Method for producing a composite arrangement and composite arrangement

Abstract

Method for producing a composite arrangement (1, 1') from several electrically conductive components (2, 2') and an electrically conductive connecting component (3, 3'), wherein - the components (2, 2') are arranged one above the other as a parallel joint, so that the components (2, 2') lie on top of each other with their flat sides, - a predetermined section (2.1, 2.1') of the parallel joint is bent by pressing down and / or holding down on an inclined plane (E1, E1', E2, E2') having a predetermined angle of inclination (β) of a wedge-shaped recess (A, A') of the connecting component (3, 3'), so that the predetermined section (2.1, 2.1') of the parallel joint rests positively on the inclined plane (E1, E1', E2, E2') of the wedge-shaped recess (A, A'), and - the electrically conductive components (2, 2') arranged one above the other are integrally connected to one another and to the connecting component (3, 3') in the wedge-shaped recess (A, A') in an exposed end region of the angled section (2.1, 2.1') arranged on the inclined plane (E1, E1', E2, E2') by means of a fillet and I-seam introduced by means of laser welding (L).

Description

[0001] The invention relates to a method for producing a composite assembly comprising a plurality of electrically conductive components and an electrically conductive connecting component. Furthermore, the invention relates to a composite assembly.

[0002] DE 10 2020 120 263 B3 discloses a method for welding metallic foils. The method provides: a. Forming a parallel joint with several metallic foils to be joined by arranging the foils in such a way that they lie against each other over a wide area and the end faces of the stacked foils form one end face of the parallel joint, b. Welding the metallic foils by directing a laser beam onto the end face of the parallel joint so that a weld seam connecting the foils is formed.

[0003] Furthermore, DE 10 2014 223 352 A1 describes a connection arrangement. The connection arrangement comprises a semiconductor, a substrate, and a metal strip. The semiconductor has an electrical connection, which is ultrasonically welded to the substrate by means of the metal strip. The metal strip consists of two metal layers made of different metals or metal alloys. The thickness of the metal layer of the metal strip connected to the connection is half the thickness of the additional metal layer connected to the metal layer.

[0004] WO 2020 / 096973 A1 describes a cell of an energy storage device. The cell comprises: - a first substrate comprising a first coating, wherein a second portion of the first substrate at a proximal end along a width of the first substrate comprises a conductive material; - a second substrate comprising a second coating; and - an inner separator disposed between the first substrate and the second substrate, wherein the first substrate, the inner separator, and the second substrate are rolled around a central axis to form a cell. The second portion of the first substrate formed from the conductive material protrudes beyond an edge of the second substrate and an edge of the inner separator.

[0005] The energy storage device comprises a cell and a casing having a first end and a second end. The first end comprises a cover comprising a contact surface. The contact surface is structured to correspond to and be connected to the conductive portion of the rolled-up first substrate projecting beyond the second substrate and the separator. The conductive portion is welded to the cover.

[0006] The invention is based on the object of specifying a method for producing a composite arrangement comprising a plurality of electrically conductive components and an electrically conductive connecting component and a composite arrangement.

[0007] The object is achieved according to the invention by a method which has the features specified in claim 1 and by a composite arrangement which has the features specified in claim 4.

[0008] Advantageous embodiments of the invention are the subject of the subclaims.

[0009] A method according to the invention for producing a composite arrangement comprising several electrically conductive components and an electrically conductive connecting component provides that - the components are arranged one above the other in a parallel joint so that the components lie on top of each other with their flat sides, - a predetermined section of the parallel joint is bent by pressing down and / or holding down on an inclined plane of a wedge-shaped recess of the connecting component having a predetermined angle of inclination, so that the predetermined section of the parallel joint rests positively on the inclined plane of the wedge-shaped recess, and - the electrically conductive components arranged one above the other are joined in an exposed end region of the angled section arranged on the inclined plane by means of a fillet and I-seam introduced by means of laser welding and are joined in a materially bonded manner to one another and to the connecting component in the wedge-shaped recess.

[0010] By applying this method, flexibility regarding the number of electrically conductive components to be joined and improved quality of the connection between them and to the connecting component can be achieved. In particular, the contact resistance of such a material connection is comparatively low, so that electrical conduction between the components and the connecting component can be essentially ensured.

