Multilayer contact for a high-voltage component

Abstract

The invention relates to a multilayer contact (1) for a high-voltage component (2), comprising at least the following components: - a plurality of contact layers (3) stacked along a stacking direction (12); - a first connection section (4); - a second connecting section (5); and - one connecting the first section (4) with the second The connecting section (5) along a longitudinal direction (13) connects to the intermediate section (6). The multilayer contact (1) is characterized primarily by the fact that the contact layers (3) are positively connected to each other. Here, a multilayer contact with a positive-locking connection of the contact layers is proposed, which can be manufactured cost-effectively.

Description

[0001] The invention relates to a multilayer contact for a high-voltage component, a high-voltage component with such a multilayer contact, a manufacturing method for a multilayer contact, and an assembly method with such a manufacturing method for a high-voltage component in a motor vehicle.

[0002] When electrically connecting high-voltage components, flexible electrical contacts are advantageous. This allows for the compensation of manufacturing tolerances, thermal expansion, or other relative movements of the high-voltage components to each other or to connecting conductors.

[0003] Flexible multilayer contacts are known from industrial practice. Such multilayer contacts have a plurality of contact layers stacked along a stacking direction, which increases the flexibility of the multilayer contact along the stacking direction.

[0004] The individual contact layers are welded together and to a connection point of the high-voltage component using resistance welding. However, such welding processes are complex and expensive.

[0005] Based on this, the present invention aims to overcome, at least partially, the disadvantages known from the prior art. The features of the invention are defined in the independent claims, for which advantageous embodiments are shown in the dependent claims. The features of the claims can be combined in any technically meaningful way, whereby the explanations in the following description and features from the figures, which comprise supplementary embodiments of the invention, can also be used.

[0006] The invention relates to a multilayer contact for a high-voltage component, comprising at least the following components: - a plurality of contact layers stacked along a stacking direction; - a first connection section; - a second connecting section; and - an intermediate section connecting the first connecting section with the second connecting section along a longitudinal direction.

[0007] The multilayer contact is primarily characterized by the fact that the contact layers are positively connected to each other.

[0008] Unless explicitly stated otherwise, ordinal numbers used in the preceding and following descriptions serve solely for unambiguous differentiation and do not indicate any order or ranking of the components referred to. An ordinal number greater than one does not necessarily imply the presence of another such component.

[0009] Here is a proposed multilayer contact for a high-voltage component.

[0010] Such a high-voltage component is, for example, a battery, power electronics and / or an electric traction motor for a motor vehicle.

[0011] The multilayer contact is designed to electrically connect the high-voltage component to other high-voltage components of a high-voltage network, for example by means of connecting conductors.

[0012] The multilayer contact has multiple contact layers, a first connection section, a second connection section, and an intermediate section.

[0013] The contact layers are stacked along a stacking direction. For example, the individual contact layers are strip-shaped. Preferably, the length of such a contact layer along the longitudinal direction is greater than its width, perpendicular to the longitudinal direction. The width of the contact layer is, in turn, greater than its thickness along the stacking direction, perpendicular to both the longitudinal direction and the width.

[0014] The contact layers are made of an electrically conductive material, preferably copper.

[0015] The multilayer contact has a first connection section, a second connection section, and an intermediate section. In other words, the contact layers of the multilayer contact form these sections.

[0016] The connection sections are designed to be electrically connected to the connection point of the high-voltage component or a connecting conductor. Preferably, the corresponding connection section has a mounting opening through which a fastener, such as a rivet or a screw, can be inserted. Alternatively, such a connection section can be welded to the connecting conductor or the connection point of the high-voltage component.

[0017] Preferably, the connecting sections form the two ends of the multilayer contact along the longitudinal direction. An intermediate section is arranged between the two connecting sections along the longitudinal direction. Preferably, the intermediate section is flexible. For example, the intermediate section has a bend or a kink, preferably transverse to the longitudinal direction, and particularly preferably in the stacking direction. This, along with the multiple contact layers in the stacking direction, provides, for example, a high degree of flexibility for the multilayer contact along the longitudinal direction.

[0018] The contact layers are now positively connected to each other. For example, the contact layers are positively connected to each other at least along the longitudinal and / or the lateral direction.

