Connecting system for contact-connecting busbars having different thicknesses

Abstract

The invention provides, in one aspect, a connecting system (10) for contact-connecting busbars (11a, 13a; 11b, 13b) having different thicknesses (d11a, d13a; d11b, d13b). In illustrative embodiments in this invention, the connecting system (10) comprises a first busbar element (11a; 13a) having a first thickness (d11a; d11b) and a second busbar element (13a; 13b) having a second thickness (d13a; d13b), wherein the first thickness (d11a; d11b) is greater than the second thickness (d13a; d13b). In this case, the first busbar element (11a; 11b) has an opening (111a; 111b) that is formed in the first busbar element (11a; 11b) and the second busbar element (13a; 13b) has a plug-in connector (13a2; 13b2) that is integrally formed on the second busbar element (13a; 13b) and is designed to form a plug-in connection with the opening (111a; 111b) formed in the first busbar element (11a; 11b).

Description

[0001] Connection system for contacting busbars with different thicknesses

[0002] The present invention relates to a connection system for contacting busbars with different thicknesses, in particular a plug connection system for connecting busbars with different thicknesses.

[0003] Applications for assemblies in which busbars of different thicknesses must be connected to one another are known. For example, in applications involving battery modules or on-board distribution and supply systems in electric vehicles, busbars in the form of leadframes equipped with resistors and capacitors are often mechanically and electrically coupled to busbars that serve as supply rails connected to power sources. Supply rails are thicker than leadframes. Until now, leadframes and supply rails have been connected either via additional connecting elements provided between the supply rail and the leadframe or via complex through-hole connections, which generally require machining of busbars with greater thickness to achieve a reliable through-hole connection.Regardless of the type of connection, on the one hand, the material costs for providing such a connection are increased, and on the other hand, further sources of error that impair the reliability of connected busbars are introduced through additional interfaces and / or machining steps. For example, with conventional through-hole connections, complex post-processing, e.g., milling, waterjet cutting, EDM, etc., is required to create a hole with the required tolerance. This increases the manufacturing costs for producing reliable connections, so that industrial-scale production can be uneconomical. A common approach to connecting busbars often involves welding two connecting partners together at their flat sides.

[0004] When using punched holes in busbars, additional connecting elements are required, which on the one hand increase the material costs for the final product and on the other hand introduce an additional interface and thus an additional source of error.

[0005] DE 196 22 895 A1 discloses a method for producing a connecting device for a set of busbars arranged parallel to one another at a distance from one another and encased in an insulating cast material. Each busbar comprises connecting elements attached to the busbars. US 2011 / 0195585 A1 describes a connecting device for connecting at least one external electrical conductor to an electrical connection system of a solar module, the current-carrying parts of which are designed as busbars. These busbars are mounted on a support element and each connected to an external electrical connection cable.

[0006] Document US 2012 / 0015550 A1 describes a battery connector used in a power unit mounted on a hybrid vehicle or an electric vehicle. The battery connector has a plurality of bus bars for connecting a plurality of batteries, with a positive electrode successively connected to an adjacent negative electrode. A bus bar is connected to a connecting wire via a terminal.

[0007] Given the background described above, one task is to provide a non-error-prone, yet space-saving and process-reliable connection system for contacting busbars with greatly differing thicknesses with a simplified structure and at low cost.

[0008] In one aspect, the present invention provides a connection system for contacting busbars of different thicknesses. The connection system can be designed as a plug-in connection system, for example, with a through-hole connection.

[0009] In illustrative embodiments herein, the connection system comprises a first busbar element having a first thickness and a second busbar element having a second thickness, wherein the first thickness is greater than the second thickness. The first busbar element has an opening formed in the first busbar element, and the second busbar element has a plug-in connector formed integrally on the second busbar element, which connector is configured for a plug-in connection with the opening formed in the first busbar element.