[0011] The electrically conductive components are arranged relative to each other and relative to the connecting component in such a way that only a single laser weld is required for the integral connection, thereby reducing the effort and cycle time required to produce the composite assembly. Since only one laser weld is required to produce the composite assembly, energy expenditure and input are comparatively low.

[0012] The composite assembly can be manufactured using conventional equipment technology available in a production environment, in particular scanner optics, so that no further investment is required to manufacture the composite assembly.

[0013] The wedge-shaped recess in the connecting component can be introduced into the connecting component comparatively easily and, for example, with almost no additional effort in a production process.

[0014] The process is particularly suitable for the material-to-material joining of electrically conductive metallic materials, in particular copper and / or aluminum in similar or dissimilar combinations.

[0015] The method is particularly suitable for the material-to-material connection of electrically conductive components of a vehicle, in particular of metallic foils with a current collector within an electrochemical single cell and / or of current conductors with busbars in an electrical energy storage device with several electrically interconnected single cells and / or of connection points within a power electronics system of the vehicle.

[0016] The negative influence of oxide layers on the material bond can be reduced by a weld geometry, especially the fillet and I-weld.

[0017] Embodiments of the invention are explained in more detail below with reference to drawings.

[0018] Showing: Fig. 1 schematically shows a sequence of a method for producing a composite arrangement, Fig. 2 schematically shows an alternative manufacturing step for producing the composite arrangement and Fig. 3 schematically shows a sequence of a method for producing a further composite arrangement.

[0019] Corresponding parts are provided with the same reference numerals in all figures.

[0020] Fig. 1 shows a sequence of a method for producing a composite arrangement 1 from a number of electrically conductive components 2 and an electrically conductive connecting component 3.

[0021] It is generally known that a material-to-material bond between electrically conductive components is possible using laser beam welding due to the low contact resistance that can be achieved. However, this requires the introduction of a comparatively large number of individual weld seams N to join multiple components. Furthermore, a material-to-material bond is comparatively limited and often of only moderate quality due to possible oxide layers on the individual components.

[0022] In the following, a method for producing a composite arrangement 1 is described, which optimizes at least a material connection of the components 2 to one another and with respect to the connecting component 3.

[0023] The electrically conductive components 2 are, for example, electrically conductive foils, current collectors, or the like, in particular of an electrochemical single cell of an electrical energy storage device, in particular for a vehicle. The electrically conductive components 2 have, for example, a thickness of at least 0.05 mm and at most 2.0 mm.

[0024] The electrically conductive connecting component 3 is, for example, a busbar, a current collector or the like, in particular for electrically connecting the individual cells and / or for current collection.

[0025] In a first method step S1, the electrically conductive components 2 are arranged one above the other, with the components 2 lying on top of each other, particularly with their flat sides, i.e., across a wide area. The superimposed components 2 form a so-called parallel joint.

[0026] In one possible embodiment, the components 2 are arranged one above the other in such a way that the end faces of the components 2 are arranged flush with each other.

[0027] In an alternative embodiment, the components 2 are arranged one above the other in such a way that the electrically conductive components 2 are arranged one above the other in a step-like manner with at least one respective end having a predetermined step offset.

[0028] In the first method step S1, a wedge-shaped recess A is introduced into the electrically conductive connecting component 3, wherein an inclined plane E1 has an inclination angle β of at least 5° and at most 89°. A further inclination angle δ of a further inclined plane E2 of the wedge-shaped recess A is at least 5°.

[0029] The superimposed, electrically conductive components 2 arranged as a parallel joint are arranged with respect to the wedge-shaped recess A in a second method step S2 such that a predetermined section 2.1 is bent, in particular angled, by means of pressing down and / or holding down, so that the predetermined section 2.1 rests positively on the inclined plane E1 of the wedge-shaped recess A. In this case, an exposed end region of the angled predetermined section 2.1 is arranged, for example, at a predetermined distance, from the further inclined plane E2.

[0030] In a third method step S3, the electrically conductive components 2 arranged one above the other are integrally connected to one another and to the connecting component 3 in the wedge-shaped recess A in the exposed end region of the angled section 2.1 arranged in the wedge-shaped recess A by means of a weld seam N in the form of a fillet and I-seam introduced by means of laser welding L.

[0031] Such a weld seam N is in particular a hybrid seam, which is a combination of a fillet weld and an I-weld.

