Multilayer contact for a high-voltage component of a motor vehicle

Abstract

The invention relates to a multilayer contact (1) for a high-voltage component (2) of a motor vehicle, comprising at least the following components: - a plurality of contact layers (3) stacked along a stacking direction (17); - 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 (18). The multilayer contact (1) is characterized in particular by the fact that the contact layers (3) are fastened to one another by means of a fastening element (7), and the fastening means (7) has a contact surface (8) to the contact layers (3) on both sides of the multilayer contact (1) along the stacking direction (17) in order to connect the contact layers (3) to each other along the stacking direction (17). Here, a multilayer contact with a fastening device for transport securing is proposed for particularly simple and cost-effective manufacturing and assembly.

Description

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

[0002] When electrically connecting high-voltage components, electrical contacts with high flexibility 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 of a motor vehicle, 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 characterized primarily by the fact that the contact layers are attached to each other by means of a fastening means, and the fastening means has a contact surface to the contact layers on both sides of the multilayer contact along the stacking direction in order to connect the contact layers to each other along the stacking direction.

[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 of 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 is now divided into a first connection section, a second connection section, and an intermediate section. In other words, the contact layers 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 through-opening through which a fastening element, 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 or fastened using a clamping sleeve.

[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 multilayer contact now also includes a fastening element. The contact layers are fastened to one another by means of this fastening element. The fastening element serves, for example, as a transport safety device and / or as an assembly aid. The fastening element is made of, for example, metal and / or plastic.

[0019] The fastener forms a contact surface on both sides of the stack at the contact layers. These contact surfaces are located on the outer sides of the stack, running parallel to the stack direction. Thus, the two outermost contact layers form the contact surfaces.

[0020] Preferably, the contact layers are force-fitted together along the longitudinal direction and in a transverse direction, orthogonal to the longitudinal direction and the stacking direction, by means of the fastening element. Particularly preferably, the contact layers are pressed together between the contact surfaces along the stacking direction by means of the fastening element.

[0021] Such a multilayer contact can be manufactured cost-effectively. Furthermore, the multilayer contact can be manufactured separately and transported or delivered as a finished, easily assembled component for mounting a high-voltage component, where it can be installed particularly easily.

[0022] In a further advantageous embodiment of the multilayer contact, it is proposed that the fastening means penetrates the contact layers along the stacking direction or laterally surrounds them. wherein the fastening means is preferably a rivet or a sheath.

[0023] According to this embodiment, the fastening element penetrates or surrounds all contact layers of the multilayer contact along the stacking direction. Thus, the fastening element has two support sections that form the contact surfaces and at least one connecting section that joins the two support sections together along the stacking direction.

[0024] Preferably, the fastening means is a rivet or a sleeve. For example, the sleeve is designed as a ring circumferentially around the contact layers, perpendicular to the longitudinal direction. For example, the sleeve is cast or injection-molded. Alternatively, the sleeve is, for example, pushed onto the contact layers. Preferably, the sleeve is a plastic sleeve.

[0025] If the fastening element is designed as a rivet, the contact layers preferably have through-holes in which the rivet is arranged.

[0026] In an advantageous embodiment of the multilayer contact, it is further proposed that the connection section of the multilayer contact has a groove by means of which the sheathing is fixed along the longitudinal direction.

[0027] It is proposed here that the multilayer contact in the connection section has a groove. The groove is arranged, for example, on one or two opposite sides of the connection section or circumferentially, orthogonally to the longitudinal direction. The sheathing is arranged or recessed in the groove, at least partially. Thus, the sheathing is positively locked in the groove along the longitudinal direction.

[0028] For example, the casing is cast into the groove, injected and / or pushed onto the connecting section until it snaps into the groove along the longitudinal direction.

[0029] In a further advantageous embodiment of the multilayer contact, it is proposed that the fastening means be arranged on at least one of the connection sections.

[0030] According to this embodiment, the fastening element is arranged on one of the connection sections. Preferably, one fastening element is arranged on each of the two connection sections. This maintains a high degree of flexibility in the intermediate section.

[0031] In an advantageous embodiment of the multilayer contact, it is further proposed that the intermediate section be a flexible section, preferably bent transversely to the longitudinal direction.

[0032] According to the embodiment proposed here, the intermediate section is a flexible section and is designed to compensate for relative movement between the two connecting sections.

