BRACKET FOR FLEXIBLE HOLD OF A DOUBLE CURRENT BUSBAR

A flexible holder with adjustable spring stiffnesses in multiple directions addresses the issue of material stress in high-voltage double-current rails by accommodating movements, reducing stress and preventing fatigue.

DE102023113638B4Active Publication Date: 2025-11-06LISA DRAXLMAIER GMBH
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Patent Information

Application Number
DE102023113638
Authority / Receiving Office
DE · DE
Patent Type
Patents
Current Assignee / Owner
Filing Date
2023-05-24
Publication Date
2025-11-06
Estimated Expiration
2043-05-24

AI Technical Summary

Technical Problem

Existing holders for high-voltage double-current rails in electric vehicles fail to accommodate the relative movements between the electric machine and the battery, leading to material stress and premature fatigue due to insufficient clearance for movement.

Method used

A holder with a flexible material and specific geometry, featuring different spring stiffnesses in two spatial planes, allowing predefined movement ranges to reduce material stress by accommodating these movements.

Benefits of technology

The holder effectively reduces material stress and prevents premature fatigue by allowing controlled movement of the double busbar, using a flexible material with adjustable spring stiffnesses in multiple directions.

✦ Generated by Eureka AI based on patent content.

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Abstract

Mounting bracket (100) for flexibly holding a double conductor rail (110) in an electric vehicle, wherein the double conductor rail (110) comprises two electrically conductive, elongated and parallel conductor rails (111, 112) with a flat cross-section, each enclosed by insulation (113) and stacked flat side (115) to flat side (115) to form a conductor rail stack (116), wherein the mounting bracket (100) comprises the following: a first component (120) made of a flexible material, configured to enclose the double busbar (110) around a longitudinal direction (114) of the two busbars (111, 112), wherein the first component (120) has a first spring stiffness along the outer flat sides (115) of the busbar stack (116) and a second spring stiffness along two side surfaces (117) of the busbar stack (116) that laterally bound the outer flat sides (115); and a second component (130) which encloses the first component (120) and has a fixing element (131) for fixing the holder (100) in the electric vehicle, wherein the first component (120) forms a central web (133) along the two side surfaces (117) of the conductor rail stack (116), which is adapted to a contour of the two side surfaces (117) of the conductor rail stack (116).
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Description

Technical field

[0001] The present invention relates to a bracket for flexibly holding a double busbar, in particular a high-voltage double busbar, in an electric vehicle. The bracket serves to support and fix the double busbar and can be integrated into a traction path or a charging path of the electric vehicle. State of the art

[0002] Due to relative movements between the electric motor (“Electric Drive Unit”) and the high-voltage (HV) battery during operation of a battery electric vehicle (BEV), the traction path must compensate for certain movements. These relative movements create stresses in the aluminum conductor that the material cannot withstand permanently. To manage this with a rigid conductor, specific supports must be used to guide and dampen these movements.

[0003] DE 10 2018 109 863 B4 discloses a multi-component seal for sealing a rail, in particular a conductor rail for a vehicle electrical system, against a housing, comprising two lateral support components for transmitting forces between the rail and the housing; a sealing component which connects the two support components to each other in the transverse direction of the multi-component seal and has a through-opening for enclosing the rail on its outer circumference and is designed to abut an inner contour of the housing, wherein the support components are made of a material with a higher strength than the sealing component; and the support components have at least one locking element on the inside for locking with the rail.

[0004] JP 2005 - 160 273 A discloses a busbar fastening device that is able to prevent thermal deformation and improve the insertion of a busbar. Description of the invention

[0005] One objective of the invention is therefore to create an improved support that tolerates and allows to a certain degree of play in the rigid conductor in order to reduce stresses in the material.

[0006] The problem is solved by the subject matter of the independent claims. Advantageous embodiments of the invention are specified in the dependent claims, the description, and the accompanying figures.

[0007] The inventive solution is based on the idea of ​​creating a bracket for a high-voltage double rail in an electric vehicle, which can selectively influence the stresses in the material through the bracket's geometry and material. The bracket presented here allows for a certain degree of play in the rigid conductor's movement, thus reducing stresses in the material. This limited freedom of movement is achieved in the disclosed bracket through a flexible material, such as TPE or LSR, with a specific geometry. This geometry and material allow for specific spring stiffnesses and damping characteristics in two spatial planes, thereby enabling the bracket to tolerate a certain degree of movement in the high-voltage double rail.

