Contact arrangement for electrical components

Abstract

Arrangement (1) comprising an electrical component (2), a busbar (8) and a connecting seam (9), wherein the electrical component (2) has an electrical connection (3) which is connected to the busbar (8) via the connecting seam (9), wherein the electrical connection (3) is designed as a bent tab which is inserted into a contact slot (7) of the busbar (8) and thereby forms a press fit connection.

Description

[0001] The present invention relates to an arrangement for electrical components which are electrically connected via busbars.

[0002] In particular, there is a need for the compact and reliable integration of electronic devices into power electronic systems. The arrangement must ensure both mechanical stability and high electrical conductivity while simultaneously minimizing space requirements and parasitic inductances.

[0003] In view of the shortcomings of the prior art, the object of the present invention is to disclose an alternative solution.

[0004] The scope of the invention is defined by the claims.

[0005] An arrangement is provided that includes an electrical component and a power busbar.

[0006] In one embodiment, the arrangement comprises an electrical component, a busbar or a set of busbars and a connecting seam, e.g. a soldered seam or preferably a welded seam.

[0007] In one embodiment, the arrangement comprises multiple busbars or a set of busbars. In this text, the terms "busbar(s)" refer to (a set of) electrically conductive plates with at least two electrical poles. The current busbars of a current busbar set preferably have a specific overlapping configuration.

[0008] In one embodiment, the electrical component comprises one or more electrical connections which are connected to the busbar(s).

[0009] In one embodiment, the electrical connection(s) is / are connected to the busbar via the seam, preferably the connecting seam. This makes the connection more stable and robust.

[0010] In one embodiment, the electrical connection is designed as a bent tab that is inserted into a contact slot of the busbar, creating a press fit connection.

[0011] In a preferred embodiment, the electrical connection is designed as a bent tab which is inserted into a contact slot of the busbar, thus forming a press fit connection.

[0012] The press-fit connection ensures a (lateral) contact pressure between the busbar and the electrical connection.

[0013] This configuration enables a mechanically stable and electrically reliable connection without the need for additional fasteners or (support) devices or other (intermediate) support structures.

[0014] Advantageously, in the described configuration, even without / before soldering or welding, there is no or only a minimal gap between the electrical connection and the busbar, i.e., an edge of the contact slot in the busbar, which is preferably compatible with welding techniques that do not require filler wire. This advantageously increases the efficiency and reliability of a subsequent laser welding process.

[0015] In one embodiment, the curved tab includes a bend that is inserted into the contact slot.

[0016] This has the advantage of improving the mechanical locking between the electrical connection and the power busbar, which increases vibration resistance, etc.

[0017] In one embodiment, the bend is bent at an angle between 160° and 200°, preferably between 170° and 190°, most preferably exactly 180° or approximately, but slightly less than 180°, to allow an improved press fit effect of the bend in the groove, which is advantageous for compact integration into the contact groove and for a configuration as a (leaf) spring that is press-fitted in the contact groove.

[0018] In one embodiment, the bend is designed as a leaf spring.

[0019] This ensures elastic deformation of the bend / electrical connection when inserted into the contact slot, which guarantees a secure press fit and compensates for tolerances.

[0020] In all embodiments, the contact slot is any type of hole or recess suitable for receiving the electrical connection.

[0021] Preferably, the slot is a through hole, the shape of which is preferably adapted to the shape of the electrical connection or, in particular, the bend, and is preferably slightly smaller than or as large as a contour of the bend.

[0022] In one embodiment, the electrical connections protrude through the contact slot of the busbar. This advantageously facilitates visual inspection and allows direct access during welding or soldering.

[0023] In one embodiment, the bend comprises a rounded section, wherein at least the rounded section protrudes through the contact slot.

[0024] The rounded shape reduces stress concentrations and improves fatigue strength. Furthermore, the rounded shape facilitates the smooth insertion of the electrical connector into the contact slot and improves ergonomics and alignment during assembly.

