High-current connection system

Abstract

The present invention relates to a high-current connection system for the high-current conductive connection of at least two spaced-apart high-current busbars (11), comprising a) a high-current conductive bridging element, attachable to each of the high-current rails (11), with which the distance between the high-current rails (11) can be bridged in a current-conducting manner and to which at least two spherically inwardly curved connecting surfaces are assigned, b) for each high-current busbar (11) a high-current conductive compensating element (19) that can be assigned to it, which can be arranged between the bridging part (13) and the respective high-current busbar (11) and which has a spherically outwardly curved compensating surface (20) which, in the fixed state of the bridging part (13), is directed towards one of the preferably spherically inwardly curved connecting surfaces, and c) for each high-current rail (11) at least one fastening means (17) attributable to it, with which the bridging part (13) and the respective compensating element (19) can be fastened to the respective high-current rail (11) and secured against movements relative to the respective high-current rail (11).

Description

[0001] The present invention relates to a high-current connection system with which at least two spaced-apart high-current rails can be connected to each other in a high-current-conducting manner.

[0002] Especially for battery-powered vehicles (but also for other applications), high-current busbars made of conductive materials such as copper or similar are used to conduct the high currents required to operate such vehicles from the power source, i.e., the battery pack, to the loads (electric motor, etc.). Such high-current busbars have comparatively large material cross-sections for this purpose.

[0003] For the purposes of the application, components that can conduct currents of at least 40 amperes, preferably at least 400 amperes, are understood to be in the high-current range or suitable for the high-current range.

[0004] When high-current rails are spaced apart from each other, it may be necessary to connect them at certain contact points to conduct high currents. For this purpose, lamella connectors are known, for example, which must be screwed to the ends of the rails to be connected.

[0005] Depending on local or other conditions, it may happen that the individual components of known high-current connection systems cannot be connected to the high-current rails or cannot be connected optimally - for example due to tolerances - so that no or no optimal electrical connection can be established.

[0006] The object of the present invention is to further develop the high-current connection system mentioned at the outset.

[0007] This object is achieved by a high-current connection system having the features of claim 1 or an arrangement comprising such a high-current connection system and at least two high-current rails according to claim 13.

[0008] A high-current connection system according to the invention for the high-current conducting, preferably detachable, in particular tolerance-compensating connection of at least two spaced-apart high-current rails accordingly comprises a) a high-current-conducting bridging part, which can be fastened to each of the high-current rails, in particular a metallic bridging part, preferably designed as a solid material body, with which the distance between the high-current rails can be bridged in a current-conducting manner and to which at least two, preferably spaced-apart, spherically inwardly curved connecting surfaces are assigned, in particular with a uniform material connection thereto, b) for each high-current rail, a respective high-current conducting, in particular metallic, compensating element which can be assigned to the high-current rail and which can be arranged between the bridging part and the respective high-current rail and which has a spherically outwardly curved compensating surface which, in the fastened state of the bridging part, in particular with a positive, preferably detachable connection thereto, faces one of the preferably spherically inwardly curved connecting surfaces of the bridging part, preferably with an electrically conductive connection thereto, particularly preferably in contact with the respective connecting surface, and c) for each high-current rail, at least one fastening means assignable to it, with which the bridging part and the respective compensating element can be fastened, preferably detachably, to the respective high-current rail and can be secured against movement relative to the respective high-current rail.

[0009] According to the invention, when the high-current connection system is used, the bridging part is accordingly connected to each of the two high-current rails in a high-current-conducting manner, for example in the region of two opposite ends of the bridging part, for example in a respective contact region of the respective high-current rail.

[0010] Preferably, the bridging part is detachably attached or connected to the respective high-current busbar in the contact areas using a compensating element and a fastening element, so that in an installation situation where the position of the high-current busbars is already fixed and possibly only a small installation space is available, subsequent installation of the high-current connection system is also possible. This would also make it easy to replace individual components of the high-current connection system in the event of wear.

[0011] In order to be able to adapt the high-current connection system according to the invention with regard to possible installation tolerances and / or possible component tolerances, etc., the compensating elements each have the spherically outwardly curved compensating surface, and the bridging part is correspondingly assigned the preferably spherically inwardly curved connecting surfaces.