[0019] The positive-locking connection is preferably designed for transport securing and / or as an assembly aid. In such a case, for example, it is not necessary that the individual contact layers are pressed together in the stacking direction by means of the positive lock and / or are permanently and stably connected in all directions.

[0020] Preferably, the contact layers are positively connected to each other at at least one or both of the connection sections.

[0021] The proposed multilayer contact is therefore cost-effective and easy to install.

[0022] In a further advantageous embodiment of the multilayer contact, it is proposed that the contact layers are positively connected to each other by means of an embossing.

[0023] Preferably, the individual contact layers are connected to each other by means of embossing. Preferably, the embossing is a debossing. Preferably, the contact layers are embossed along the stacking direction.

[0024] Preferably, an embossing of a contact layer engages with the complementary opposite side of an identical embossing of a contact layer adjacent in the stacking direction.

[0025] For example, the embossings are circular or square when viewed along the stacking direction.

[0026] In a further advantageous embodiment of the multilayer contact, it is proposed that the embossing forms an edge of a mounting opening for a fastening element.

[0027] According to this embodiment, the multilayer contact has at least one mounting opening on at least one of the connection sections. Preferably, the mounting opening extends continuously through all contact layers of the multilayer contact.

[0028] According to the embodiment proposed here, the embossing forms an edge of the mounting opening. Preferably, the embossing is produced in a single operation together with punching the mounting opening.

[0029] In an advantageous embodiment of the multilayer contact, it is further proposed that each of the embossings creates a projection on one side of each contact layer along the stacking direction, so that the individual contact layers can be plugged into each other to form a positive connection transverse to the stacking direction.

[0030] According to this embodiment, projections are formed by means of the embossing. For example, the respective contact layers are embossed. The respective projection can thus be inserted into a receptacle, preferably a negative of the projection created during the embossing of the contact layer on the opposite side to the projection, or the through-hole with the negative embossing. Thus, the individual contact layers can be stacked similarly to a block system and can be positively locked to one another transversely to the stacking direction.

[0031] According to another aspect, a high-voltage component is proposed, comprising at least the following components: an electrical connection point; and a multilayer contact according to an embodiment as described above, wherein the multilayer contact is electrically conductively attached to the connection point by means of one of the connecting sections.

[0032] A high-voltage component is proposed here. Preferably, this high-voltage component is for a high-voltage electrical system in a motor vehicle.

[0033] Such a high-voltage component is, for example, a battery, power electronics and / or an electric traction motor for a motor vehicle.

[0034] Such a high-voltage network preferably includes a battery, power electronics and an electric traction machine, which are electrically connected to each other by means of connecting conductors.

[0035] The high-voltage component includes, for example, electrical loads, electrical switching elements, and / or electrical storage units. Preferably, the high-voltage component also includes a housing. Particularly preferably, the housing is electrically insulated from the high-voltage network.

[0036] The high-voltage component has an electrical connection point and a multilayer contact. Preferably, the high-voltage component has several connection points, preferably three connection points, wherein each connection point is particularly preferably assigned to a phase of the high-voltage component.

[0037] The connection points are designed, for example, by means of busbars or conductor rails. For example, the connection points have a through-opening for receiving a fastening element, such as a rivet or screw, and / or are designed for welding the multilayer contact.

[0038] The multilayer contact is designed according to the description above. The multilayer contact is electrically connected to the connection point of the high-voltage component by means of at least one of its connection sections, for example by welding, riveting, or screwing. For example, a screw or rivet is passed through the mounting opening of the multilayer contact, as described above, and the through-hole of the connection point.

[0039] An electrically conductive connection is established, preferably by means of a contact surface between the connecting section and the connection point. Preferably, the connection point and the connecting section are pressed together along the stacking direction.

[0040] In a further advantageous embodiment of the high-voltage component, it is proposed that the multilayer contact comprises a fastening means, wherein the fastening means penetrates all contact layers and thus connects positively to a terminal point of the high-voltage component.

[0041] According to this embodiment, the positive locking is formed by means of a fastening element. Such a fastening element is, for example, a rivet or a screw.

[0042] The fastening element penetrates all contact layers of the multilayer contact along the stacking direction, thus creating a positive connection. For example, the fastening element is located in the fastening opening or a separate locking opening.