[0025] In one embodiment, the electrical connection comprises a support section that connects the electrical component to the bend. The connection seam is made either between the busbar and the support section or between the busbar and the bend, on the side of the bend that is connected to the support section.

[0026] This flexibility in the placement of the weld seam allows for optimal thermal and mechanical performance.

[0027] By placing the connecting seam at the specified location, the conductor path between the electrical component (with the exception of the electrical connection) and the busbar via the electrical connection is preferably made as short as possible.

[0028] In one embodiment, the connecting seam is placed in and / or next to the contact slot.

[0029] This advantageously ensures a firm connection at the point of mechanical intervention, thereby also improving electrical conductivity.

[0030] In one embodiment, the support section is designed as a straight section. This has the advantage of simplifying machining and creating a stable base for welding.

[0031] In one embodiment, the electrical component is an electrical capacitor. This makes the arrangement suitable for energy storage and filter applications in power electronics.

[0032] In one embodiment, the electrical connection and / or the busbar is made of copper or entirely of copper. Copper has the advantage of providing excellent electrical conductivity and thermal performance.

[0033] In one embodiment, the electrical connection and / or the busbar comprises or consists entirely of aluminum or aluminum alloys.

[0034] In other words, the electrical connection and / or the busbar is made of copper or aluminum or aluminum alloys or any mixture of these materials.

[0035] In one embodiment, the electrical connection and / or the busbar are formed from metal sheets or plates, preferably copper sheets, with a preferred thin sheet width of 0.5 mm to 2 mm.

[0036] In other embodiments, the connections are designed as round terminals or connecting pins.

[0037] In one embodiment, the distance between the electrical component, with the exception of the electrical connection, and the busbar is preferably 2 to 5 mm.

[0038] This small distance advantageously supports miniaturization and efficient use of space in the arrangement. Parasitic inductances are beneficially reduced.

[0039] The present disclosure further relates to a method for manufacturing an arrangement comprising an electrical device and a current busbar.

[0040] Preferably, the manufacturing process is geared towards producing an arrangement as described above. Optionally, all features of the arrangement also apply to the process, or vice versa.

[0041] In one embodiment, the method comprises providing the busbar with the contact slot, providing the electrical component with the electrical connection, inserting the bent tab of the electrical connection through the contact slot so that a bend in the bent tab is compressed, thereby forming a press fit between the bent tab and the busbar, and preferably welding the bent tab and the busbar together, wherein the joining seam is formed in and / or next to the contact slot.

[0042] This method enables a robust and repeatable assembly process that is suitable for automation.

[0043] In some embodiments, fixing by soldering is possible instead of welding.

[0044] In one embodiment, welding is carried out by laser welding.

[0045] Laser welding offers the advantage of high precision and minimal thermal impact on surrounding components.

[0046] In one embodiment, no additional material is added during (laser) welding. This reduces the complexity of the process and avoids contamination, thus ensuring a clean and reliable joint.

[0047] In an alternative embodiment, laser welding is carried out using an additional wire.

[0048] In alternative embodiments, TIG welding (tungsten inert gas), hybrid welding, brazing or soldering is performed instead of laser welding. Detailed description of the embodiments:

[0049] The invention is explained in more detail below with reference to the accompanying drawings. The invention is not limited to the examples shown. The drawings show: Fig. 1: Shows a detailed view of an example of an electrical component with a basic electrical connection structure including a bend. Fig. 2: Shows in a detailed view an example of an arrangement that includes the electrical component, a busbar and a connecting seam. Fig. 3: Shows a section through the example arrangement in a detailed view Fig. 2. Fig. 4: Shows the entire example arrangement of the busbar in a perspective top view. Fig. 2 / 3. Fig. 5: Schematic representation of the steps of the manufacturing process.

[0050] Similar or seemingly identical elements in the figures are marked with the same reference symbols. The figures and their proportions are not scalable.