[0012] According to the invention, the high-current rails can then be connected to one another in a high-current-conducting manner, when the bridging part is attached, via the electrically conductive bridging part and the respective electrically conductive compensating element(s), so that electrical current can flow through these components from one high-current rail to the other. In the simplest case, for this purpose, each (metallic) compensating element can, on the one hand, be in direct electrically conductive contact with the respective contact area of ​​the high-current rail assigned to it, and, on the other hand, be directly electrically conductive with the respective connecting surface connected to the bridging part using the same material. Naturally, however, it is also conceivable to use electrically conductive connecting pastes, etc., as intermediate layers.

[0013] The respective compensation surface and the respective connecting surface preferably form an articulated connection (with corresponding degrees of freedom) in the manner of a ball joint.

[0014] In the simplest case, the connecting surfaces can, for example, be a uniform component of the bridging part. They can be molded into the bridging part, for example, if the bridging part is a cast part, or incorporated into it through suitable material processing. However, it is also theoretically conceivable for additional connecting elements to be assigned to the bridging part, which can, for example, be welded or soldered to the bridging part and which then comprise the connecting surfaces. As the person skilled in the art will recognize, a wide variety of possibilities are conceivable here.

[0015] Preferably, the compensating elements can each have a central through-hole, in particular designed as an elongated hole, through which one of the particularly elongated fastening elements passes relative to or in the attached state of the bridging part. The use of such an elongated hole enables adjustment of the respective position of the compensating elements relative to the respective high-current rail or the respective contact area thereof.

[0016] Furthermore, the compensating elements can have a flat side on their side opposite the compensating surface, which, when the bridging part is fastened, then faces the respective high-current rail, in particular - in the simplest case - in electrically conductive contact with the respective high-current rail, if necessary using an electrically conductive intermediate layer or intermediate layer.

[0017] Further preferably, for a similar purpose, the bridging part can also have at least two through holes, each designed in particular as an elongated hole, wherein each of these through holes is penetrated by one of the fastening elements, in particular elongated, when the bridging part is fastened.

[0018] Further preferably, in the fastened state of the bridging part, each through-hole of the bridging part can be aligned with a through-hole of one of the compensating elements along a common axis (one above the other) and the respective fastening element can pass through these two through-holes in this state.

[0019] Specifically, it can be provided that the respective fastening means, in particular a screw, penetrates into a through-hole of the respective high-current busbar when the bridging part is fastened or passes through it and is connected, in particular screwed, in a force-locking and / or form-locking manner to a matching securing part of the high-current connection system, which is supported on the high-current busbar and preferably has a matching thread. This is preferably done with a threaded sleeve or a nut. Alternatively, the respective fastening means, designed as a screw, can also be screwed to a thread introduced into the high-current busbar when the bridging part is fastened.

[0020] Regarding the specific design of the bridging part, it can, for example, be wave-shaped in a longitudinal section. When the bridging part is attached, a wave trough of the bridging part can be arranged between the high-current rails and / or each of the connecting surfaces assigned to the bridging part can be located in the region of a wave crest of the bridging part, in particular on the underside of the respective wave crest.

[0021] In the fastened state of the bridging part, a head part of the respective fastening means, in particular designed as a screw, can rest force-locking and / or form-locking under tension directly on the bridging part or on a washer arranged between the head part and the bridging part in order to secure the bridging part against the relative movements relative to the respective high-current rail.

[0022] It can be provided that the washer has, on its side facing the bridging part, a spherically inwardly curved compensating surface which faces a spherically outwardly curved connecting surface of the bridging part, in particular with a positive, preferably detachable connection, particularly preferably in contact with the respective connecting surface.

[0023] The high-current connection system can further comprise a holding part for each compensating element, which can be fastened to the bridging part in a force-fitting and / or form-fitting manner, preferably designed as a plastic component, with which the respective compensating element can be releasably fastened to the bridging part with its outer side facing the respective connecting surface of the bridging part, preferably with the components releasably clamped against one another, in particular to form a pre-assembly assembly. With such a holding part, the aforementioned components of the high-current connection system and, if necessary, additional components, such as the aforementioned washer(s), can first be pre-assembled to form a unit or pre-assembly assembly and then connected to the respective high-current rail in this pre-assembled state.