[0033] For example, the intermediate section has a bend or a kink, preferably transverse to the longitudinal direction, particularly preferably in the stacking direction.

[0034] According to another aspect, a multi-phase conductor contact is proposed, whereby the multi-phase conductor contact has a plurality of multilayer contacts according to an embodiment as described above, and The fastening means encloses and fixes the majority of multilayer contacts, preferably at a predetermined distance from each other.

[0035] Preferably, the multi-phase conductor contact is a multi-phase conductor contact for a high-voltage component of a high-voltage network of a motor vehicle.

[0036] Such a high-voltage component is, for example, a battery, power electronics and / or an electric traction motor of a motor vehicle.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] The multi-phase conductor contact has a plurality of multilayer contacts, preferably one multilayer contact per connection point or phase of the high-voltage component. The individual multilayer contacts are designed according to the description above.

[0041] A common fastening element encloses the majority of multilayer contacts and fixes them together. Preferably, the multilayer contacts are arranged at a predefined distance from each other within the fastening element, so that the multiphase conductor contact can be easily mounted on the high-voltage component.

[0042] The fastening means is preferably a sheath, particularly preferably a plastic sheath. For example, the sheath is designed to electrically insulate the multilayer contacts from each other and / or from the housing of the high-voltage component.

[0043] For example, the individual contact layers are attached to each other by means of an additional pre-fixing mechanism. For example, the individual contact layers are positively joined to form the multilayer contact by means of embossing.

[0044] According to another aspect, a manufacturing process for a multilayer contact is proposed, comprising the following steps: a. Providing multiple contact layers; b. Stacking the contact layers along a stacking direction; and c. Applying a fastening element which forms a contact surface to the contact layers on both sides of the multilayer contact along the stacking direction, thus fastening the contact layers to each other.

[0045] A manufacturing process for a multilayer contact is proposed here. The manufacturing process includes at least the steps a., b., and c. described below.

[0046] In step a., a plurality of contact layers are provided. Preferably, such a contact layer is strip-shaped. Furthermore, the contact layer is preferably made of a conductive material, particularly preferably a metal sheet. Preferably, all or at least some of the plurality of contact layers are identical.

[0047] In step b, the contact layer blanks or contact layers are stacked to form the conductor contact. For example, the contact layers are stacked using a magazine into which the contact layers can be inserted.

[0048] In step c., the fastening element is applied to the stacked contact layers. Preferably, the contact layers are pressed together along the stacking direction. Preferably, the fastening element is applied to at least one of the connection sections of the multilayer contact, and particularly preferably to both. For example, the contact layers are further joined together in a form-fitting manner, for instance by means of embossing. In one embodiment, the magazine in which the contact layers are stacked also serves as a casting or injection molding tool for applying a coating as a fastening element.

[0049] For example, the contact layers are secured for transport using the fastening device and / or attached to each other as an assembly aid. For example, the multilayer contacts produced in this way are then transported for mounting on a high-voltage component. For example, the multilayer contacts are subsequently attached to the high-voltage component using one of the connection sections, for example by screwing, riveting, welding, and / or crimping with a clamping sleeve.

[0050] In an advantageous embodiment of the manufacturing process, it is further proposed that the manufacturing process is a method for producing a multilayer contact according to an embodiment as described above.

[0051] In an advantageous embodiment of the manufacturing process, it is further proposed that in step c. a coating is cast around the contact layers and / or a rivet is inserted through the contact layers.

[0052] According to this embodiment, the fastening means is a sheath, preferably a plastic sheath. The sheath is cast around the contact layers in step c., which also includes injection molding. For example, several multilayer contacts are simultaneously encased with a common sheath to produce a multiphase conductor contact as described above.

[0053] Alternatively, the fastening element is a rivet, which is inserted in step c. For example, the contact layers each have a through-hole, preferably one through-hole per connection section. In step b., the contact layers are stacked such that the through-holes are aligned. Alternatively, the through-holes are created after stacking, preferably by punching or drilling. The rivet is then guided through the aligned through-holes and formed accordingly.

[0054] In a further advantageous embodiment of the manufacturing process, it is proposed that the contact layers in step b. are stacked in a magazine, and / or in step c. when applying the fastener along the stacking direction, they are compressed.

