Connection arrangement comprising contact element with improved geometry
Patent Information
- Application Number
- DE202025100542
- Authority / Receiving Office
- DE · DE
- Patent Type
- Utility models
- Current Assignee / Owner
- Filing Date
- 2025-02-04
- Publication Date
- 2025-07-17
- Estimated Expiration
- 2035-02-28
Smart Images

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Abstract
Description
[0001] The subject matter relates to a connecting arrangement between a metallic flat part and a metallic contact element.
[0002] Flat conductors (so-called busbars) are increasingly being used in electrical applications, particularly in automotive applications. Flat conductors are used not only as power lines, but also as battery cell connectors, module connectors, or similar applications. The flat conductors are typically formed from a flat metallic part. For contacting contact elements, it is known to apply the contact elements to the surface of the flat metallic part and join them there, preferably by means of a material bond, in particular by welding.
[0003] However, when welding a flat metallic part made of a first metallic material to a metallic contact element made of a second metallic material, increased contact corrosion may occur at the weld seam, depending on the material combination. Furthermore, when using aluminum or an aluminum alloy, especially for the flat part, the contact point may be damaged under high mechanical stress. When using aluminum or aluminum alloys, the metallic material may flow at the contact point.
[0004] In addition to welding the flat part to the contact element, mechanical fixing of the contact element to the flat part is also known. In this case, for example, a connecting bolt is pushed through a through-hole in the flat part and the contact element is connected to the connecting bolt. The connecting bolt and / or the contact element are mechanically fixed to the flat part. This is usually done by screwing. Over time, however, and particularly under mechanical stress, such a screw connection can become mechanically unstable, especially when using aluminum or an aluminum alloy. The contact pressure of the screw connection and mechanical stress can cause the material to flow in the area of the through-hole in the flat part and thus lead to plastic deformation of the flat part, which leads to the mechanical connection being released.
[0005] To prevent this, it has already been proposed to arrange a metallic contact element in the through-hole. The metallic contact element serves as a mechanical and electrical contact point for further connecting elements that are to be connected to the metallic flat part. For example, a sleeve-shaped contact element can be arranged in the through-hole. A connecting bolt can be pushed through this through-hole. The contact element thus stabilizes the mechanical connection between the flat part and the connecting bolt. Such sleeve-shaped contact elements often have a projecting area. In other words, known contact elements have, for example, the shape of a bolt comprising a bolt shaft and a bolt head, with a through-hole extending from the end face of the bolt shaft to the end face of the bolt head facing away from the shaft.
[0006] Metallic contact elements and flat conductors of such connection arrangements are conventionally bonded to ensure adequate mechanical and electrical connection. Friction welding processes have proven particularly advantageous in this regard, as the friction welding process keeps the contact resistance of the corresponding contact low and reduces electrical losses. A frequently used friction welding process is rotational friction welding, in which the flat conductor is held stationary and the contact part rotates.
[0007] When selecting materials for friction-welded contact elements, pure copper or aluminum materials, which have low electrical resistance, are often used, especially in high-voltage applications. For friction welding of the contact elements, an external drive is preferably used on the outer surface of the contact element in the area of the bolt head of the contact element, or an internal drive is used in the area of the through hole to achieve the required rotation of the contact element. However, the torques required for friction welding are relatively high, particularly for contact elements with large welding surfaces and diameters. If the torques are now introduced into the contact element by a positive-locking internal or external drive, the loads on the flanks of the contact surfaces of the drive can become so great that plastic deformation of the contact element occurs.If the contact element is screwed to a contact part or terminal in such a case, the contact part or terminal only rests on the area of the displaced material that protrudes beyond the electrical contact surface. This prevents or limits reliable, large-area contact.
[0008] Accordingly, the object is to provide a connection arrangement which comprises a contact element with a geometry improved for friction welding.
[0009] This object is achieved by a connecting arrangement according to claim 1.