[0051] Fig. Figure 1 shows part of an arrangement 1 with a component 2 according to the invention.

[0052] Component 2 can be any electrical component 2 - such as an electrical (film) capacitor that has specially designed electrical connections 3, e.g. for mounting and electrical contacting on a busbar.

[0053] In Fig. The busbar is omitted for clarity.

[0054] In Fig. 1 The electrical connection 3 is designed as a curved tab, which has a straight support section 5 and a bend 4 with a rounded section 6.

[0055] The curved tab, and in particular the bend 4, is advantageously designed such that it can be inserted into a contact slot 7 formed in the busbar, preferably with the rounded section 6 first. The rounded section 6 advantageously ensures precise alignment and smooth insertion.

[0056] The insertion advantageously creates a press-fit connection that ensures mechanical stability and electrical conductivity. The bent tab therefore has a bend 4, preferably a 180° bend, which preferably acts as a leaf spring, providing elasticity and maintaining the contact pressure over time after insertion.

[0057] In particular, bend 4 acts as a leaf spring, since the ends of bend 4 are at least slightly curved in a direction that leads into the Fig. 1, Fig. 2, Fig. 3 to Fig. 4 the lateral direction, can be pressed against each other.

[0058] The electrical connection 3 also includes a support section 5 that bridges the remaining electrical component 2 and the bend 4.

[0059] The entire configuration is designed so that the distance between the electrical component 2 (excluding the electrical connection 3) and the busbar 8 is as small as possible - ideally no more than 3 mm and preferably less than 2 mm - thereby reducing inductance and improving electrical performance.

[0060] Furthermore, a gap between the busbar 8 and the inserted electrical connection 3 is minimized or completely closed, so that (laser) welding can be carried out easily and precisely.

[0061] Fig. Figure 2 shows a detailed view of the assembly 1 in its mounted or integrated state, highlighting the spatial arrangement and interaction of its main components. The figure illustrates how the electrical connection is designed in a compact and mechanically stable arrangement.

[0062] In the center of the figure, three electrical connections 3 in the form of curved tabs with rounded sections 6 are arranged at equal intervals. The electrical connections 3 serve to electrically connect the component 1.

[0063] The terminals 3 are inserted into the contact slots 7 of the busbar 8. The size of the contact slots 7 is adapted to the size of the bend 4 of the terminals 3. Preferably, the slots 7 are slightly smaller so that the bends 4 are slightly compressed and thus clamped to ensure a secure press fit. The slots 7 guide and hold the terminals 3 in their position, thus ensuring both mechanical fixation and optimal electrical conductivity between the terminal 3 of component 2 and the busbar 8.

[0064] For a secure mechanical connection, the rounded sections 6 of the terminals 3 protrude through the contact slot 7.

[0065] After insertion, a weld seam 9 is applied, which firmly connects the terminals 3 and the busbar 8. Preferably, the weld seam 9 is applied by laser welding, specifically by melting only the metallic material of the electrical terminal 3 and / or the busbar 8, but without the addition of any other welding materials.

[0066] The connecting seam 9 is preferably located either on the support section 5 or on the bend 4, preferably in or next to the contact slot 7, to permanently secure the connection and ensure long-term reliability under thermal and mechanical stress. By placing it at this location, the length of an electrically conductive path between the busbar 8 and the electrical component 2 (excluding the terminal 3) is advantageously minimized, thereby also minimizing parasitic inductances.

[0067] Furthermore, in application examples, several busbars 8 can be stacked on top of each other, preferably separated by electrically insulating plates or films 8A.

[0068] Preferably, the busbar 8 consists of a thin metal sheet, e.g., a copper or aluminum sheet. The electrical connections 3 are also preferably formed from thin metal sheets such as copper or aluminum sheets. The sheet width or thickness of the copper sheets is preferably between 0.5 mm and 2 mm.