[0008] Although this disclosure describes a bracket for high-voltage double rails (HVDS), it is understood that the bracket can also be used for other rigid conductors, such as round rigid conductors or rigid conductors of other geometries. The bracket is particularly suitable for use with rigid conductors like HVDS in the traction path of an electric vehicle, but it can also be used in the charging path of an electric vehicle.

[0009] The bracket presented here includes a flexible element, hereinafter also referred to as the first component made of a flexible material. The technical advantage of this flexible element lies in the fact that it allows for more specific control and compensation of the electric motor movements of the electric vehicle.

[0010] According to a first aspect, the problem described above is solved by a support for flexibly holding a double busbar in an electric vehicle, wherein the double busbar has two electrically conductive, elongated and parallel busbars with a flat cross-section, each enclosed by insulation and stacked flat-side to flat-side to form a busbar stack, wherein the support comprises: a first component made of a flexible material configured to enclose the double busbar around a longitudinal direction of the two busbars, wherein the first component has a first spring stiffness along the outer flat sides of the busbar stack and a second spring stiffness along two side surfaces of the busbar stack that laterally bound the outer flat sides;and a second component which encloses the first component and has a fixing element for fixing the bracket in the electric vehicle;

[0011] The technical advantage of this bracket lies in the fact that, due to the spring stiffnesses in both directions perpendicular to the longitudinal direction, it tolerates and allows to a certain degree of play in the double busbar, thus reducing stresses in the material.

[0012] According to an exemplary embodiment of the bracket, the first spring stiffness is designed to allow a predetermined range of movement of the double busbar in one direction along the outer flat sides of the busbar stack perpendicular to the longitudinal direction of the two busbars; and the second spring stiffness is designed to allow a predetermined range of movement of the double busbar in one direction along the two side surfaces of the busbar stack perpendicular to the longitudinal direction of the two busbars.

[0013] This offers the technical advantage of allowing movement in two spatial directions perpendicular to the longitudinal direction of the double busbar. This eliminates stresses in the material and prevents premature material fatigue.

[0014] According to an exemplary embodiment of the bracket, the first component has material recesses of a first geometric shape along the outer flat sides of the busbar stack, which allows compression and / or elongation of the first component according to the first spring stiffness along the outer flat sides of the busbar stack; and the first component has material recesses of a second geometric shape along the two side surfaces of the busbar stack, which allows compression and / or elongation of the first component according to the second spring stiffness along the two side surfaces of the busbar stack.

[0015] This offers the technical advantage that specific spring stiffnesses can be easily achieved using the material cutouts. In particular, different spring stiffnesses can be set in the various spatial directions according to the design of the material cutouts.

[0016] According to an exemplary embodiment of the bracket, the material recesses of the first geometric shape and / or the material recesses of the second geometric shape form a regular pattern.

[0017] This offers the technical advantage that the spring stiffness can be adjusted evenly along the length of the material recesses.

[0018] According to an exemplary embodiment of the bracket, the material recesses of the first geometric shape form circular and square openings, with each circular opening following a square opening; and the material recesses of the second geometric shape form square openings of different widths, each arranged consecutively.

[0019] This offers the technical advantage that the material recesses are easy to produce, for example using an injection molding process.

[0020] According to an exemplary embodiment of the holder, the first component consists of a thermoplastic elastomer (TPE) or a liquid silicone (LSR).

[0021] This offers the technical advantage that, due to the constantly increasing number of material types and the possibilities for bonding with various metals and plastics, TPE and LSR can be used in a wide variety of applications and with various other materials. For example, LSR material types with hardnesses ranging from 20 to 70 can be used, which meet different flexibility requirements.

[0022] According to an exemplary embodiment of the bracket, the second component consists of a glass fiber reinforced polyamide, for example PA6 GF30.

[0023] This offers the technical advantage that PA6 is versatile and can be used for cast and extruded components, for example. The plastic offers excellent toughness and wear resistance, along with good sliding properties, and can therefore be used for highly stressed components. Its strength properties are further enhanced by glass fiber reinforcement.

[0024] According to an exemplary embodiment of the bracket, the bracket with the two components consists of a two-component (2K) injection molded part or a two-component (2K) 3D printed part.

[0025] This offers the technical advantage that the bracket can be easily manufactured, for example using 2-component injection molding or 3D printing.