[0010] The invention relates to a metallic flat conductor with at least one contact element. A metallic flat conductor can have a polygonal, in particular quadrangular, cross-sectional profile. A metallic flat conductor can in particular have a square or rectangular cross-sectional profile. In the cross-sectional profile, the flat conductor can be formed from two parallel wide sides and two parallel narrow sides, which can optionally have curves. A wide surface of the flat conductor extends longitudinally along the wide sides, and a narrow surface extends longitudinally along the short sides. The flat conductor comprises at least one through-opening in which at least one contact element is arranged. The at least one through-opening preferably runs completely through the metallic flat conductor.The through-hole preferably extends along a surface normal on a wide surface. The through-hole can be a punched or drilled hole.
[0011] A metallic flat conductor can be a power conductor, a battery cell connector, a module connector, a terminal lug, a crimp terminal, or the like. A metallic flat conductor can be used as a flat conductor in automotive applications, for example, as a power conductor, battery conductor, or the like. In a motor vehicle, a metallic flat conductor can connect a battery to a drive train, power electronics, a starter and / or generator, or a drive motor, or connect electrical components to each other.
[0012] An electrical component is preferably connected to the metallic flat conductor. This can be an electrical component, a cable, in particular a round cable, a flexible cable, in particular a flexible round cable, or the like. For connecting such electrical components, the connection arrangement has at least one contact element. For example, at least two contact elements can also be arranged at opposite ends of the flat conductor, whereby an electrical connection between two terminal bolts of a motor vehicle, which are contacted at the contact elements, can be provided via the flat conductor.
[0013] According to the invention, the connecting arrangement comprises a metallic flat conductor with at least one through-hole. A metallic contact element is firmly bonded to the flat conductor in the area of the through-hole.
[0014] According to the invention, the contact element is friction-welded to the flat conductor, preferably by means of rotational friction welding. The welding between the flat conductor and the contact element ensures low electrical contact resistance, allowing the contact element to serve, for example, as an electrical connection component.
[0015] In rotational friction welding, the stud is set into oscillation or rotation relative to the flat part. This is achieved by the contact element being pressed against the flat conductor, whereby a contact surface of the contact element is pressed against a surface of the flat conductor while simultaneously moving relative to the longitudinal axis of the contact element. This generates frictional heat at the interface between the contact element and the flat conductor in the area of the contact surface of the contact element. The frictional heat causes at least one material at the interface between the flat conductor and the contact element to plasticize. The plasticized materials bond together and form a material-to-material connection.
[0016] The contact element is designed as a bolt comprising a bolt head, a bolt shaft and optionally a through-opening and has an engagement surface for a friction welding tool in the region of the outer circumferential surface of the bolt head or in the region of the inner circumferential surface of the through-opening, wherein the bolt head has a chamfer and / or a tapered region in the region of the engagement surface of the friction welding tool and the chamfer and / or the tapered region are set back by 0.5 mm to 5.0 mm, preferably 0.5 mm to 3.0 mm, particularly preferably 1.0 mm to 2.0 mm compared to the end face of the bolt head facing away from the flat conductor.
[0017] The chamfer and / or tapered section provided in the contact area ensures that flanks deformed by the friction welding tool no longer protrude into the contact area. The electrical contact surface formed by the surface of the bolt head facing away from the flat conductor is thus freely accessible as a flat support surface. This allows, for example, another flat conductor, a connection module, or another electrical component to be placed over the entire contact surface.
[0018] The stud head preferably has a taper on the end face facing the flat conductor. In the area of the taper, the diameter of the stud head is smaller than the diameter along the remaining height of the stud head. This creates a pocket along the outer circumference of the stud head, which directs the material plasticized during the welding process outwards. The resulting weld bead is flat and therefore does not protrude beyond the electrical contact surface of the stud head. A gap can form between the larger radius of the stud head and the flat conductor, which is completely or partially filled with weld bead.
[0019] Additionally or alternatively, the bolt head can penetrate the flat cable in the area of the taper, whereby an increase in the friction surface occurs when the step is exceeded. This can be used during the welding process to stop the process in the Z direction along the longitudinal axis of the contact element. The bolt head can also penetrate the flat cable beyond the taper on the surface facing the flat cable. The friction welding system registers the resulting increase in resistance, and the welding process is stopped.
[0020] Protrusions and / or relief-like structures are preferably provided on the end face of the contact element intended for welding. These ensure only a small contact surface on the flat conductor at the beginning of the welding process, thus achieving higher temperatures with the same contact pressure.
