and the width 42 in order to be able to overcome the gap 40 accordingly by the second welded joint 30.

[0033] Fig. Figure 2 shows, in particular, that the second elevation 36 in the present embodiment was melted and welded in due to the faulty further first weld 26, and a corresponding mechanical connection was now realized between the further component 16 and the upper component 12. However, the elevation 34 is not melted because the first weld 22 was not faulty.

[0034] In particular, the Fig. 1 and Fig. 2 also that the upper component 12 has the elevation 34 near a first end 44 and has the further elevation 36 near a second end opposite the first end 44.

[0035] In particular, it is thus provided that the upper component 12 is provided via the material thickening with the height 38 depending on the expected gap 40, which can fill the missing volume in the gap 40 by melting during the welding process, so that an I-beam can be reliably applied in the area of ​​the elevation 34. Particularly in applications with a curved upper component 12, the material thickenings are located on the side facing the process, so that the unaffected component curvature can continue to serve to compensate for tolerances with the underlying components 14, 16. In the case of a previously faulty first weld connection 22, in particular a laser weld connection, the component shape according to the invention with material thickenings offers a process-reliable solution for supplementary or repair welding.The welding can be carried out as a linear weld or, in the case of laser welding, with superimposed beam oscillation in order to melt and melt the material thickening well. List of reference symbols 10 Arrangement 12 Superstructure 14 additional components 16 another component 18 Component connection 20 first welding area 22 first welded joint 24 subpage 26 more first welds 28 second welding area 30 second weld for component 16 32 Surface 34 Increase 36 further increase 38 additional second welding area 39 Amount of increases 40 gap 42 width 44 first end QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2021 005 274 A1

[0003] DE 10 2022 000 445 A1

[0004]

Claims

[1] Upper component (12) for producing a component connection with a lap joint (18), with at least one first welding area (20) for producing a first welded connection (22) between the upper component (12) and at least one further component (14), wherein the further component (14) faces an underside (24) of the upper component (12), characterized by that the upper component (12) has a second welding region (28) for producing a second welded connection with the further component (14), which has an elevation (34) relative to a surface (32) of the upper component (12). [2] Upper component (12) according to claim 1, characterized by that the upper component (12) is formed with at least one curved underside (24). [3] Upper component (12) according to claim 2, characterized by that a height (38) of the elevation (34) is formed depending on a radius of curvature of the underside (24). [4] Upper component (12) according to claim 2 or 3, characterized by that a width (42) of the elevation (34) is formed depending on a radius of curvature of the underside (24). [5] Upper component (12) according to one of the preceding claims, characterized by that a height (38) of the elevation (34) is formed depending on a radius of curvature of the surface (32). [6] Upper component (12) according to one of the preceding claims, characterized by that a width (42) of the elevation (34) is formed depending on a radius of curvature of the surface (32). [7] Upper component (12) according to one of the preceding claims, characterized by that the upper component (12) is designed as a cell connector for at least two battery cells as further components (14, 16). [8] Upper component (12) according to one of the preceding claims, characterized bythat the upper component (12) has the elevation (34) near a first end (44) and has a further elevation (38) near a second end (46) opposite the first end (44). [9] Arrangement (10) with at least one further component (14) and an upper component (12) according to one of claims 1 to 8, wherein a mechanical connection between the upper component (12) and the further component (14) is produced by means of a first welded connection (22) and a second welded connection. [10] A method for manufacturing an arrangement (10) according to claim 9, comprising the steps: - Providing the upper component (12) and the further component (14); - producing a first welded joint (22) between the upper component (12) and the further component (14); - Evaluate the first weld (22); and - Creating a second welded joint at the elevation (34) between the upper component (12) and the further component (14) depending on the evaluation.

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