[0026] According to an exemplary embodiment of the bracket, the bracket with the two components can be folded up and, in the unfolded state, placed around the double busbar.

[0027] This offers the technical advantage that the bracket can be easily attached to the double power rail and also easily detached from it, which makes maintenance and repair easy.

[0028] According to an exemplary embodiment of the bracket, the bracket in the unfolded state consists of two housing shells, each comprising a part of the first component and a part of the second component.

[0029] This offers the technical advantage that the two housing shells can be easily opened and closed again, which reduces the assembly effort.

[0030] According to one exemplary embodiment of the bracket, the first component further forms a film hinge with which the two housing halves can be opened. Instead of the film hinge, another type of hinge can also be formed.

[0031] This offers the technical advantage that the film hinge makes handling easier, as the upper and lower halves of the housing are connected.

[0032] According to an exemplary embodiment of the bracket, the second component has a locking element designed to lock the two housing shells together in the closed state.

[0033] This offers the technical advantage that the bracket can be securely attached to the double power rail without the two housing halves accidentally opening.

[0034] According to an exemplary embodiment of the bracket, the first component has a third spring stiffness along the longitudinal direction of the two busbars, which is several times greater than the first and / or second spring stiffness, wherein the third spring stiffness is designed to suppress movement of the two busbars in the longitudinal direction of the two busbars.

[0035] This offers the technical advantage that a fixed fixing is achieved in the longitudinal direction of the busbars, while different freedom of movement is only permitted in the two transverse directions of the busbars.

[0036] According to the invention, the first component forms a central web along the two side surfaces of the busbar stack, which is adapted to a contour of the two side surfaces of the busbar stack.

[0037] This offers the technical advantage that the central web can engage in the space between the two stacked busbars, thus ensuring a firm hold through the bracket.

[0038] According to an exemplary embodiment of the bracket, the fixing element has a through-hole for screwing the bracket into the electric vehicle.

[0039] This offers the technical advantage that the bracket can be attached to the vehicle in a simple and robust manner.

[0040] According to a second aspect, the problem described above is solved by a method for manufacturing a support for flexibly holding a double busbar in an electric vehicle, wherein the double busbar comprises two electrically conductive, elongated and parallel busbars with a flat cross-section, each enclosed by insulation and stacked flat-side to flat-side to form a busbar stack, wherein the method comprises the following steps: injection molding a first component from a flexible material configured to enclose the double busbar around a longitudinal direction of the two busbars, wherein the first component has a first spring stiffness along the outer flat sides of the busbar stack and a second spring stiffness along two side surfaces of the busbar stack that laterally bound the outer flat sides;and injection molding of a second component which encloses the first component and has a fixing element for fixing the bracket in the electric vehicle;

[0041] The technical advantage of such a method lies in the fact that a bracket, as described above, can be manufactured in a simple manner. A bracket can be produced which, due to the spring stiffness in both directions perpendicular to the longitudinal direction, tolerates and allows a certain degree of play in the double busbar, thus reducing stress in the material.

[0042] According to an exemplary embodiment of the method, the holder can be manufactured as a two-component (2K) injection molded part using the 2K injection molding process.

[0043] Using this method, a bracket can be easily manufactured as a 2K injection molded part, in accordance with the first aspect described above. Brief character description

[0044] The invention will now be described in more detail with reference to exemplary embodiments and the figures. The figures show: Fig. 1 a 3D representation of a holder 100 according to the invention with a double busbar 110 inserted; Fig. 2 a 3D representation of the holder 100 according to the invention in the unfolded state; Fig. 3 a side view of the holder 100 according to the invention in the folded-up state; Fig. 4a a 3D representation of the first component 120 of the bracket 100 made of flexible material in the folded state; Fig. 4b a 3D representation of the first component 120 of the bracket 100 made of flexible material in the unfolded state; and Fig. 5 a 3D representation of a complete assembly 500 of the bracket 100 with double power rail 110 on a support 501 in the vehicle.

[0045] The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are consistently identified by the same reference numerals.

[0046] The following detailed description refers to the accompanying drawings, which form part thereof and illustrate specific embodiments in which the invention can be implemented. It is understood that other embodiments can also be used and structural or logical modifications can be made without deviating from the concept of the present invention. Therefore, the following detailed description is not to be understood as limiting. Furthermore, it is understood that the features of the various embodiments described herein can be combined with one another, unless specifically stated otherwise.