[0055] 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 with a rivet in a perspective view; Fig. 2: a schematic representation of a connection section of a multilayer contact according to Fig. 1; Fig. 3: a schematic representation of a multilayer contact with a sheath in a perspective view; and Fig. 4: A multi-phase conductor contact with a plurality of multilayer contacts in a perspective view.

[0056] In Fig. Figure 1 shows a schematic representation of a multilayer contact 1 in a perspective view.

[0057] 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.

[0058] The contact layers 3 are stacked on top of each other along a stacking direction 17. The width direction 19 is defined orthogonal to the stacking direction 17, and the length direction 18 is arranged orthogonal to both the width direction 19 and the stacking direction 17.

[0059] The multilayer contact 1 is divided along the longitudinal direction 18 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.

[0060] The intermediate section 6 is arranged along the longitudinal direction 18 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 17 to increase the flexibility of the intermediate section 6 and thus of the multilayer contact 1.

[0061] The multilayer contact 1 has a mounting opening 15 at each of the connection sections 4 and 5. The mounting opening 15 is continuous and thus allows a fastening element 7 to be inserted through it (not shown here, see Figure 1). Fig. 4).

[0062] Furthermore, the contact layers 3 of the multilayer contact 1 are connected to each other by means of a fastener 7, shown as a rivet 9, at each connection section 4, 5. The rivet 9 extends through the multilayer contact 1, i.e., all contact layers 3, along the stacking direction 17. On both sides of the multilayer contact 1 along the stacking direction 17, i.e., shown as above and (here obscured due to perspective) below, the rivet 9 forms rivet heads. The rivet heads are thus the support sections 12 of the rivet 9, which are supported by a contact surface 8 on the uppermost and the lowermost contact layer 3, respectively. The rivet heads are connected to each other via the rivet shank. Thus, the rivet shank forms a connecting section 13 (here obscured) of the fastener 7 and transmits a tensile force by which the contact layers 3 are pressed together by the rivet heads along the stacking direction 17.Accordingly, the rivet is arranged in a through-opening extending through the connection section 4.5 along the stacking direction 17.

[0063] 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.

[0064] In Fig. Figure 2 is a schematic representation of a connection section 4,5 of a multilayer contact 1 according to Fig. 1 shown.

[0065] It can be seen that the rivet heads as support sections 12 are supported on both sides of the multilayer contact 1 via contact surfaces 8 along the stacking direction 17 and that the rivet shank as connecting section 13 extends through the multilayer contact 1 in a through-opening along the stacking direction 17.

[0066] The mounting opening 15 is shown as a purely optional feature at an outer end of the connection section 4 along the longitudinal direction 18, by means of which the multilayer contact 1 can be connected to a high-voltage component 2 or a connecting conductor.

[0067] In Fig. Figure 3 shows a schematic representation of a multilayer contact 1 with a sheathing 10 in a perspective view.

[0068] The multilayer contact 1 corresponds to the multilayer contact 1 according to [reference missing], with the exception of the fastening element 7 used. Fig. 1, which is why reference is made to the relevant description.

[0069] A sheath 10 is arranged as a fastening element 7 at both connection sections 4, 5. The sheaths 10 enclose the connection sections 4, 5 in a ring-like fashion. On the upper and lower surfaces of the multilayer contact 1 as shown, the sheath 10 forms a support section 12, which provides a contact surface 8 to the uppermost and lowermost contact layers 3, respectively. The force along the stacking direction 17, for example, to press the contact layers 3 together along the stacking direction 17, is transmitted by means of the connecting sections 13. The connecting sections 13 extend on both sides along the width direction 19 of the multilayer contact 1. Thus, the contact layers 3 are preferably connected to each other in a form-fit and force-fit manner.

[0070] For example, the contact layers 3 are fixed in a magazine for stacking the contact layers 3 in a desired position relative to each other and pressed along the stacking direction 17 when the coating 10 is applied.

[0071] In Fig. Figure 4 shows a multi-phase conductor contact 11 with a plurality of multilayer contacts 1 in a perspective view.

[0072] The individual multilayer contacts 1 correspond to the multilayer contact 1 from Fig. 3, to whose description reference is made. The multi-phase conductor contact 11 shown here differs from the representation in Fig.3. This is achieved by enclosing a plurality of multilayer contacts 1 by means of a single sheath 10. The sheath 10 fixes the multilayer contacts 1 at predefined intervals from one another, thus simplifying assembly. Furthermore, the sheath 10 electrically insulates the multilayer contacts 1 from each other.