[0024] The holding part can also have at least one locking means designed for fastening to the respective compensating element, in particular at least one elastic locking arm (preferably at least two elastic locking arms), which then engages in a suitable fastening recess in the compensating element when fastened.

[0025] The holding part can furthermore have a particularly round through-hole into which the head part of the respective fastening means is at least partially immersed when the bridging part is fastened.

[0026] Further features of the present invention emerge from the appended patent claims, the following description of preferred embodiments and the appended drawings.

[0027] It shows: Fig. 1 an oblique view of an embodiment of an arrangement comprising two high-current rails and a high-current connection system connecting them in a high-current-conducting manner in an exploded view, Fig. 2 the arrangement Fig. 1 in a pre-assembled state in exploded view, Fig. 3 the arrangement Fig. 1 in plan view, Fig. 4 a section through the arrangement of Fig. 1 along the section line B - B in Fig. 3, Fig. 5 a section through the arrangement of Fig. 1 along the section line A - A in Fig. 3.

[0028] With a high-current connection system 10 according to the invention shown in the drawings, two spatially spaced high-current rails 11 (busbars) are connected to one another in a high-current-conducting manner.

[0029] The metallic (rigid) high-current rails 11, for example made of copper or another electrically conductive metal or another electrically conductive metal alloy, are in the present case each formed in an L-shaped manner with an end section angled by 90° to the main longitudinal extent of the respective high-current rail 11, which at the same time serves as a contact area 12 in which the respective high-current connection system 10 contacts the high-current rails 11.

[0030] In order to be able to compensate for possible tolerances etc. in the position of the two high-current rails 11 relative to one another and / or dimensional and / or angular tolerances of the high-current rails 11, the high-current connection system 10 is designed in a special way.

[0031] For this purpose, it comprises a wave-shaped, solid metallic bridging part 13, which in the present case is electrically conductively or high-current-conductingly connected to the respective contact area 12 of the respective high-current busbar 11 by contact areas 16 arranged at opposite ends of the bridging part 13, which are located in the area of ​​wave crests 14a and 14b of the bridging part 13 formed there. This electrical connection between the contact areas 12 of the respective high-current busbar 11 and the contact areas 16 of the bridging part 13 is detachable in this case, so that it could also be subsequently established for high-current busbars 11 already permanently installed on site.

[0032] When the bridging part 13 is fastened to the high-current rails 11, it is secured to the high-current rails 11 and secured against relative movement by means of elongated fastening means 17, in this case designed as a screw. For this purpose, the fastening means 17 are screwed into threaded sleeves 18, which are each inserted into through holes 11a of the end sections of the high-current rails 11. It is understood that other fastening means could also be used.

[0033] The bridging part 13 does not lie directly on each high-current rail 11, but is supported on a respective special compensating element 19 designed in the manner of a washer, which in turn lies with a flat underside on the respective upper side of the respective end section of the respective high-current rail 11.

[0034] Each compensating element 19 has a spherically outwardly curved compensating surface 20 which, in the fastened state of the bridging part 13, faces the bridging part 13, more precisely its underside facing the end section of the high-current rail 11.

[0035] In the present case, on this underside of the bridging part 13, in the area of ​​the wave crests 14 a and 14 b, two spaced-apart connecting surfaces 21 or counter-surfaces for the compensation surfaces 20 are formed, which are spherically curved inwards and which fit the respective compensation surface 20 or whose dimensions are matched to the respective compensation surface 20.

[0036] When the bridging part 13 is in the attached state, the compensating surface 20 of each compensating element 19 rests against one of the two connecting surfaces 21 of the bridging part 13, in this case directly, so that a direct metallic, current-conducting contact is established. Above all, however, the respective compensating surface 20 forms a type of ball joint with the respective counter-surface or connecting surface 21, which allows for corresponding compensating movements of the high-current connection system 10 during assembly to compensate for tolerances in three spatial directions.

[0037] With the side opposite the compensating surface 20 of the respective compensating element 19, which in the present case is flat as already mentioned, the compensating element 19 lies directly against a corresponding contact surface of the contact area 12 of the high-current rails 11, also forming a corresponding electrically conductive connection.

[0038] It is understood that intermediate layers or intermediate layers made of electrically conductive material can also be arranged between the opposing surfaces of the respective components.