[0069] Fig. 2 adds the Fig. 1. by showing the arrangement in a more complete form and clarifying how the arrangement supports both electrical performance and mechanical durability in practical applications.

[0070] Fig. Figure 3 shows a section through arrangement 1. Fig. Figure 2 provides an insight into the structural layering and mechanical integration of its components. This figure complements the preceding figures by highlighting the spatial relationships and the mounting configuration of the electrical connections 3 within the busbar 8.

[0071] The figure shows that a straight support section 5 of the connection 3 protrudes vertically from the component 2, e.g. a film capacitor.

[0072] Adjacent to the straight, vertical support section 5, a 180° bend 4 is formed as a further component of the electrical connection 3, wherein a leaf spring is formed which is inserted into the contact slot 7 to establish an electrical connection with the busbar 8.

[0073] The connecting seam 9 is preferably attached to the unopened side of the electrical connection 3, i.e., to the side of the bend 4 where the support section 5 connects.

[0074] The sections of the electrical connection 3, in particular the support section 5, the bend 4 (and the rounded section 6, which is part of the bend), preferably form a monolithic element.

[0075] Preferably, the connecting seam 9 is placed on the side of the busbar 8 facing away from the electrical component 2, as this side is more easily accessible.

[0076] Furthermore, the connecting seam 9 is appropriately positioned to reinforce the press fit connection and to ensure long-term mechanical stability and electrical conductivity.

[0077] In other words, the support section 5 and the bend 4 with the rounded section 6 together form the curved tab structure described above.

[0078] Fig. Figure 4 shows a detailed perspective view of the arrangement 1, focusing on the interface between the electrical connection 3 of component 2 and the busbar 8, as well as on the integration of these elements into the arrangement 1. The figure serves to illustrate the spatial arrangement and the mechanical features.

[0079] The lower part of the figure shows an electrical component 2, which must be electrically contacted. A flat, sheet-metal busbar 8 is mounted on the component 3, representing the central electrically conductive element in the arrangement 1.

[0080] The busbar 8 is equipped with, for example, three precisely positioned and dimensioned holes, the contact slots 7, through which the electrical terminals 3 are inserted to create an interference fit with the busbar 8. The slots 7 are produced, for example, by cutting, sawing, punching, etc., preferably with dimensional tolerances to achieve an interference fit between the slots 7 and the terminals 3.

[0081] Several busbars 8 can be connected in series, with the connections preferably being connected to only one common busbar 8, or with each connection being contacted with another of the busbars 8.

[0082] An electrically insulating plate 8A is arranged between the busbars 8.

[0083] To avoid electrical contact between an electrical terminal 3 and several busbars 8, a recess is preferably formed in the other busbars 8 at the location of the terminal 3. These recesses are not in contact with the terminal 3. In the figure, the recess has a rectangular shape.

[0084] Furthermore, the rounded sections 6 of the bent tabs are visible, which protrude through the contact slots of the busbar to be contacted and preferably through the recess of the other busbar(s) not to be contacted.

[0085] The example shows three terminals (3), but the number of terminals can vary depending on the type of electrical component.

[0086] This figure highlights the precision and compactness of the arrangement 1 and shows how the busbar 8, the terminals 3 and the insulating plates 8A are arranged to achieve optimal performance. Fig. Figure 4 complements the preceding figures by providing a clear overview of the overall structure of Arrangement 1 and the integration of the individual elements into Arrangement 1.

[0087] Fig. Figure 5 schematically shows the steps of the manufacturing process, which are preferably carried out in the specified order: - Providing the power busbar 8 with the contact slot 7. - Providing the electrical component 2 with the electrical connection 3, which is a bent tab. - Inserting the electrical connection 3 / the bent tab through the contact slot, whereby a bend 4 of the bent tab is pressed together (laterally), creating an interference fit between the bent tab and the busbar 8. - Welding the bent tab and the busbar 8 together, wherein the joining seam 9 is formed in and / or next to the contact slot 7.