[0043] According to another aspect, a manufacturing process for a multilayer contact is proposed, comprising the following steps: a. Providing a plurality of contact layer blanks; b. Embossing of the contact layer blanks; and c. Stacking the contact layer blanks to form the multilayer contact, so that the embossing of the contact layers creates a positive fit.

[0044] A manufacturing process for a multilayer contact is proposed here. The manufacturing process includes at least the steps a., b., and c. described below.

[0045] In step a., a plurality of contact layer blanks are provided. Preferably, such a contact layer blank is strip-shaped. Furthermore, the contact layer blank is preferably made of a conductive material, particularly preferably a metal sheet. Preferably, all or at least some of the plurality of contact layer blanks are identical.

[0046] In step b., the contact layer blanks are embossed. A projection is introduced into the contact layer blank; preferably, this projection is pressed from one side of the contact layer blank to the opposite side along a stacking direction using debossing. This creates a negative of the embossing on one side, which is suitable for receiving a corresponding embossing on an adjacent contact layer.

[0047] For example, a spherical shape, such as a hemisphere, or a square shape, such as a cuboid, is embossed or stamped.

[0048] Preferably, all or at least a portion of the majority of contact layer blanks are stamped identically.

[0049] In step c, the contact layer blanks or contact layers are stacked to form the multilayer contact. For example, the contact layers are stacked using a magazine into which the contact layers can be inserted.

[0050] Step c is performed either before step b, after step b, or at the same time as step b.

[0051] For example, step c is performed before step b. In such an embodiment, the contact layer blanks are first stacked, for example in the magazine. Then, preferably all contact layers are debossed together.

[0052] Alternatively, step b is performed before step c. For example, all contact layer blanks are embossed separately and then stacked in step c, for example in the magazine, in such a way that the embossings interlock.

[0053] Alternatively, for example, subgroups of the majority of contact layers are stacked and embossed all at once, such as two, three, four, or five contact layers simultaneously. The subgroups are then stacked so that their embossings interlock.

[0054] Alternatively or additionally, the contact layers can be embossed during stacking. For example, a single contact layer or a subgroup of contact layers is placed on top of the stack of contact layers and then embossed into the existing markings of the already stacked contact layers.

[0055] Preferably, the contact layers are embossed in one, or preferably both, of the connection sections. This maintains a high degree of flexibility in the intermediate section.

[0056] For example, further embossing, drilling, punching, and / or forming of the contact layers and / or the multilayer contact is performed before or after stacking. For example, the intermediate section is bent or folded to increase flexibility along the longitudinal direction; preferably, the intermediate section is bent transversely to the longitudinal direction. Alternatively or additionally, for example, mounting holes are punched or drilled.

[0057] In a further advantageous embodiment of the manufacturing process, it is proposed that in step b. the embossing is carried out in one step together with the punching of a fastening opening.

[0058] According to this embodiment, step b. involves creating a fastening opening in the multilayer contact together with the embossing. For example, the fastening opening is punched through along the stacking direction. Preferably, the fastening opening is punched through in such a way that an embossing, for example in the form of a collar, is formed around the fastening opening, which engages in or can be inserted into an adjacent contact layer along the stacking direction, so that the positive locking is present or can be created.

[0059] It is further proposed in an advantageous embodiment of the manufacturing process that the manufacturing process for producing a multilayer contact is set up according to an embodiment as described above.

[0060] According to another aspect, an assembly method for a high-voltage component in a motor vehicle is proposed, wherein the assembly method comprises the manufacturing method according to an embodiment as described above. The multilayer contact is arranged at an electrical connection point of the high-voltage component by means of one of the connection sections, and is attached to the connection point by means of a fastening device

[0061] Here is a proposed assembly method for a high-voltage component in a motor vehicle.

[0062] The high-voltage component is designed according to the above description, to which reference is therefore made.

[0063] For example, one of the connection sections is attached to the connection point of the high-voltage component. For example, the connection section is welded, riveted, or screwed to the connection point. For example, the individual contact layers are only finally attached or pressed together in the stacking direction when attached to the connection point. For example, the positive-locking connection of the multilayer contact is designed only for one transverse direction and / or as an assembly aid.

[0064] Preferably, the contact layers are pressed together at least partially along the stacking direction to ensure good conductivity and reduce resistance in the contact surfaces. For example, sufficient compression between the contact layers is only achieved when fastened at the connection point, for instance by means of a rivet or screw that penetrates all contact layers of the multilayer contact.

