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), each with two contact surfaces (4) perpendicular to the stacking direction (12) and layer edges (5) connecting the two contact surfaces (4); - a first connection section (6); - a second connecting section; and - an intermediate section (7) connecting the first connection section (6) with the second connection section along a longitudinal direction (13), wherein two adjacent contact layers (3) along the stacking direction (12) are connected by means of a weld seam (8). The multilayer contact (1) is characterized in particular by the fact that the weld seam (8) is arranged in a weld angle (9) which is formed by the layer edge (5) of one of the two contact layers (3) and the contact surface (4) of the other contact layer (3). wherein the layer edges (5) of the two contact layers (3) are arranged offset from each other in order to form a welding angle (9) between two adjacent contact layers (3). Here, a multilayer contact with contact layers welded together at welding angles is proposed, which is particularly cost-effective and mechanically stable.

Description

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

[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 welds are subjected to high shear forces, which in the worst case can lead to a failure of the connection.

[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, each with two contact surfaces perpendicular to the stacking direction and layer edges connecting the two contact surfaces; - 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, wherein two contact layers adjacent to each other along the stacking direction are joined by means of a weld seam.

[0007] The multilayer contact is characterized primarily by the fact that the weld seam is arranged in a welding angle formed by the layer edge of one of the two contact layers and the contact surface of the other contact layer, wherein the layer edges of the two contact layers are arranged offset from each other in order to form a welding angle between two adjacent contact layers.

[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 designed as strips. In a Cartesian coordinate system, a longitudinal direction and a transverse direction are also defined, orthogonal to each other and to the stacking direction.

[0014] Preferably, the length of such a contact layer along the longitudinal direction is greater than its width, perpendicular to the longitudinal direction. Preferably, the width of the contact layer is in turn greater than its thickness along the stacking direction. 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.

[0015] The contact layers are made of an electrically conductive material, preferably copper.

[0016] Each contact layer forms two contact surfaces. These contact surfaces define the boundaries of the contact layers along the stacking direction. Two contact layers adjacent to each other along the stacking direction thus lie on top of each other with their respective contact surfaces. Preferably, the contact surfaces are arranged transversely, and particularly preferably orthogonally, to the stacking direction.

[0017] The contact surfaces are bounded along the stacking direction by the layer edges. The layer edges define the contact layers transversely, preferably orthogonally, to the stacking direction.

[0018] 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.

[0019] 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.

[0020] 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.

[0021] The two contact layers adjacent to each other along the stacking direction are connected by means of at least one weld seam.

[0022] At least one layer edge of each of two adjacent contact layers is now offset from each other perpendicular to the stacking direction, i.e., along the longitudinal and / or transverse direction. Thus, at least one layer edge of one of the two contact layers abuts the contact surface of the other contact layer, forming a weld angle with it. In other words, one flank of the angle is formed by the layer edge of one contact layer, and the other flank of the angle by the contact surface of the other contact layer.

[0023] The welding angle is a non-zero angle. Preferably, the welding angle is an angle between 30° and 120°, more preferably more than 45°, more than 60° and / or less than 100°, and most preferably a right angle.

[0024] The weld is positioned at or within the welding angle. This allows for particularly strong welds. For example, the welds can be arranged along the longitudinal direction and / or along the transverse direction.

[0025] The proposed multilayer contact is therefore particularly stable and can be manufactured cost-effectively.

[0026] In a further advantageous embodiment of the multilayer contact, it is proposed that the connection sections of two adjacent contact layers are offset from each other along the longitudinal direction, so that the layer edges are offset from each other.

[0027] Accordingly, two stacked connection sections of the contact layers, meaning those in contact via their contact surfaces, are arranged offset from each other along the longitudinal direction. Thus, for example, the layer edges that define the contact layers along the longitudinal direction are offset from each other. Alternatively or additionally, further layer edges, arranged perpendicular to the longitudinal direction, for example at a through-cut, are also offset from each other.

[0028] In an advantageous embodiment of the multilayer contact, it is further proposed that the contact layers each have at least one through-hole, each forming a layer edge and thus a welding angle.

[0029] Accordingly, each contact layer has a through-hole. For example, the through-hole has a rectangular cross-section. The through-holes extend along the stacking direction through the contact layers.

[0030] The through-hole also forms layer edges. At least one layer edge of the through-hole is offset from contact layer to contact layer perpendicular to the stacking direction. Thus, the layer edges of the through-hole also form weld angles, at which, for example, a weld seam is located.

[0031] In an advantageous embodiment of the multilayer contact, it is further proposed that the connection sections and / or the through-holes in each of the contact layers have a different size, so that the offset of the layer edges is formed in each case.

[0032] Accordingly, for example, the connection sections are of different sizes perpendicular to the stacking direction, i.e., in the longitudinal and / or width direction, so that the layer edges of the smaller connection section meet the contact surfaces of the larger contact layer and thus form a welding angle.

