Device and method for electromagnetically noise-suppressed power connection for a motor vehicle

Abstract

The invention relates to a device and a method for manufacturing the device for an electromagnetically noise-suppressed power connection for a motor vehicle, in particular for contacting a transformer (20) of a DC-DC converter, wherein the device comprises at least one busbar (40), furthermore at least one additional busbar (42), at least one fastening means (48), at least one receptacle (50) which is electrically conductively connected to the busbar (40), in particular formed in one piece, and which serves to receive the fastening means (52), further comprising at least one electromagnetic noise suppression (44) which is arranged adjacent to the busbar (40) and / or to the receptacle (50), wherein at least one flexible part (46) is provided which cooperates with the electromagnetic noise suppression (44) for fixing.

Description

[0001] The invention relates to a device and a method for electromagnetically noise-suppressed power connection for a motor vehicle according to the preamble of the independent claims. State of the art

[0002] From DE 19855076 A1, a DC-DC converter is known, comprising a primary circuit, a secondary circuit, and a transformer connecting the primary and secondary circuits. The primary circuit is arranged on a high-voltage printed circuit board (PCB) and the secondary circuit on a high-current PCB, both of which are mounted on a metallic substrate. Recesses are provided in the high-voltage PCB and / or the high-current PCB to accommodate the transformer and the power components of the primary and secondary circuits. The power components are attached to respective ceramic substrates using adhesive layers.

[0003] A power converter is known from DE 2354663 C3. Nodal elements of the low-voltage support are screwed to current-carrying bolts made of electrically conductive material. These bolts are connected via conductors either to the thyristor column of the same level or, via a busbar, to a bolt of the next level. Ring-shaped ferrite cores are slid onto the bolts. The bolts and ferrite cores form blocking chokes, which are part of the circuitry of each level.

[0004] The invention is based on the objective of further improving the fault tolerance, in particular of a DC-DC converter. This objective is achieved by the features of the independent claims. Disclosure of the invention

[0005] By incorporating at least one electromagnetic noise suppressor located adjacent to the busbar and / or the mounting surface, and by including at least one flexible component that interacts with the electromagnetic noise suppressor for fixation, a robust fixation can be achieved. This has a positive effect on reducing electromagnetic noise generation. Furthermore, dimensional tolerances and thermal expansions caused by vibrations or chatter can be easily compensated for.

[0006] In a suitable advanced training, the noise reduction is arranged around the recording. This achieves a defined and positionally precise fixation of the electromagnetic noise reduction while ensuring the required functionality of the electromagnetic noise reduction.

[0007] In a suitable further development, the electromagnetic noise suppression and / or the flexible part are designed in a ring shape and / or the housing is sleeve-shaped. This allows the use of standard ring-shaped components, further reducing manufacturing costs.

[0008] In a suitable further development, the additional busbar has at least one opening through which the fastening element for connection to the mounting is guided. This allows for a secure and reliable electromagnetic noise-suppressed power connection through a captive fastening of the additional busbar.

[0009] In a suitable further development, the flexible part is designed as an O-ring and / or made of an elastic material such as elastic plastic or rubber. This allows the use of another standard component for the cost-effective production of the electromagnetically noise-suppressed power connection.

[0010] In a further advantageous embodiment, the electromagnetic noise suppression is arranged between the additional busbar and the flexible part. This ensures that when the fastener is tightened, the additional busbar presses the electromagnetic noise suppression against the flexible part, thus facilitating a secure fix. Preferably, the fastening device presses the additional busbar together with the electromagnetic noise suppression against the flexible part.

[0011] In a suitable training system, at least one support surface is provided to support the flexible part and / or the busbar. This ensures secure fixation of the flexible part relative to the busbar.

[0012] In a suitable further development, an electromagnetically noise-suppressed current connection is provided for contacting a transformer or converter, in particular a DC-DC converter. Especially in applications in motor vehicles, particularly with electric drives, high currents flow, requiring a particularly robust connection between the converter or transformer and the power supply.

[0013] Furthermore, a method for producing the electromagnetically noise-suppressed current connection according to the preamble of the independent claim is disclosed. This enables the electromagnetic noise suppression to be fixed in a simple and reliable manner.

[0014] Further appropriate training courses result from other dependent requirements and from the description. Brief description of the drawing

[0015] They show: Fig. 1. A schematic overview of a DC-DC converter, Fig. 2 a cut through an electromagnetically noise-suppressed power connection as well as Fig. 3 A perspective view of two electromagnetically noise-suppressed power connections. embodiment of the invention

[0016] The invention is schematically illustrated using an exemplary embodiment and is described in detail below with reference to the drawing.