[0047] The aspects and embodiments are described with reference to the drawings, where the same reference numerals generally refer to the same elements. For illustrative purposes, numerous specific details are presented in the following description to provide a thorough understanding of one or more aspects of the invention. However, it may be obvious to a person skilled in the art that one or more aspects or embodiments can be implemented with a lesser degree of specific detail. In other cases, known structures and elements are shown schematically to facilitate the description of one or more aspects or embodiments. It is understood that other embodiments may be used and structural or logical modifications may be made without departing from the concept of the present invention.

[0048] Fig. Figure 1 shows a 3D representation of a holder 100 according to the invention with a double busbar 110 inserted.

[0049] Such a bracket 100 serves to flexibly hold a double busbar 110, as shown in Figure 1, in an electric vehicle. Such a double busbar 110 has two electrically conductive, elongated busbars 111, 112 running parallel to each other with a flat cross-section, each encased in insulation 113 and stacked flat-side 115 to flat-side 115 to form a busbar stack 116. The busbar stack 116 then has two outer flat sides 115, as shown in Fig. 1, and two side surfaces 117 laterally bounding the outer flat sides 115, with respect to which the two busbars 111, 112 are stacked. The two inner flat sides 115 of the busbars 111, 112 are no longer visible in the busbar stack 116. The elongated and parallel busbars 111, 112 extend along a longitudinal direction 114, as shown in Fig. 1 recognizable. This longitudinal direction 114 corresponds to the current direction or the opposite current direction of the current flowing through the double busbar 110.

[0050] The bracket 100 comprises a first component 120 made of a flexible material. The first component 120 is designed to enclose the double busbar 110 around the longitudinal direction 114 of the two busbars 111, 112, i.e., transversely to the longitudinal direction 114 or radially to the longitudinal direction 114. The first component 120 exhibits a first spring stiffness along the outer flat sides 115 of the busbar stack 116, which thus run transversely or perpendicularly to the longitudinal direction 114, and a second spring stiffness along two side surfaces 117 of the busbar stack 116 that laterally bound the outer flat sides 115 and also run transversely or perpendicularly to the longitudinal direction 114.

[0051] The bracket 100 comprises a second component 130, which encloses the first component 120, and a fixing element 131 for fixing the bracket 100 in the electric vehicle or on a support 501 in the vehicle, as shown in Fig. 5 shown.

[0052] The first spring stiffness can be designed to allow a predetermined range of movement of the double conductor rail 110 in one direction along the outer flat sides 115 of the conductor rail stack 116 perpendicular to the longitudinal direction 114 of the two conductor rails 111, 112.

[0053] The second spring stiffness can be designed to allow a predetermined range of movement of the double conductor rail 110 in one direction along the two side surfaces 117 of the conductor rail stack 116 perpendicular to the longitudinal direction 114 of the two conductor rails 111, 112.

[0054] The two spring stiffnesses are different in one embodiment, but can also be the same in another embodiment.

[0055] The first component 120 has material recesses of a first geometric shape 121 along the outer flat sides 115 of the busbar stack 116, which allow compression and / or elongation of the first component 120 according to the first spring stiffness along the outer flat sides 115 of the busbar stack 116.

[0056] The first component 120 further has material recesses of a second geometric shape 122 along the two side surfaces 117 of the busbar stack 116, which allow compression and / or elongation of the first component 120 according to the second spring stiffness along the two side surfaces 117 of the busbar stack 116.

[0057] The material recesses of the first geometric shape 121 and the second geometric shape 122 are located within an outer contour of the first component, for example, between an inner contour and the outer contour of the first component, i.e., each enclosed by the flexible material of the first component 120, whereby the inner contour is not necessarily required. They can, as shown here in Fig. Figure 1 shows the recesses positioned centrally between the inner and outer contours of the first component 120. These recesses can be through holes in the flexible material of the first component 120 or blind holes that are inserted from one side of the first component 120 and do not extend all the way to the other side.

[0058] In the exemplary embodiment of the Fig. 1. The two geometric shapes 121, 122 are different, but they can also be identical.

[0059] As in Fig. As can be seen in Figure 1, the material recesses of the first geometric shape 121 and the material recesses of the second geometric shape 122 can each form a regular pattern. In another embodiment, however, the material recesses of the first and / or second geometric shape can also have a random distribution.