[0021] For rotational friction welding, it is ideal if the contact element is axially symmetrical to its longitudinal axis. The contact element can be rotationally symmetrical, axially symmetrical, or elliptical, or similar, to the longitudinal axis. If the shape is not rotationally symmetrical, the contact element can be used as an external drive. This means that a rotational friction welding tool can rest on the outside of the outer circumference of the bolt head and introduce rotation into the contact element. This rotation can cause the contact element to weld to the flat part. The contact element particularly preferably has a section comprising a polygonal envelope, which serves to attach a friction welding tool. Preferred shapes are polygons that approximate a circle, for example hexagons, octagons, decagons, or dodecagons.
[0022] The contact element is formed from at least two sections. The two sections extend in the axial direction of the contact part. The first section is also referred to as the bolt shank, and the second section as the bolt head. The bolt head and the bolt shank can have identical or different circumferences.
[0023] Preferably, the first section has a first circumference and the second section has a second, larger outer circumference than the first outer circumference. The second section can thus project radially outwards relative to the first section. When the contact element is attached to the through-opening of the flat conductor, the contact element is inserted into the through-opening of the flat conductor with the first section. After the contact element has been inserted into the through-opening of the conductor, the friction welding process can begin, for example. The second section means that the insertion depth of the contact element in the through-opening of the flat conductor is limited, since the second section forms a stop. During a friction welding process, the contact element is preferably welded by friction welding in the region of the contact surface between the flat conductor and the second section of the contact element.
[0024] The second section of the contact element is preferably formed as a flange and serves on the one hand as a contact surface on the flat conductors and on the other hand as an enlarged support surface for a connecting bolt or a connection of a consumer. The support surface forms the electrical contact surface. The contact surface is the surface facing the flat conductor. The support surface is the surface opposite it. The support surface is shaped as a flat surface. A head of a connecting bolt or a nut screwed onto the connecting bolt or a washer can rest on the surface of the flange facing away from the flat conductor. A connection of a consumer can also be arranged on the support surface. The support surface can be round, rectangular, square, polygonal or the like. Along the circumference, the contact surface can have areas that project radially further outwards and areas that project radially less far outwards.
[0025] The first and second sections of the contact element are formed in one piece or in multiple parts. In particular, the contact element can be formed as a stamped part, cold-formed part, milled part, turned part, or forged part.
[0026] The metallic contact element is arranged in the region of the first through-opening of the flat conductor. In this sense, "in the region of the through-opening" means that the contact element is arranged adjacent to the through-opening of the flat conductor. The through-opening of the contact element preferably overlaps at least partially with the through-opening of the flat conductor. The contact element preferably extends partially, particularly preferably completely, through the through-opening of the flat conductor.
[0027] The through-hole of the contact element can preferably be round, elliptical, slot-shaped, or polygonal. If the contact element is to be welded using the friction welding process with an internal drive, the through-hole preferably has an elliptical, slot-shaped, or polygonal inner contour. A hexagonal shape is particularly preferred.
[0028] Especially with an internal drive, it can be advantageous not to form the inner contour used for the drive over the entire height of the contact element, but only in the beginning or end area. This offers the possibility of a simplified manufacturing process using cold extrusion and thus a reduction in the cost of the individual components. This option is not limited to contact elements with an internal drive, but can also be used with an external drive. It could be advantageous here to implement the drive only in the upper area of the bolt head facing away from the end face to be welded and to leave the lower area rotationally symmetrical. This can minimize the formation of a welding bead in the area adjacent to the welding surface due to the flat conductor material being pushed through the edges of the drive contour.
[0029] The contact element preferably has a through-hole for receiving a bolt or threaded pin, through which a screw connection can be made using additional electrical components. The screw connection should preferably provide a uniform surface pressure greater than 10 N / mm 2 on the electrical contact surface.
[0030] The underhead surface pressure of the contact element is preferably smaller than the yield strength of the material of the contact element.
[0031] The electrical contact resistance of the connection arrangement is preferably less than 10 µOhm.
[0032] The contact element can be installed on the center line of the flat cable or offset to the side.
[0033] The inner wall of the through hole of the contact element can be smooth, threaded or have a threaded insert.