[0065] In a further advantageous embodiment of the assembly method, it is proposed that the contact layers are pressed together along the stacking direction by means of the fastening means.

[0066] The invention described above is explained in detail below against the relevant technical background with reference to the accompanying drawings, which show preferred embodiments. The invention is in no way limited by the purely schematic drawings, although it should be noted that the drawings are not dimensionally accurate and are not suitable for defining size relationships. It is illustrated in Fig. 1: a schematic representation of a multilayer contact in a perspective view; Fig. 2: a schematic representation of a connection section of a multilayer contact according to Fig. 1; Fig. 3: a cross-sectional view of the connection section after Fig. 2; Fig. 4: a schematic representation of a positive-locking fastening of a contact layer in a cross-sectional view; Fig. 5: a schematic representation of a multilayer contact with contact layers according to Fig. 4 in a cross-sectional view; Fig. 6: a multilayer contact after Fig. 5 at a connection point of a high-voltage component in a cross-sectional view; and Fig. 7: a multilayer contact after Fig. 6 with a fastener in a cross-sectional view.

[0067] In Fig. Figure 1 shows a schematic representation of a multilayer contact 1 in a perspective view.

[0068] The multilayer contact 1 has a plurality of contact layers 3, shown as three. Preferably, the multilayer contact 1 has a larger number of contact layers 3, the representation of which has been omitted here for the sake of clarity.

[0069] The contact layers 3 are stacked on top of each other along a stacking direction 12. The width direction 14 is defined orthogonal to the stacking direction 12, and the length direction 13 is arranged orthogonal to both the width direction 14 and the stacking direction 12.

[0070] The multilayer contact 1 is divided along the longitudinal direction 13 into a first connection section 4, a second connection section 5 and an intermediate section 6, meaning that the multilayer contact 1 has these three sections.

[0071] The intermediate section 6 is arranged along the longitudinal direction 13 between the first connection section 4 and the second connection section 5. In a preferred embodiment shown here, the intermediate section 6 is bent along the stacking direction 12 to increase the flexibility of the intermediate section 6 and thus of the multilayer contact 1.

[0072] The multilayer contact 1 has a mounting opening 8 at each of the connection sections 4 and 5. The mounting opening 8 is continuous and thus allows a fastening element 9 to be inserted through it (not shown here, see Figure 1). Fig. 6).

[0073] Furthermore, the contact layers 3 of the multilayer contact 1 are positively connected to each other by means of an embossing 7 at each connection section 4, 5. The embossing 7 of the upper contact layer 3, as shown in the illustration, engages with the adjacent contact layer 3 below it along the stacking direction 12. Thus, the contact layers 3 are secured to each other, for example, for transport and / or assembly on a high-voltage component 2 and / or a connecting conductor.

[0074] In Fig. Figure 2 is a schematic representation of a connection section 4,5 of a multilayer contact 1 according to Fig. Figure 1 shows the connection section 4. Accordingly, the connection section 4 has the embossing 7 and the mounting opening 8. In the illustrated embodiment, the embossing 7 and the mounting opening 8 are separate from each other.

[0075] In Fig. Figure 3 is a cross-sectional view of the connection section 4.5 according to Fig. Figure 2 shows a cross-section. The section runs through the embossing 7 and the fastening opening 8. It can be seen that the embossing 7 forms a projection on the lower side shown in the illustration along the stacking direction 12 and a corresponding complementary negative on the upper side, so that the embossings 7 of the stacked contact layers 3 interlock.

[0076] In Fig. Figure 4 shows a schematic representation of a positive-locking fastening of a contact layer 3 in a cross-sectional view. In contrast to the contact layer 3 in Fig. 2 and Fig. In Figure 3, the mounting opening 8 and the embossing 7 of the multilayer contact 1 shown are not formed separately. Rather, the embossing 7 is formed adjacent to the mounting opening 8 and forms its edge. Preferably, the mounting opening 8 is punched and the embossing 7 is created in a single operation.

[0077] In Fig. Figure 5 is a schematic representation of a connection section 4,5 of a multilayer contact 1 with contact layers 3 according to Fig. Figure 4 shows a cross-sectional view. Such a multilayer contact 1, or such a positive-locking connection between the multilayer contacts 1, is similarly designed for the contact layers 3 according to Fig. 2 or Fig. 3 can be produced.