[0060] The material recesses of the first geometric shape 121 can form circular and square openings, as in Fig. 1 is shown, each of which has a circular opening followed by a square opening.

[0061] The material recesses of the second geometric shape 122 can form rectangular openings of different widths, as in Fig. 1 shown, each arranged consecutively.

[0062] The first component, 120, can consist of a thermoplastic elastomer (TPE) or a liquid silicone rubber (LSR). The flexible material would then be TPE or LSR. Other types of elastomers, silicones, or rubber are also possible.

[0063] The second component 130 can consist of a polyamide, for example a glass fiber reinforced polyamide, such as PA6 GF30.

[0064] The bracket 100 with the two components 120, 130 can consist of a two-component (2K) injection-molded part. It can also be a single component that can be manufactured using the 2K injection molding process.

[0065] The bracket 100 with the two components 120, 130 can be designed to be foldable, as shown in Fig. Figure 2 shows that it can be placed around the double busbar 110 when unfolded. This allows for easy installation in the vehicle. However, a non-folding version is also possible, in which the bracket is attached to the double busbar during its manufacture, for example by sliding the busbar into place.

[0066] The bracket 100, when unfolded, consists of two housing shells 101 and 102, as shown in Fig. 2 shown in more detail, each comprising a part of the first component 120 and a part of the second component 130.

[0067] A version with a non-folding design is also possible, in which the two housing halves 101 and 102 are not folded together, but can be joined together, for example, by means of fastening elements on both sides. For instance, a snap-in connection or a screw connection can be used to join the two housing halves 101 and 102.

[0068] In the exemplary embodiment of the first component 120, Fig. 1 Furthermore, a film hinge 123 is provided, with which the two housing shells 101, 102 can be opened. Instead of a film hinge, another type of hinge can also be used.

[0069] The bracket 100 is placed around the high-voltage double rail 110 for mounting and locked together, as shown in the Fig. Figure 1 shows the film hinge 123, which makes handling easier because the upper and lower shells 101, 102 are connected.

[0070] The second component 120 can have a locking element 132, as shown in Fig. Figure 1 shows a mechanism designed to lock the two housing shells 101, 102 together in the closed position. The locking element 132 can also be used without a hinge, for example, when the two housing shells 101, 102 are placed on top of each other and their assembled position is secured by the locking element 132.

[0071] The first component 120 can have a third spring stiffness along the longitudinal direction 114 of the two conductor rails 111, 112, which can be greater, in particular several times greater, than the first and / or the second spring stiffness.

[0072] The third spring stiffness can be designed to suppress or hinder movement of the two busbars 111, 112 in the longitudinal direction 114 of the two busbars 111, 112.

[0073] The first component 120 can form a central web 133 along the two side surfaces 117 of the busbar stack 116, as better shown in Fig. Figure 3 shows a contour adapted to the two side surfaces 117 of the busbar stack 116. The central web 133 can engage in the lateral recess of the busbar stack 116, which is formed by stacking two laterally rounded flat busbars 111, 112 on top of each other, as shown in Figure 3. Fig. 1 shown.

[0074] The fixing element 131 can have a through-hole or bore for screwing the bracket 100 into the electric vehicle. Other types of fastening are also possible, for example a clip fastening or a plug fastening.

[0075] Fig. Figure 2 shows a 3D representation of the holder 100 according to the invention in the unfolded state.

[0076] The bracket 100 with the two components 120, 130 can be designed to be foldable, as shown in Fig. Figure 2 shows the unfolded state. In this unfolded state, the bracket 100 can be placed around the double busbar 110. This allows for easy installation in the vehicle.

[0077] When unfolded, the bracket 100 consists of two housing shells 101, 102, each comprising a part of the first component 120 and a part of the second component 130.

[0078] In Fig. Figure 2 shows two housing shells 101, 102 which can be opened along the outer flat sides 115 of the busbar stack 116. In another embodiment, the two housing shells 101, 102 can also be opened along a direction perpendicular to the outer flat sides 115 of the busbar stack 116.

[0079] The bracket can consist of a 2K plastic injection molded component (TPE / LSR and PA6 GF30) that connects the upper and lower shells 101, 102 by means of a TPU / LSR film hinge 123, as shown in Fig. 2 shown.