[0034] In a further preferred embodiment, the contact element has a non-through opening in the form of a blind hole, which can preferably also be provided with a thread.
[0035] For example, the contact element is designed as a nut that is welded by an external drive.
[0036] The flat conductor preferably comprises aluminum, an aluminum alloy, copper and / or a copper alloy.
[0037] The contact element is preferably made of aluminum, an aluminum alloy, copper, a copper alloy, iron, an iron alloy and / or steel.
[0038] Preferably, the materials of the contact element are selected to have greater strength than the material of the flat conductor. The materials of the contact element have an elastic limit R p0,2 which is greater than the elastic limit of the flat conductor material.
[0039] According to one embodiment, it is proposed that the contact element be metallically coated. A metallic coating can be applied to the material of the contact element. This can be done in a wet-chemical process. Depending on the specific application, and in particular depending on the material of the flat conductor and / or the material of the electrical component to be attached to the contact element, it may be expedient to coat the contact element with one or more different metallic materials. In particular, the contact element can be coated only in partial areas, while other partial areas of the contact element remain uncoated.
[0040] It is proposed that a material for the coating be tin, gold, nickel, silver, copper, or an alloy thereof. Electroplated nickel has proven particularly advantageous for coating the first and / or second contact element, particularly due to its ductility. A coating of pure nickel is preferably applied as electroplated nickel. Nickel sulfamate is particularly preferred for electroplating nickel.
[0041] A multi-layer, in particular two-layer coating is also proposed. In a first step, at least one contact element can be coated with a first metallic material, and in a second step, the coated contact element can be coated with a metallic material that is different from the first metallic material. It has been found that pre-nickel plating is particularly useful. In this case, at least one contact element is first coated with a nickel layer and / or a nickel alloy, in particular a nickel-phosphorus alloy. The nickel-containing layer ensures that the contact element is well protected mechanically. A tin, gold, copper, silver, or alloy layer can be applied to the nickel-containing layer.Nickel plating and tin plating can be advantageous, for example, if the contact element is subsequently soldered or welded to an electrical component. A tin layer can also be useful to provide a good electrical contact layer, eliminating the need to remove the tin layer in the welding area. In particular, a coating with nickel, gold, copper, or silver, with nickel, copper, and silver being preferred for cost reasons, has proven advantageous in the welding area.
[0042] According to one embodiment, it is proposed that a coating have a maximum thickness of 10 µm. It has been found that such a layer thickness represents a good compromise between electrical conductivity at the electrical transition between the contact element and the flat conductor, on the one hand, and mechanical stability and protection against environmental influences, on the other. In particular, a single-layer coating, i.e., a coating comprising a homogeneous layer of material, has a thickness of 1 µm to 10 µm, preferably 3 µm to 10 µm.
[0043] For a multilayer coating, a maximum coating thickness of 20 µm is proposed. A multilayer coating comprises several layers of different compositions applied one above the other. Preferably, each of the layers has a maximum thickness of 10 µm.
[0044] According to one embodiment, it is proposed that the contact element is welded to the flat conductor with a penetration depth of at least 0.2 mm, preferably between 0.2 mm and 2 mm, particularly preferably between 0.2 mm and 1.5 mm. During welding, the contact element is pressed against the flat conductor with its side facing the flat conductor. The interface between the flat conductor and contact element is then plasticized by introducing welding energy. This can be done using frictional energy, electrical energy, or the like. During plasticizing, a joining zone is created into which the contact element can penetrate. In particular, the material of the flat conductor can have a lower melting point than the material of the first contact element and / or the coating of the contact element, so that the material of the flat conductor plasticizes first. The contact element can penetrate the flat conductor through contact pressure.It has been shown that a penetration depth of 0.2 mm to 2 mm is both mechanically and electrically advantageous. If the penetration depth is too small, the mechanical and electrical properties of the connection deteriorate. Very deep penetration depths, on the other hand, require very high welding energy and, in combination with thin flat conductors, can lead to mechanically disadvantageous connections.