[0032] In Fig. 2 shows an alternative third method step S3' for producing the electrically conductive composite arrangement 1'.

[0033] In this alternative third method S3', the weld seam N is introduced into the end region of the specified section 2.1 of the components 2 to be joined by a material bond and the connecting component 3 by means of beam oscillation, so-called wobbling.

[0034] Fig. Figure 3 shows a sequence of a method for producing a further composite assembly 1', wherein the further composite assembly 1' comprises two such parallel joints, each having a number of electrically conductive components 2'. The two parallel joints are formed in a first method step S1'.

[0035] In the first method step S1', a wedge-shaped recess A' is also introduced into the connecting component 3', wherein the two planes E1', E2' have the same angle of inclination β, which is at least 5° and at most 89°.

[0036] In a second method step S2', the electrically conductive components 2' arranged in a parallel joint are arranged with respect to an inclined plane E1' of the wedge-shaped recess A' in such a way that a predetermined section 2.1' of this parallel joint is bent, in particular angled, by means of pressing down and / or holding down.

[0037] In addition, the electrically conductive components 2' arranged to form a further parallel joint are arranged with respect to a further inclined plane E2' of the wedge-shaped recess A' such that a predetermined section 2.1' of the further parallel joint of the electrically conductive components 2' is bent, in particular angled, by means of pressing down and / or holding down.

[0038] If the two specified sections 2.1' of the two parallel joints comprising the electrically conductive components 2' are angled, they are joined together in a third process step S3" by means of laser welding L and a weld seam N' produced thereby.

[0039] In this further composite arrangement 1', electrically conductive components 2' of two parallel joints are materially connected at least to the connecting component 3'.

Claims

[1] Method for producing a composite arrangement (1, 1') from several electrically conductive components (2, 2') and an electrically conductive connecting component (3, 3'), wherein - the components (2, 2') are arranged one above the other as a parallel joint, so that the components (2, 2') lie on top of each other with their flat sides, - a predetermined section (2.1, 2.1') of the parallel joint is bent by pressing down and / or holding down on an inclined plane (E1, E1', E2, E2') having a predetermined angle of inclination (β) of a wedge-shaped recess (A, A') of the connecting component (3, 3'), so that the predetermined section (2.1, 2.1') of the parallel joint rests in a form-fitting manner on the inclined plane (E1, E1', E2, E2') of the wedge-shaped recess (A, A'), and - the electrically conductive components (2, 2') arranged one above the other are integrally connected to one another and to the connecting component (3, 3') in the wedge-shaped recess (A, A') in an exposed end region of the angled section (2.1, 2.1') arranged on the inclined plane (E1, E1', E2, E2') by means of a fillet and I-seam introduced by means of laser welding (L). [2] Method according to claim 1, wherein the electrically conductive components (2, 2') are arranged one above the other in a step-like manner with at least one respective end having a predetermined step offset. [3] Method according to claim 1 or 2, wherein the electrically conductive components (2, 2') arranged one above the other are integrally connected to one another and to the connecting component (3, 3') in the wedge-shaped recess (A, A') in the exposed end region of the angled section (2.1, 2.1') arranged on the inclined plane (E1, E1', E2, E2') by means of laser welding (L) with beam oscillation. [4] Composite arrangement (1, 1') produced by a method according to one of the preceding claims, wherein - the components (2, 2') are arranged one above the other as a parallel joint, so that the components lie on top of each other with their flat sides, - a predetermined section (2.1, 2.1') of the parallel joint is angled by pressing down and / or holding down on an inclined plane (E1, E1', E2, E2') having a predetermined angle of inclination (β) of a wedge-shaped recess (A, A') of the connecting component (3, 2'), so that the predetermined section (2.1, 2.1') of the parallel joint rests positively on the inclined plane (E1, E1', E2, E2') of the wedge-shaped recess (A, A'), and - the electrically conductive components (2, 2') arranged one above the other are integrally connected to one another and to the connecting component (3, 3') in the wedge-shaped recess (A, A') by means of at least one laser weld seam in an exposed end region of the angled section (2.1, 2.1') arranged on the inclined plane (E1, E1', E2, E2'). [5] Composite arrangement (1, 1') according to claim 4, wherein the electrically conductive components (2, 2') are foils and / or current conductors and the electrically conductive connecting component (3, 3') is a busbar and / or a current collector.

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