[0080] The film hinge 123 can therefore be made from the flexible material. The entire bracket 100, as it is in Fig. 2, shown in the unfolded state, can be manufactured as a single component in 2-component injection molding, where the first component 120 represents the first component of the 2K injection molding and the second component 130 represents the second component of the 2K injection molding.

[0081] Fig. Figure 3 shows a side view of the holder 100 according to the invention in the folded-up state.

[0082] When folded, the two components 120, 130 of the holder 100 can be seen, as well as the material recesses of the first geometric shape 121 and the second geometric shape 122 on the flexible material of the first component 120.

[0083] The material recesses of the first geometric shape 121 and the second geometric shape 122 are located within an outer contour of the first component, for example, between an inner contour and the outer contour of the first component, i.e., each enclosed by the flexible material of the first component 120, whereby the inner contour is not necessarily required. As in Fig. As shown in Figure 3, they can be formed approximately midway between the inner contour and the outer contour of the first component 120. They can be designed as through holes or as blind holes.

[0084] In the exemplary embodiment of the Fig. In section 3, the two geometric shapes 121 and 122 are different. They each exhibit a regular pattern. The material cutouts of the first geometric shape 121 can form circular and rectangular openings, with each circular opening following a rectangular opening. The rectangular openings can have two parallel edges and two rounded edges, with the rounded edges always adjacent to the circular openings.

[0085] The material cutouts of the second geometric shape 122 can form quadrilateral openings of different widths, arranged consecutively. Thus, two quadrilaterals forming a parallelogram can enclose a rectangle in the center of the side face.

[0086] Fig. Figure 4a shows a 3D representation of the first component 120 of the bracket 100 made of flexible material in the folded state.

[0087] When folded, the material recesses of the first geometric shape 121 and the second geometric shape 122 can be seen on the flexible material of the first component 120.

[0088] Furthermore, the film hinge 123 is shown, with which the bracket 100 can be folded open and closed.

[0089] The first component 120 forms a flexible element, for example made of TPE / LSR material, with a specific geometry to adjust stiffnesses in different axes.

[0090] Depending on the chosen pattern of material cutouts of the first geometric shape 121 and the second geometric shape 122, corresponding spring stiffnesses are achieved.

[0091] Fig. Figure 4b shows a 3D representation of the first component 120 of the bracket 100 made of flexible material in the unfolded state.

[0092] When unfolded, the material recesses of the first geometric shape 121 and the second geometric shape 122 can be seen on the flexible material of the first component 120.

[0093] Furthermore, the film hinge 123 is shown, with which the bracket 100 can be opened and closed. It consists of the flexible material of the first component 120. The film hinge 123 can be designed as two thin struts that flexibly connect the two housing halves 101, 102 to each other.

[0094] Fig. Figure 5 shows a 3D representation of a complete assembly 500 of the bracket 100 with double power rail 110 on a support 501 in the vehicle.

[0095] The bracket 100 is attached around the double busbar 110 and mounted on a support 501 in the vehicle. Screw fixings can be used for fastening. The fixing element 131 can be a metal bushing hole with a screw to fix the bracket to the support. The insert bushing for the screw can be overmolded to prevent settling or creep of the screw connection.

[0096] The disclosure also relates to a method for manufacturing a bracket as described above. Fig. 1 to 5 described. Such a procedure comprises the following steps: Injection molding of a first component from a flexible material, which is configured to enclose the double busbar around a longitudinal direction of the two busbars, wherein the first component has a first spring stiffness along the outer flat sides of the busbar stack and a second spring stiffness along two side surfaces of the busbar stack that laterally bound the outer flat sides. Injection molding of a second component which surrounds the first component and has a fixing element for fixing the bracket in the electric vehicle.

[0097] The bracket can be manufactured, for example, as a two-component (2K) injection molded part using the 2K injection molding process.