[0045] According to one embodiment, it is proposed that a surface of the contact element facing away from the flat conductor, also referred to as the first end face, protrudes from the surface of the flat conductor in the joined state. The flat conductor preferably has insulation, and the first and / or second contact element protrudes from the surface of the insulation facing away from the flat conductor. The contact element is preferably welded to the flat conductor only with such a penetration depth that at least part of the contact element protrudes from the surface of the flat conductor, in particular the wide surface of the flat conductor. This prevents a mechanical or electrical attachment that is placed on the contact element in question from coming into direct contact with the flat conductor.
[0046] The contact element extends through a through-opening in the flat conductor, with a second end face opposite the first end face of the contact element protruding from the surface of the flat conductor on the side of the flat conductor facing away from the first end face. The protrusion of the first and / or second end face of the contact element from the wide surface of the flat conductor is preferably between 0.1 mm and 1 mm. A minimum dimension of 0.1 mm ensures that an electrical and / or mechanical attachment that rests against the contact element does not come into direct contact with the flat conductor in the area of the through-opening and the electrical contact element. In a preferred embodiment, the flat conductor has insulation, and the second end face protrudes at least 0.1 mm from the insulation on the wide surface of the flat conductor.
[0047] When friction welding the contact element to the flat conductor, a friction welding tool is preferably used as an external drive on the outer contour of the contact element. Contact elements with polygonal outer contours are particularly suitable for this purpose. Alternatively, an internal drive of a friction welding tool is preferably inserted into the through-hole of the contact element. Here, too, the use of a polygonal geometry in the area of the contact surface of the internal drive allows for particularly effective torque application to the contact element.
[0048] The subject matter is explained in more detail below with reference to a drawing showing exemplary embodiments. The drawings are not to scale and do not limit the invention in any way. The drawings show: Fig. 1a,b cross-sectional views of the connecting arrangement according to the invention and the contact element of the connecting arrangement, Fig. 2 shows a further embodiment of a contact element in cross section, Fig. 3 a further embodiment of a contact element in cross section, Fig. 4 a schematic representation of a contact element penetrating a flat conductor in cross-sectional view, Fig. 5a-g various embodiments of the bolt head of the contact element in plan view, Fig. 6 an exploded view of a flat conductor with contact element.
[0049] Fig. 1a shows a connection arrangement 100 comprising a flat conductor 1 with a through-opening 2 in which a contact element 3 is integrally connected by friction welding. Fig. 1b shows the contact element 3 of the Fig. 1a in detail. The contact element 3 comprises a bolt head 3a and a bolt shaft 3b, with the bolt shaft 3b protruding through the through-opening 2 of the flat conductor 1. The contact element 3 has a through-opening 5 along its longitudinal axis 20. The bolt head 3a is provided with a chamfer 4a on its outer surface 6a, which is arranged adjacent to the surface of the bolt head 3a facing away from the flat conductor 1. On the surface of the bolt head 3a facing the flat conductor 1, the diameter of the bolt head 3a is tapered. In the area of this taper 7, the outer surface 6a is offset inward in the direction of the through-opening 5. This taper 7 guides the plasticized material flatly outwards during the welding process, so that a flat welding bead 10 is created that radially surrounds the bolt head and does not protrude beyond the electrical contact surface of the bolt head. The contact element 3 according to Fig. 1a,b is intended for use with an external drive using the friction welding process.
[0050] Fig. 2 shows a further embodiment of a contact element 3. This essentially corresponds to the Fig. 1a and Fig. 1b. In contrast, no chamfer is arranged on the outer surface 6a, but instead a chamfer 4a is provided on the inner surface 6b in the region of the through-opening 5. The contact element 3 according to Fig. 2 is intended for use with an internal drive.
[0051] Fig. 3 shows a further embodiment of a contact element 3. This essentially corresponds to the Fig. 1a and Fig. 1b. In contrast, no chamfer is arranged on the outer surface 6a, but instead a taper 4b is provided on the inner surface 6b in the region of the through-opening 5 and a taper 4b in the region of the outer surface 6a. The contact element 3 according to Fig. 3 can be used in the friction welding process with an external drive or with an internal drive.