[0078] The contact layers 3 are stacked along the stacking direction 12, and the embossings 7 of the individual contact layers 3 interlock. The mounting openings 8 of the individual contact layers 3 are aligned so that the mounting opening 8 extends continuously through the multilayer contact 1.

[0079] In Fig. 6 is a multilayer contact 1 according to Fig. Figure 5 shows a cross-sectional view of a connection point 10 of a high-voltage component 2. The connection point 10 of the high-voltage component 2 has a through-opening 11. The mounting opening 8 of the connection section 4 of the multilayer contact 1 is aligned with the through-opening 11 of the high-voltage component 2 such that a fastening element 9 can be passed through the through-opening 11 and the mounting opening 8 to connect the multilayer contact 1 to the high-voltage component 2. For example, the mounting opening 8 and the through-opening 11 are arranged coaxially and / or in alignment with each other. Preferably, as shown, the embossing 7 of the outermost contact layer 3 engages in the through-opening 11. This allows for adjustment or alignment during assembly.

[0080] In Fig. 7 is a multilayer contact 1 according to Fig. 6 with a fastening element 9 shown in a cross-sectional view. Opposite Fig. 6 is now the fastening element 9, here a rivet, guided through the fastening opening 8 and the through-hole 11 and thus connects the multilayer contact 1 with the connection point 10 of the high-voltage component 2.

[0081] Here, a multilayer contact with a positive-locking connection of the contact layers is proposed, which can be manufactured cost-effectively. Reference symbol list 1 Multilayer contact 2 High-voltage components 3 contact layers 4 first connection section 5 second connection section 6 Intermediate section 7. Embossing 8 Mounting opening 9 Fasteners 10 Interchange 11. Passage opening 12 Stacking direction 13 Longitudinal direction 14 Latitude

Claims

[1] Multilayer contact (1) for a high-voltage component (2), comprising at least the following components: - a plurality of contact layers (3) stacked along a stacking direction (12); - a first connection section (4); - a second connecting section (5); and - an intermediate section (6) connecting the first connection section (4) with the second connection section (5) along a longitudinal direction (13), characterized by , that the contact layers (3) are positively connected to each other. [2] Multilayer contact (1) according to claim 1, wherein the contact layers (3) are positively connected to each other by means of an embossing (7). [3] Multilayer contact (1) according to claim 1 or claim 2, wherein the embossing (7) forms an edge of a fastening opening (8) for a fastening means (9). [4] Multilayer contact (1) according to claim 2 or claim 3, wherein each of the embossings (7) creates a projection on one side of each contact layer (3) along the stacking direction (12) so that the individual contact layers (3) can be plugged into each other in a form-fitting connection transverse to the stacking direction (12). [5] High-voltage component (2) comprising at least the following components: an electrical connection point (10); and a multilayer contact (1) according to any one of claims 1 to 4, wherein the multilayer contact (1) is electrically conductively attached to the connection point (10) by means of one of the connecting sections (4,5). [6] High-voltage component (2) according to claim 1, wherein the multilayer contact (1) includes a fastening element (9), wherein the fastening element (9) penetrates all contact layers (3) and thus connects positively to a connection point (10) of the high-voltage component (2). [7] Manufacturing process for a multilayer contact (1) comprising the following steps: a. Providing a plurality of contact layer blanks; b. Embossing of the contact layer blanks; and c. Stacking the contact layer blanks to form the multilayer contact (1) so that the embossings (7) of the contact layers (3) form a positive fit. [8] Manufacturing method according to claim 7, wherein in step b. the embossing is carried out in one step with a punching of a fastening opening (8). [9] Manufacturing method according to claim 7 or claim 8, wherein the manufacturing method for producing a multilayer contact (1) is set up according to any one of claims 1 to 6. [10] Assembly method for a high-voltage component (2) in a motor vehicle, wherein the assembly method comprises the manufacturing method according to any one of claims 7 to 6, the multilayer contact (1) is arranged by means of one of the connection sections (4,5) at an electrical connection point (10) of the high-voltage component (2), and is attached to the connection point (10) by means of a fastening device (9).

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