[0098] The process allows the simple production of a bracket 100, as described above, as a 2K injection molded part. REFERENCE MARK LIST 100 brackets 101 first housing shell 102 second housing shell 110 double busbar 111 first busbar 112 second busbar 113 Insulation 114 Longitudinal direction of the two conductor rails 115 flat side(s) of the busbars 116 busbar stacks 117 side faces of the power rail stack 120 first component 121 material recesses of a first geometric form 122 material recesses of a second geometric shape 123 Film hinge 130 second component 131 Fixing element 132 Locking element 133 Central web of the first component 500 complete assembly 501 carriers

Claims

[1] Mounting bracket (100) for flexibly holding a double conductor rail (110) in an electric vehicle, wherein the double conductor rail (110) comprises two electrically conductive, elongated and parallel conductor rails (111, 112) with a flat cross-section, each enclosed by insulation (113) and stacked flat side (115) to flat side (115) to form a conductor rail stack (116), wherein the mounting bracket (100) comprises: a first component (120) made of a flexible material, configured to enclose the double busbar (110) around a longitudinal direction (114) of the two busbars (111, 112), wherein the first component (120) has a first spring stiffness along the outer flat sides (115) of the busbar stack (116) and a second spring stiffness along two side surfaces (117) of the busbar stack (116) that laterally bound the outer flat sides (115); and a second component (130) which encloses the first component (120) and has a fixing element (131) for fixing the holder (100) in the electric vehicle, wherein the first component (120) forms a central web (133) along the two side surfaces (117) of the conductor rail stack (116), which is adapted to a contour of the two side surfaces (117) of the conductor rail stack (116). [2] Mounting bracket (100) according to claim 1, wherein the first spring stiffness is designed to allow a predetermined range of movement of the double conductor rail (110) in one direction along the outer flat sides (115) of the conductor rail stack (116) perpendicular to the longitudinal direction (114) of the two conductor rails (111, 112); and wherein the second spring stiffness is designed to allow a predetermined range of movement of the double conductor rail (110) in one direction along the two side surfaces (117) of the conductor rail stack (116) perpendicular to the longitudinal direction (114) of the two conductor rails (111, 112). [3] Holder (100) according to claim 1 or 2, wherein the first component (120) has material recesses of a first geometric shape (121) along the outer flat sides (115) of the busbar stack (116), which allow compression and / or elongation of the first component (120) according to the first spring stiffness along the outer flat sides (115) of the busbar stack (116); and wherein the first component (120) has material recesses of a second geometric shape (122) along the two side surfaces (117) of the busbar stack (116), which allow compression and / or elongation of the first component (120) according to the second spring stiffness along the two side surfaces (117) of the busbar stack (116). [4] Holder (100) according to claim 3, wherein the material recesses of the first geometric shape (121) and / or the material recesses of the second geometric shape (122) form a regular pattern. [5] Holder (100) according to claim 3 or 4, wherein the material recesses of the first geometric shape (121) form circular and square openings, with each circular opening following a square opening; and wherein the material recesses of the second geometric shape (122) form square openings of different widths, which are arranged consecutively. [6] Holder (100) according to one of the preceding claims, wherein the first component (120) consists of a thermoplastic elastomer (TPE) or a liquid silicone (LSR). [7] Holder (100) according to one of the preceding claims, wherein the second component (130) consists of a glass fiber reinforced polyamide (PA6 GF30). [8] Holder (100) according to one of the preceding claims, wherein the holder (100) with the two components (120, 130) consists of a two-component (2K) injection molded part. [9] Mounting bracket (100) according to one of the preceding claims, wherein the mounting bracket (100) with the two components (120, 130) can be folded open and, in the unfolded state, can be placed around the double busbar (110). [10] Mounting bracket (100) according to claim 9, wherein the mounting bracket (100) in the unfolded state consists of two housing shells (101, 102) which each comprise a part of the first component (120) and a part of the second component (130). [11] Mounting device (100) according to claim 10, wherein the first component (120) further forms a film hinge (123) with which the two housing shells (101, 102) can be opened. [12] Holder (100) according to claim 10 or 11, wherein the second component (120) has a locking element (132) configured to lock the two housing shells (101, 102) together in the closed state. [13] Mounting bracket (100) according to any one of the preceding claims, wherein the first component (120) along the longitudinal direction (114) of the two conductor rails (111, 112) has a third spring stiffness which is several times greater than the first and / or the second spring stiffness, wherein the third spring stiffness is designed to suppress movement of the two conductor rails (111, 112) in the longitudinal direction (114) of the two conductor rails (111, 112). [14] Mounting bracket (100) according to one of the preceding claims, wherein the fixing element (131) has a through-hole for screwing the mounting bracket (100) into the electric vehicle.

Citation Information

Patent Citations

  • Multi-component seal for sealing a rail, in particular a power rail for a vehicle electrical system, against a housing

    DE102018109863B4

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