[0033] Alternatively or additionally, the through-holes are of different sizes perpendicular to the stacking direction, i.e., along the longitudinal direction and / or the width direction, so that the layer edges of the larger through-hole meet the contact surfaces of the smaller through-hole and thus form a welding angle.

[0034] In an advantageous embodiment of the multilayer contact, it is further proposed that the through-holes in each of the contact layers and / or the contact layers are arranged and / or designed identically.

[0035] Accordingly, the contact layers, for example, are identically designed and manufactured, at least except for a difference in deformation. Alternatively or additionally, the through-holes are identically manufactured, designed, and arranged.

[0036] This enables a particularly cost-effective embodiment of the multilayer contact.

[0037] In an advantageous embodiment of the multilayer contact, it is further proposed that layer edges of the contact layers arranged transversely to the longitudinal direction are offset from each other by means of a deformation of the contact layers in the intermediate section.

[0038] Accordingly, the layer edges of adjacent contact layers are offset from each other because the contact layers in the intermediate section are deformed. Preferably, the contact layers in the intermediate section are bent or folded to increase the flexibility of the multilayer contact in the intermediate section.

[0039] 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.

[0040] A high-voltage component is proposed here. Preferably, this high-voltage component is for a high-voltage electrical system in a motor vehicle.

[0041] Such a high-voltage component is, for example, a battery, power electronics and / or an electric traction motor for a motor vehicle.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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 fastener, such as a rivet or screw, and / or are designed for welding the multilayer contact.

[0046] 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.

[0047] 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. For example, the connecting section is screwed, welded, riveted, and / or fastened to the connection point by means of a clamping sleeve.

[0048] 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 majority of contact layers to form a multilayer contact; c. Bending the contact layers in the intermediate section so that the layer edges of adjacent contact layers are offset from each other; and d. Welding the contact layers at the welding angles created by the offsetting in step c.

[0049] A manufacturing process for a multilayer contact is proposed here. The manufacturing process comprises at least the following steps a., b., c. and d., preferably in the order mentioned.

[0050] In step a., a plurality of contact layers are provided.

[0051] In step b., the majority of contact layers are stacked to form a multilayer contact, for example in a magazine.

[0052] In step c., the contact layers are bent into an intermediate section. During this process, the layer edges in the connection sections of the contact layers are shifted differently along the longitudinal direction and thus offset from one another. Preferably, the contact layers are bent together, for example in the magazine, in the aforementioned sequence after stacking. Alternatively or additionally, the contact layers are bent individually before step b. Preferably, the contact layers or the multilayer contact are bent transversely to the longitudinal direction, and particularly preferably along the stacking direction.

[0053] The contact layers are then welded together at the welding angle created by the offset.

[0054] It is further proposed in an advantageous embodiment of the manufacturing process that the manufacturing process is designed to produce a multilayer contact according to an embodiment as described above.

[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 top view of a connection section of a multilayer contact before welding; Fig. 2: the connecting section to Fig. 1 after welding in a schematic top view; Fig. 3: A cross-sectional view of a connection section of a multilayer contact before welding; Fig. 4: the connecting section to Fig. 3 after welding in a cross-sectional view; Fig. 5: A cross-sectional view of a connection section of a multilayer contact before welding; and Fig. 6: the connecting section to Fig. 5 after welding in a cross-sectional view.

[0056] In Fig. Figure 1 shows a schematic top view of a connection section 6 of a multilayer contact 1 before welding. The connection section 6 is part of a multilayer contact 1 with a plurality of contact layers 3. Each of the contact layers 3 has two contact surfaces 4 and a plurality of layer edges 5 that connect the two contact surfaces 4 to each other.

[0057] In a Cartesian coordinate system, a longitudinal direction 13 and a latitude direction 14 are defined, each orthogonal to each other and to the stacking direction 12.

[0058] The contact surface 4 limits the contact layers 3 along the stacking direction 12. Thus, two contact surfaces 4 of two adjacent contact layers 3 are in contact with each other.

[0059] The layer edges 5 are arranged along the longitudinal direction 13 and along the transverse direction 14, as shown in the illustration. The connection sections 6 of the individual contact layers 3 are offset from each other along the longitudinal direction 13. Thus, the layer edges 5 arranged along the transverse direction are also offset from each other along the longitudinal direction 13. As shown in the illustration, this results in three welding angles 9 per contact layer 3.

[0060] Two of the welding angles 9 are each formed by two through-holes 10, which are arranged in the contact layers 3. The third welding angle 9 is formed by the end-side layer edge 5 of the respective contact layer 3 along the longitudinal direction 13.

[0061] As shown on the left, a connection point 11 of the high-voltage component 2 is depicted on the component side. The connection point 11 is formed here by a conductor bar on which the connection section 6 of the multilayer contact 1 rests with its contact surface 4, which is shown to be the lower surface. Thus, the layer edges 5 of the lowest contact layer 3 form weld angles 9 with the connection point 11, so that the multilayer contact 1 can also be connected to the multilayer contact 1 by means of weld seams 8.