[0073] The illustration shows a connection between the multilayer contacts 1 and a high-voltage component 2. A clamping sleeve 14 and a contact sleeve 16 are shown for each multilayer contact 1.

[0074] Each set consisting of multilayer contact 1, clamping sleeve 14, and contact sleeve 16 is designed to connect one phase of the high-voltage component 2 to a connecting conductor (not shown here). As shown, three phases of the high-voltage component 2 can be connected accordingly.

[0075] For this purpose, for example, the clamping sleeve 14 is pushed through the mounting opening 15 of the respective first connection section 4 of the multilayer contact 1 and crimped onto the contact sleeve 16. The contact sleeve 16 is electrically and mechanically connected to the high-voltage component 2 and thus establishes the electrical contact to the respective phase of the high-voltage component 2. For example, the contact sleeve 16 is held in the housing of the high-voltage component 2 in an electrically insulating manner.

[0076] The second connection section 5 of each multilayer contact 1 is designed to be electrically connected to the connecting conductor. As already explained, the two connection sections 4 and 5 of the multilayer contacts 1 are each connected to each other via an intermediate section 6. The intermediate section 6 is bent along the stacking direction 17. The multiple contact layers 3 and the bending of the intermediate section 6 ensure high flexibility of the multilayer contacts 1 in the longitudinal direction 18.

[0077] Here, a multilayer contact with a fastening device for transport securing is proposed for particularly simple and cost-effective manufacturing and assembly. Reference symbol list 1 Multilayer contact 2 High-voltage components 3 contact layers 4 Connection section 5 Connection section 6 Intermediate section 7 Fasteners 8 Contact area 9 rivets 10 Sheathing 11 Multi-phase conductor contact 12 Support section 13 Connecting section 14 clamping sleeve 15 Mounting opening 16 Contact sleeve 17 Stacking direction 18 Longitudinal direction 19 Latitude

Claims

[1] Multilayer contact (1) for a high-voltage component (2) of a motor vehicle, comprising at least the following components: - a plurality of contact layers (3) stacked along a stacking direction (17); - 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 (18), characterized by , that the contact layers (3) are fastened to each other by means of a fastening means (7), and the fastening means (7) has a contact surface (8) to the contact layers (3) on both sides of the multilayer contact (1) along the stacking direction (17) in order to connect the contact layers (3) to each other along the stacking direction (17). [2] Multilayer contact (1) according to claim 1, wherein the fastening means (7) penetrates or laterally surrounds the contact layers (3) along the stacking direction (17), wherein the fastening means (7) is preferably a rivet (9) or a sheath (10). [3] Multilayer contact (1) according to claim 2, wherein the connection section (4) of the multilayer contact (1) has a groove by means of which the sheathing (10) is fixed along the longitudinal direction (18). [4] Multilayer contact (1) according to one of the preceding claims, wherein the fastening means (7) is arranged on at least one of the connection sections (4,5). [5] Multilayer contact (1) according to one of the preceding claims, wherein the intermediate section (6) is a flexible section, preferably bent transversely to the longitudinal direction (18). [6] Multiphase conductor contact (11), wherein the multiphase conductor contact (11) comprises a plurality of multilayer contacts (1) according to one of the preceding claims, and the fastening means (7) encloses and fixes the plurality of multilayer contacts (1), preferably at a predetermined distance from each other. [7] Manufacturing process for a multilayer contact (1) comprising the following steps: a. Providing a plurality of contact layers (3); b. Stacking the contact layers (3) along a stacking direction (17); and c. Applying a fastening element (7) which forms a contact surface (8) to the contact layers (3) on both sides of the multilayer contact (1) along the stacking direction (17), thus fastening the contact layers (3) to each other. [8] Manufacturing method according to claim 7, wherein the manufacturing method is a method for producing a multilayer contact (1) according to any one of claims 1 to 5. [9] Manufacturing method according to claim 7 or claim 8, wherein in step c. a coating (10) is cast around the contact layers (3) and / or a rivet (9) is inserted through the contact layers (3). [10] Manufacturing method according to any one of claims 7 to 9, wherein the contact layers (3) are stacked in a magazine in step b. and / or are compressed together along the stacking direction (17) in step c. when applying the fastening means (7).

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