[0039] On the upper side of each wave crest 14 a or 14 b of the bridging part 13 or on the side of the bridging part 13 facing away from the end region of the high-current rails 11, a washer 24 can also be seen, which is arranged between a head part 28 (screw head) of the fastening means 17 and the bridging part 13 and whose respective underside is spherically curved inwards or whose underside has a spherically curved inwards compensating surface 22 and, due to the clamping force of the fastening means 17, rests against the bridging part 13 in a force-fitting and / or form-fitting manner and under tension.

[0040] The compensating surface 22 of the respective washer 24 faces one of two correspondingly matching, spherically curved, outwardly curved connecting surfaces 23 of the bridging part 13, each of which is arranged on the upper sides of the wave crests 14a and 14b (and correspondingly spaced from one another) or formed by them, and in this case rests against each other, forming a type of ball joint. Accordingly, the aforementioned elements or components also allow compensating movements in three spatial directions.

[0041] As already indicated, the high-current rails 11 in this case each have a through-hole 11a into which the respective threaded sleeves 18 are inserted from below. Furthermore, the bridging part 13 also has two through-holes 13a (each designed as an elongated hole), the center axes of which are each aligned with the respective center axis of the respective through-hole 11a of the respective high-current rail 11 or which are each aligned along the same center axis as the respective through-hole 11a.

[0042] A (central) through-hole 19 a of the respective compensating element 19 or a (central) through-hole 24 a of the respective washer 24 is then aligned along the same axis, so that the respective fastening means 17 can or does reach through all of these components or all of the through-holes 11 a, 19 a, 13 a and 24 a from top to bottom and is then screwed into the respective threaded sleeve 18 supported on the underside of the respective high-current rail 11.

[0043] As can further be seen, the high-current connection system 10 has for each compensating element 19 a holding part 25 which can be fastened to the latter in a force-fitting and / or form-fitting manner, with which the respective compensating element 19 is releasably fastened to the bridging part 13 with its outer side facing the respective connecting surface of the bridging part 13, preferably with releasably clamping the components against one another, in particular to form a pre-assembly group 26 which simplifies the final assembly of the high-current connection system 10, cf. Fig. 1, which in the present case comprises, in addition to the bridging part 13, the two compensating elements 19, the two holding parts 25, the two washers 24 and the two fastening means 17.

[0044] Each holding part 25 has two elastic locking or holding arms 27 for fastening to the respective compensating element 19, which each engage in a respective fastening recess 29 of the respective compensating element 19.

[0045] The holding part 25 further comprises a particularly round through-hole 25a into which the head part 28 of the respective fastening means 17 is at least partially immersed.

[0046] It is understood that the features explained in connection with the drawings are to be understood only as examples and do not limit the subject matter of the present application. List of reference symbols: 10 High-current connection system 11 High-current rail 11 a Through hole 12 Contact area high-current rail 13 Bridging part 13 a Through hole 14 a, b Wave crests bridging part 15 Wave trough bridging part 16 Contact area bridging part 17 Fasteners 18 threaded sleeve 19 compensation elements 19 a Through hole 20 compensation areas 21 Connecting surface bridging part 22 Compensating surface washer 23 Connecting surface bridging part 24 Washer 24 a through hole 25 Holding part 25 a through hole 26 Pre-assembly assembly 27 locking arms 28 headboard 29 recesses compensation element