[0062] In Fig. 2 is the connection section 6 after Fig. Figure 1 shows a schematic top view after welding. It can be seen that a weld seam 8 has been applied in each of the welding angles 9.

[0063] For clarity, only three contact layers 3 are shown. Each contact layer 3 is welded to the contact layer 3 below it by means of three welds 8. The lowest contact layer 3 is welded to the connection point 11 of the high-voltage component 2.

[0064] In Fig. Figure 3 shows a cross-sectional view of a connection section 6 of a multilayer contact 1 before welding. This is in comparison to the multilayer contact 1 after welding. Fig. 1 and Fig. In section 2, the contact layers 3 each have only one through-hole 10. Otherwise, the multilayer contact 1 corresponds to the multilayer contact 1 from [reference missing]. Fig. 1 and Fig. 2, whose description is therefore referenced.

[0065] In Fig. 4 is the connecting section 6 after Fig. Figure 3 shows a cross-sectional view after welding. Accordingly, the welds 8 are now located at welding angles 9 of the layer edges 5, i.e., the end layer edges 5 along the longitudinal direction 13 and the layer edges 5 in the through-cuts 10.

[0066] In Fig. Figure 5 shows a cross-sectional view of a connection section 6 of a multilayer contact 1 before welding. The illustrated embodiment differs from the one above with respect to Fig. 1 to Fig. 4. This is achieved by the fact that the connecting sections 6 are not offset along the longitudinal direction 13, but rather the passage recesses 10 are of different sizes along the longitudinal direction 13, so that the welding angles 9 are formed.

[0067] To facilitate the application of the welds 8, the lowest contact layer 3, which rests on the connection point 11, has the smallest through-hole 10. The size of the through-holes 10 then increases with each contact layer 3 upwards.

[0068] The passage openings 10 are arranged centrally one above the other, so that a welding angle 9 results at the layer edges 5 on both sides of the passage openings 10.

[0069] In Fig. 6 is the connection section 6 after Fig. Figure 5 shows a cross-sectional view after welding. The weld seams are now incorporated into the welding angles 9 along the longitudinal direction 13 on both sides of the through-cut openings 10.

[0070] Here, a multilayer contact with contact layers welded together at welding angles is proposed, which is particularly cost-effective and mechanically stable. Reference symbol list 1 Multilayer contact 2 High-voltage components 3 contact layers 4 contact surfaces 5 layer edges 6 Connection section 7 Intermediate section 8 weld seam 9 welding angles 10 Passage opening 11 Junction 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), each with two contact surfaces (4) perpendicular to the stacking direction (12) and layer edges (5) connecting the two contact surfaces (4); - a first connection section (6); - a second connecting section; and - an intermediate section (7) connecting the first connection section (6) with the second connection section along a longitudinal direction (13), wherein two adjacent contact layers (3) along the stacking direction (12) are connected by means of a weld seam (8), characterized by , that the weld seam (8) is arranged in a welding angle (9) which is formed by the layer edge (5) of one of the two contact layers (3) and the contact surface (4) of the other contact layer (3), wherein the layer edges (5) of the two contact layers (3) are arranged offset from each other in order to form a welding angle (9) between two adjacent contact layers (3). [2] Multilayer contact (1) according to claim 1, wherein the connection sections (6) of two adjacent contact layers (3) are offset from each other along the longitudinal direction (13) so that the layer edges (5) are offset from each other. [3] Multilayer contact (1) according to claim 1 or claim 2, wherein the contact layers (3) each have at least one through-hole (10) which each form a layer edge (5) and thus a welding angle (9). [4] Multilayer contact (1) according to one of the preceding claims, wherein the connection sections (6) and / or the through-holes (10) in each of the contact layers (3) have a different size, such that the offset of the layer edges (5) is formed in each case. [5] Multilayer contact (1) according to one of the preceding claims, wherein the through-holes (10) in each of the contact layers (3) and / or the contact layers (3) are arranged and / or designed identically. [6] Multilayer contact (1) according to one of the preceding claims, wherein layer edges (5) of the contact layers (3) arranged transversely to the longitudinal direction (13) are offset from each other by means of a deformation of the contact layers (3) in the intermediate section (7). [7] High-voltage component (2) comprising at least the following components: - an electrical connection point (11); and - a multilayer contact (1) according to any one of claims 1 to 6, - wherein the multilayer contact (1) is electrically conductively attached to the connection point (11) by means of one of the connecting sections (6). [8] Manufacturing process for a multilayer contact (1) comprising the following steps: a. Providing a plurality of contact layers (3); b. Stacking the plurality of contact layers (3) to form a multilayer contact (1); c. Bending the contact layers (3) in the intermediate section (7) so that the layer edges (5) of adjacent contact layers (3) are offset from each other; and d. Welding the contact layers (3) at the welding angles (9) created by the offsetting in step c. [9] Manufacturing method according to claim 8, wherein the manufacturing method is designed to produce a multilayer contact (1) according to any one of claims 1 to 6.

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