[0017] In Fig. Figure 1 shows the main architecture with the essential components of a DC-DC converter 30, in which, by way of example, all components are arranged on a single printed circuit board 32 for power components or on a power circuit board. Input quantities 10, indicated by an arrow, such as current I or voltage U from the high-voltage range (for example, in the range between 60 V and 800 V and higher), come, for example, from an energy storage device such as a high-voltage battery of a vehicle, in particular an electric vehicle. First, the input quantity 10 enters a high-voltage section 14, where it is initially filtered in a filter 12, in particular a current filter or so-called EMC filter. Via corresponding conductor tracks 16, the filtered output signal passes from the filter 12 to a DC-AC converter 18, which converts the supplied direct current into alternating current.In the DC-AC converter 18, suitable power semiconductors such as field-effect transistors (FETs) or others can be provided in a suitable interconnection. The AC signal from the DC-AC converter 18 is transmitted via corresponding conductor tracks 16 to one or more transformers 20. The high-voltage (HV) AC signal is converted by the transformer 20 into a low-voltage (LV) AC signal. The signal then travels via corresponding conductor tracks 16 to a low-voltage section 24. First, the AC signal, stepped down by the transformer 20, is converted into a DC voltage by an AC-DC converter 22. The DC voltage from the AC-DC converter 22 then passes via corresponding conductor tracks 16 to a low-voltage filter 26. The filtered low-voltage output signal is then fed as output 28 to an output of the DC-DC converter 30 for further use outside the DC-DC converter 30.This allows corresponding low-voltage loads or consumers of the vehicle to be supplied with energy at the desired (low) voltage level (for example, 12 V).

[0018] Fig. Figure 2 shows a cross-section through a noise-suppressed power connection 39, particularly for a transformer 20 of a converter. The electromagnetically noise-suppressed power connection 39 comprises a busbar 40, which is primarily used for conducting high currents in motor vehicles. The busbar has a high current-carrying capacity and is designed, for example, as a rod-shaped, rigid or only very limitedly flexible conductor, such as a copper busbar or similar material. The busbar 40 terminates in a receptacle 50 for a fastening element 48. The receptacle 48 is oriented transversely to the surface of the busbar 40 and projects beyond its surface. The receptacle 50 is sleeve-shaped. A thread may be provided inside the receptacle 40, which interacts with the fastening element 48, in particular a screw connection.Accordingly, the interior of the receptacle 50 is hollow, in particular blind-hole shaped, and / or preferably provided with a thread.

[0019] The fastening element 48 is shown as a screw connection. A washer 52 is provided, for example, between the screw head of the fastening element 48 and the top surface of another busbar 42. Other connection types, such as rivet connections or similar, can also be provided.

[0020] The receptacle 50 includes a support surface for an additional busbar 42. The additional busbar 42 has an opening 43. The additional busbar 42 is positioned on the receptacle 50 so that the opening 43 is aligned with the opening of the receptacle 50. This allows the fastening element 52 to be inserted or screwed into the receptacle 50 through the opening 43.

[0021] Furthermore, the electromagnetically noise-suppressed power connection 39 includes an electromagnetic noise suppression element 44. The electromagnetic noise suppression element 44 serves to block rapid changes in the electric current flowing through the busbars 40, 42, which could lead to electromagnetic noise and interference. This prevents damage to semiconductor components caused by short-term high-potential overvoltages. In the exemplary embodiment, the electromagnetic noise suppression element 44 is designed as a ring-shaped, closed component whose inner diameter approximately corresponds to the outer diameter of the receptacle 50 for the fastening element 52 on the busbar 40. The electromagnetic noise suppression element 44 can, for example, be designed as a ferrite ring or made of other suitable materials and shapes.The electromagnetic noise suppressor 44, when mounted, is in contact with the other busbar 42; in particular, the upper surface of the electromagnetic noise suppressor 44 is connected to the underside of the other busbar 42. The other busbar 42 is thus located above the electromagnetic noise suppressor 44 and / or above the receptacle 50 for the mounting 52.

[0022] The noise-suppressed power connection 39 comprises at least one flexible part 46. The flexible part 46 can, for example, be an O-ring made of a compressible and therefore flexible material, such as elastic plastic or rubber. In the exemplary embodiment, the flexible part 46 also surrounds the receptacle 50. The flexible part 46 is arranged such that it interacts with the electromagnetic noise suppression 44. In particular, vibrations of the electromagnetic noise suppression 44 can be prevented by a suitable arrangement. For this purpose, the flexible part 46 is arranged in a slightly compressed manner between a counter surface 56, 58, for example, a receptacle 56 or a housing 58, and thus presses against the underside of the electromagnetic noise suppression 44. This clamps the electromagnetic noise suppression 44 between the flexible part 46 and the further power rail 42.

[0023] The exemplary embodiment according to Fig. Figure 3 shows a perspective view of two parallel electromagnetic noise-suppressed current connections 39. Fastening elements 48 are provided for each connection, which interact with the upper surface of the respective additional busbars 42 via a washer 52 to connect them to the busbar 40. For this purpose, a common receptacle 56 is provided, which is arranged parallel to the surface of the busbar 40. The flexible part 46 is located on the common receptacle 56, and the respective electromagnetic noise suppressor 44 is arranged between the respective flexible part 46 and the underside of the additional busbar 42. When the respective fastening element 48 is tightened, the electromagnetic noise suppressor 44 is clamped between the respective additional busbar 42 and the respective flexible part 46. This prevents vibrations of the noise suppressor 44.The resulting noise is specifically prevented. In . Fig. 3 further examples of connections 54 for further contacting, for example, with the circuit board 32 or a transformer 20 are shown.