[0052] Fig. 4 shows the penetration of the contact element 3 according to Fig. 3 into a flat conductor 1 during the friction welding process. The contact element 3 is inserted into the flat conductor 1 in the Z direction along the longitudinal axis of the contact element 3. Three states during the friction welding process are shown as examples: I) start of welding with first contact between the stud head 3a and the flat conductor 1, II) reaching the welding energy for joining the welding surface, III) stop in the Z-axis by shoulder contact in the area of the taper 7 at the end of the welding process. The shoulder on the end face of the stud head facing the flat conductor can also be deeper than in Fig. 4 III) penetrate the flat conductor. The friction welding system registers the increase in resistance upon shoulder contact, whereupon the welding process is stopped.
[0053] Fig. 5a-g show various embodiments of a bolt head 3a in plan view. Any chamfers or tapers are not shown and can be Fig. 1 to 4 described. Fig. 5a shows an embodiment in which the outer surface 6a is decagonal with straight edges. Fig. 5b shows a hexagonal outer surface 6a with straight edges. Fig. Figure 5c shows an octagonal outer surface 6a with straight edges. The inner surfaces 6b have Fig. 5a-c have a circular geometry. The embodiments of the Fig. 5a-c are preferably used with an external drive in the friction welding process. Fig. 5d shows an embodiment with a hexagonal inner surface 6b. In Fig. 5e, the inner surface 6b is octagonal. In Fig. 5f shows a triangular inner surface 5f. In the embodiment of the Fig. 5g, the through-hole 5 is provided as an elongated hole. The embodiments of the Fig. 5d-g are particularly intended for use with an internal drive using the friction welding process.
[0054] Due to the polygonal or slot-shaped outer surfaces 6a,b, the friction welding tool can grip the contact element 3 with a low radial contact force due to the positive locking. The positive locking ensures that the friction welding tool is fixed relative to the contact element 3 in the rotational direction. The positive locking is particularly present in the rotational direction (in the tangential direction).
[0055] Fig. 6 shows a connection arrangement 100 comprising a flat conductor 1 with through-hole 2 and contact element 3 in an exploded view. Any chamfers and / or tapers are Fig. 1 to 4 and in Fig.6 not shown. The contact element 3 is designed as a bolt with a through-opening 5 and comprises a bolt head 3a and a bolt shaft 3b. The bolt head 3a has a front side facing away from the shaft 3b and a front side facing the shaft 3b, while the bolt shaft 3b has a distal front side. The contact element 3 is inserted with its bolt shaft 3b through the through-opening 2. The front side of the bolt head 3a facing the shaft is joined to the flat conductor 1 by friction welding. Reference symbol 100 connection arrangement 1 flat conductor 2 Through hole of the flat conductor 1 3 metallic contact element 3a Bolt head 3b Bolt shaft 4a phase 4b Rejuvenation 5 Through opening of the contact element 6 Surfaces of the bolt head 6a outer surface of the bolt head 6b inner surface of the bolt head 7 Rejuvenation 10 welding bead 20 Longitudinal axis of the through opening 5
Claims
[1] Connection arrangement (100) comprising at least: - a metallic flat conductor (1) with a first through-opening (2), - a metallic contact element (3) friction-welded to the flat conductor (1) in the region of the first through-opening (2), wherein the contact element (3) is designed as a bolt comprising a bolt head (3a), a bolt shaft (3b) and optionally a through-opening (5), and an engagement surface for a friction welding tool is present in the region of the outer circumferential surface (6a) of the bolt head (3a) or in the region of the inner circumferential surface (6b) of the through-opening (5) characterized by , - that the bolt head (3a) has a chamfer (4a) and / or a tapered region (4b) in the region of the contact surface of the friction welding tool, wherein the chamfer (4a) and / or the tapered region (4b) are set back by 0.5 mm to 5.0 mm compared to the end face of the bolt head (3a) facing away from the flat conductor (1). [2] Connecting arrangement (100) according to claim 1, characterized by that on the surface of the bolt head (3a) facing the flat conductor (1) there is a taper (7) of the diameter of the bolt head (3a). [3] Connecting arrangement (100) according to one of the preceding claims, characterized by , - that the metallic contact element is made of aluminum or an aluminum alloy or is made of copper or a copper alloy or is made of iron or an iron alloy, in particular steel. [4] Connecting arrangement (100) according to one of the preceding claims, characterized by , - that the contact element is metallically coated, preferably coated with tin, gold, nickel, silver, copper or an alloy thereof, in particular coated with a nickel-phosphorus alloy.