Claims

[1] High-current connection system for the high-current-conducting, preferably detachable, in particular tolerance-compensating connection of at least two high-current rails (11) spaced apart from one another, comprising a) a high-current-conducting bridging part, which can be fastened to each of the high-current rails (11), in particular a metallic bridging part, preferably designed as a solid material body, with which the distance between the high-current rails (11) can be bridged in a current-conducting manner and to which at least two preferably spaced-apart, spherically inwardly curved connecting surfaces are assigned, in particular with a uniform material connection thereto, b) for each high-current rail (11), a respective high-current-conducting, in particular metallic, compensating element (19) which can be assigned to the high-current rail (11), which can be arranged between the bridging part (13) and the respective high-current rail (11) and which has a spherically outwardly curved compensating surface (20) which, in the fastened state of the bridging part (13), in particular with a positive, preferably detachable connection thereto, faces one of the preferably spherically inwardly curved connecting surfaces, preferably with an electrically conductive connection thereto, particularly preferably with contact with the respective connecting surface, and c) for each high-current rail (11), at least one fastening means (17) which can be assigned to it, with which the bridging part (13) and the respective compensating element (19) can be fastened, preferably detachably, to the respective high-current rail (11) and can be secured against movement relative to the respective high-current rail (11). [2] High current connection system according to claim 1, characterized by that each compensating element (19) has a central through-hole, in particular designed as an elongated hole, through which one of the particularly elongated fastening elements passes when the bridging part (13) is fastened. [3] High current connection system according to claim 1 or 2, characterized bythat the bridging part (13) has at least two through holes, each in particular designed as an elongated hole, each of these through holes being penetrated by one of the particularly elongated fastening elements when the bridging part (13) is fastened. [4] High current connection system according to claim 2 and 3, characterized by that in the fastened state of the bridging part (13), each through-hole of the bridging part (13) is aligned with a through-hole of one of the compensating elements (19) along a common axis (one above the other), and that the respective fastening element in this state passes through these two through-holes. [5] High current connection system according to one or more of the preceding claims, characterized bythat the respective fastening means (17), in particular a screw, in the fastened state of the bridging part (13) penetrates into a through-hole of the respective high-current rail (11) or passes through this and is non-positively and / or positively connected to a matching securing part of the high-current connection system, which is supported on the high-current rail (11) and preferably has a matching thread, in particular is screwed, preferably with a threaded sleeve or a nut, or that the respective fastening means (17) designed as a screw is screwed to a thread introduced into the high-current rail (11) in the fastened state of the bridging part (13). [6] High current connection system according to one or more of the preceding claims, characterized bythat the respective compensating element (19) has a flat side on the side opposite its compensating surface (20), which, in the fastened state of the bridging part (13), faces the respective high-current rail (11), in particular while resting against the respective high-current rail (11). [7] High current connection system according to one or more of the preceding claims, characterized by that the high-current rails (11) are connected to one another in a high-current-conducting manner via the electrically conductive bridging part (13) and the respective electrically conductive compensating element (19) in the fastened state of the bridging part (13), so that electrical current can flow through these components from one high-current rail (11) to the other high-current rail (11). [8] High current connection system according to one or more of the preceding claims, characterized bythat the bridging part (13) is wave-shaped in a longitudinal section, and that in the fastened state of the bridging part (13) a wave trough of the bridging part (13) is arranged between the high-current rails (11), and / or that in the fastened state of the bridging part (13) each of the connecting surfaces assigned to the bridging part (13) is arranged in the region of a wave crest of the bridging part (13), in particular on an underside of the respective wave crest. [9] High current connection system according to one or more of the preceding claims, characterized bythat in the fastened state of the bridging part (13), a head part of the respective fastening means (17), in particular designed as a screw, for securing the bridging part (13) against the relative movements relative to the respective high-current rail (11) rests force-fittingly and / or positively under tension directly on the bridging part (13) or on a respective washer arranged between the respective head part and the bridging part (13). [10] High current connection system according to one or more of the preceding claims, characterized bythat the high-current connection system has for each compensating element (19) a holding part which can be fastened to the latter in a force-fitting and / or form-fitting manner, with which the respective compensating element (19) can be releasably fastened to the bridging part (13) with its outer side facing the respective connecting surface of the bridging part (13), preferably with releasably clamping the components against one another, in particular to form a pre-assembled module. [11] High current connection system according to claim 10, characterized by that the holding part for fastening to the respective compensating element (19) has at least one locking means, in particular at least one elastic locking arm, which engages in a fastening recess of the compensating element (19) in the fastened state. [12] High current connection system according to claim 10 or 11, characterized bythat the holding part has a particularly round through-hole into which the head part of the respective fastening means (17) is at least partially immersed in the fastened state of the bridging part (13). [13] High current connection system according to one or more of the preceding claims, at least according to claim 9, characterized by that each washer has, on its side facing the bridging part (13), a spherically inwardly curved compensating surface which faces a spherically outwardly curved connecting surface of the bridging part (13), in particular with a positive, preferably detachable connection, particularly preferably in contact with the respective connecting surface. [14] Arrangement of at least two high-current rails (11) and a high-current connection system according to one or more of the preceding claims, wherein the two high-current rails (11) are connected to one another in a high-current-conducting manner by means of the high-current connection system.

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