[0024] Preferably, a cylindrical, electrically conductive component, in particular the receptacle 50 of the busbar 40, is screwed to another electrically conductive component, in particular the further busbar 42. The electromagnetic noise suppressor 44 is arranged around the electrically conductive area of ​​the conductor, the busbar 40, and / or the further busbar 42, together with a flexible part 46 (for example, an O-ring made of flexible plastic or rubber). The arrangement is fixed by applying slight pressure to the flexible part 46, for example, via a screw connection as an example of the fastening means 48. This prevents chattering or other noise generation, and keeps the electromagnetic noise suppressor 44 in position.

[0025] The described electromagnetically noise-suppressed current connection 39 is particularly suitable for a converter, in particular a DC voltage converter or in particular for contacting the transformer 20, in particular on gel frames (or so-called gelframes).

[0026] The described electromagnetically noise-suppressed power connection 39 is particularly suitable for use in motor vehicles due to its robust design, which protects against mechanical vibrations. However, its use is not limited to this application. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] DE 19855076 A1

[0002] DE 2354663 C3

[0003]

Claims

[1] Device for electromagnetic noise suppression of a power connection for a motor vehicle, in particular for contacting a transformer (20) of a DC voltage converter, comprising at least one busbar (40), at least one further busbar (42), at least one fastening means (48), at least one receptacle (50) which is electrically conductively connected to the busbar (40), in particular formed in one piece, and which serves to receive the fastening means (52), comprising at least one electromagnetic noise suppression (44) which is arranged adjacent to the busbar (40) and / or to the receptacle (50), wherein at least one flexible part (46) is provided which cooperates with the electromagnetic noise suppression (44) for fixing. [2] Device according to claim 1, characterized by , that the electromagnetic noise suppression (44) is arranged around the recording (50). [3] Device according to any one of the preceding claims, characterized by that the electromagnetic noise suppression (44) and / or the flexible part (46) are ring-shaped and / or the receptacle (50) is sleeve-shaped. [4] Device according to any one of the preceding claims, characterized by , that the further busbar (42) has at least one opening (43) through which the fastening means (48) is guided for connection with the receptacle (50). [5] Device according to any one of the preceding claims, characterized by , that the flexible part (46) is designed as an O-ring and / or made of plastic or rubber. [6] Device according to any one of the preceding claims, characterized by , that the electromagnetic noise suppression (44) is arranged between the further current rail (42) and the flexible part (46). [7] Device according to any one of the preceding claims, characterized by, that the fastening means (48) presses the further busbar (42) together with the electromagnetic noise suppression (44) against the flexible part (46). [8] Device according to any one of the preceding claims, characterized by , that at least one support surface (56,58) is provided which serves to support the flexible part (46) and / or the busbar (40). [9] Device according to any one of the preceding claims, characterized by , that the electromagnetically noise-suppressed current connection (39) is provided for contacting a transformer (20) of a converter, in particular a DC voltage converter. [10] Device according to one of the preceding claims, wherein the converter comprises at least one filter (12) for filtering at least one supplied high-voltage input quantity (10), and / or at least one DC-AC converter (18) to which at least one output signal of the filter (12) can be supplied, and / or at least one transformer (20) to which at least one output signal of the DC-AC converter (18) can be supplied, and / or at least one AC-DC converter (22) to which at least one output signal of the transformer (20) can be supplied, and / or at least one further filter (26) to which at least one output signal of the AC-DC converter (22) can be supplied, wherein the output signal of the further filter (26) is available as a low-voltage output quantity (28), and / or at least one inductor and / or one capacitor. [11] Method for producing an electromagnetically noise-suppressed current connection (39), in particular for contacting a transformer (20) of a DC-DC converter, comprising at least one busbar (40), at least one further busbar (42), at least one fastening means (48), at least one receptacle (50) electrically connected to the busbar (40), and which serves to receive the fastening means (52), wherein at least one electromagnetic noise suppressor (44) is arranged adjacent to the busbar (40) and / or to the receptacle (50), and wherein at least one flexible part (46) is arranged adjacent to the electromagnetic noise suppressor (44) for fixing the noise suppressor (44), and wherein the fastening means (48) presses the electromagnetic noise suppressor (44) against the flexible part (46). [12] Procedure according to the preceding procedure claim, characterized by, that the fastening element (48) is inserted through an opening (43) of the further busbar (42) and is connected to the receptacle (50). [13] Method according to any of the preceding method claims, characterized by , that the fastening means (48) moves the busbar (40) and / or the further busbar (42) so that the electromagnetic noise suppression (44) and the flexible part (46) are pressed against each other. [14] Method according to one of the following method claims, characterized by , that first the flexible part (46) and the electromagnetic noise suppression (44) are placed around the receptacle (50) and then the further busbar (42) is pressed against the electromagnetic noise suppression (44) and / or the flexible part (46) by the fastening means (48).

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