[0088] Preferably, the welding is carried out with a laser, which is an advantageous energy-saving and precise method.

[0089] The pre-locking through the press-fit connection between the terminal 3 and the contact slot 7 advantageously enables precise and efficient welding.

[0090] Furthermore, the press connection prevents the formation of disruptive gaps between the terminals 3 and the busbars 8, which can impair the weldability of the connection. List of reference symbols 1. Arrangement 2 electrical component 3 electrical connection 4 bend 5 Support section of the electrical connection 6 rounded section of the electrical connection 7 contact slots 8 busbar 8A Insulating plate 9. Joining seam

Claims

[1] Arrangement (1) comprising an electrical component (2), a busbar (8) and a connecting seam (9), wherein the electrical component (2) has an electrical connection (3) which is connected to the busbar (8) via the connecting seam (9), wherein the electrical connection (3) is designed as a bent tab which is inserted into a contact slot (7) of the busbar (8) and thereby forms a press fit connection. [2] Arrangement (1) according to claim 1, wherein the bent tab has a bend (4) wherein the bend (4) is inserted into the contact slot (7). [3] Arrangement (1) according to claim 2, wherein the bend (4) is bent by 180°. [4] Arrangement (1) according to one of claims 2 to 3, wherein the bend (4) is designed as a leaf spring. [5] Arrangement (1) according to one of claims 2 to 4, wherein the electrical connections (3) protrude through the contact slot (7) of the busbar (8). [6] Arrangement (1) according to claim 5, wherein the bend (4) has a rounded section (6), wherein at least the rounded section (6) extends through the contact slot (7). [7] Arrangement (1) according to any one of claims 2 to 6, wherein the electrical connection (3) has a support section (5) that connects the electrical component (2) to the bend (4), wherein the connecting seam (9) between the busbar (8) and the support section (5) or between the busbar (8) and the bend (4) is located on the side of the bend (4) that is connected to the support section (5). [8] Arrangement (1) according to claim 7, wherein the connecting seam (9) is placed in and / or next to the contact slot (7). [9] Arrangement (1) according to one of claims 7 to 8, wherein the support section (5) is designed as a straight section. [10] Arrangement (1) according to any one of claims 1 to 9, wherein the electrical component (2) is an electrical capacitor. [11] Arrangement (1) according to any one of claims 1 to 10, wherein the electrical connection (3) and / or the busbar (8) comprises copper or aluminium or aluminium alloys or any mixture of these materials or consists of copper or aluminium or aluminium alloys or any mixture of these materials. [12] Arrangement (1) according to any one of claims 1 to 11, wherein the distance between the electrical component (2), excluding the electrical connection (3), and the busbar (8) is not more than 3 mm, preferably not more than 2 mm. [13] Arrangement (1) according to any one of claims 1 to 12, wherein the arrangement comprises several of the terminals (3) and / or the busbars (8). [14] Arrangement (1) comprising an electrical component (2), a busbar (8) and a connecting seam (9), wherein the electrical component (2) has an electrical connection (3) which is connected to the busbar (8) via the connecting seam (9), wherein the electrical connection (3) is designed as a bent tab which is inserted into a contact slot (7) of the busbar (8), thereby forming a press fit connection, the arrangement is made as follows: - Providing the power busbar (8) with the contact slot (7), - Providing the electrical component (2) with the electrical connection, - Inserting the curved tab of the electrical connection (3) through the contact slot (7), whereby a bend (4) of the curved tab is compressed, thereby forming an interference fit between the curved tab and the busbar (8), - Welding the bent tab and the busbar (8) together, wherein the joining seam (9) is formed in and / or adjacent to the contact slot (7). [15] Arrangement according to claim 14, wherein the welding is carried out by laser welding, TIG welding, hybrid welding, brazing or soldering. [16] Arrangement according to claim 14 or 15, wherein no additional material is supplied during welding.

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