[0010] A busbar element should be understood as representing a material section made of an electrically conductive material that is used to manufacture a busbar, busbar, or leadframe, or at least represents a section of a busbar, busbar, or leadframe. Thus, a busbar element can be a busbar, busbar, or a piece of material from which a busbar, busbar, or leadframe is formed by further processing. Thus, a piece of material, e.g., made of copper or aluminum, that serves as the starting point for manufacturing a busbar, busbar, such as a metal sheet from which a busbar, busbar, or leadframe is punched out, is also considered a busbar element.In illustrative examples, for example, the second busbar element is punched out of a leadframe or a piece of material suitable for producing a leadframe, wherein the correspondingly formed second busbar element has a connector integrally formed thereon. This allows a leadframe to be realized as an extension of the connector without the need for additional connecting elements between the connector and the leadframe. By providing the connector on the second busbar element, the connector can be more easily provided on the second busbar element than on the first busbar element.

[0011] In some exemplary embodiments, a thickness represents an average thickness obtained by averaging a thickness across one of the first and second busbar elements. Known techniques for averaging a value may be used, such as geometric or arithmetic averaging over a grid of measured thickness values. Alternatively, at least one of the first and second busbar elements may have a (substantially) constant thickness, in particular a thickness that is considered constant within the scope of a usual or desired tolerance requirement for the thickness of the busbar element. In specific and non-limiting examples, a thickness with a thickness variation of at most 20%, or at most 15%, or at most 10%, or at most 5%, or at most 1% may be considered substantially constant.

[0012] In illustrative embodiments of this aspect, the first busbar element, which has the opening formed in the first busbar element, can have the first thickness at least in a region of the first busbar element where the opening is formed. For example, the opening can be formed in a section of the first busbar element, wherein only this section has the first thickness and the first busbar element otherwise has a third thickness less than the first thickness and optionally less than or equal to the second thickness. For example, the first busbar element can have the first thickness at least in this section. This ensures that the first busbar element provides a stable plug-in connection at least at the opening.In illustrative embodiments of this aspect, the second busbar element, which has the plug connector formed integrally on the second busbar element, can have the second thickness at least in a region of the second busbar element on which the plug connector is formed. For example, the plug connector can be formed from a section of the second busbar element, wherein this section has the second thickness. For example, the second busbar element can have the second thickness at least in this section. This achieves that the second busbar element is formed at least in this region to provide a plug connector. In illustrative embodiments herein, the second busbar element has the second thickness at least in the plug connector.For example, the second busbar element on the connector may have the second thickness as a constant or substantially constant thickness, or, if the second thickness on the connector represents an average thickness, a maximum thickness on the connector may be smaller than the first thickness.

[0013] The connection system according to this aspect can be advantageously used for contacting busbars with greatly differing thicknesses, such as connecting at least one leadframe (with or without components on or through the leadframe) to at least one busbar connected to a power supply. In particular, no additional connecting elements are required in and / or during post-processing of the connection system to form a connection between the two busbar elements. This provides error-resistant, space-saving, and process-reliable connection systems for contacting busbars with greatly differing thicknesses with a simplified design and at low cost.

[0014] In an advantageous embodiment of this aspect, the first busbar element can comprise a busbar or busbar for power supply. This makes it possible to advantageously use the connection system in a coupling with a power supply system.

[0015] In a further advantageous embodiment of this aspect, the second busbar element can comprise a leadframe element. This allows a connector to be easily provided as an integral coupling part. Furthermore, the leadframe element can provide an electrical component; for example, leadframe elements connected to busbar elements of different electrical polarity and / or different electrical potential can form a capacitive component. In illustrative examples herein, a connection system can comprise a plurality of first busbar elements, each coupled to at least one second busbar element, wherein at least one capacitive component is provided.

[0016] In a further advantageous embodiment of this aspect, the opening can be a hole punched in the first busbar element. This allows the connection system to be provided at low cost, since the opening is provided with little effort.

[0017] In a further advantageous embodiment of this aspect, the connector can be designed as a rolled or bent plug. This provides a simple and stable design of the connector. In some illustrative examples herein, the rolled or bent plug can be provided in the form of a rolled or bent socket or a round pin. This represents a stable design that provides a reliable connection to the opening. For example, a very stable design can be achieved by a round pin that is rolled multiple times, for example, has spirally extending round pin sections that are tightly rolled, so that flexural rigidity is increased.

[0018] In a further advantageous embodiment of this aspect, the connector can be designed for a positive and non-positive connection to the opening and connected to the opening. This allows for a fault-resistant and process-reliable connection to be easily established.

[0019] In a further advantageous embodiment of this aspect, a ratio of the first thickness to the second thickness may be greater than 1.5. In some illustrative examples herein, the ratio may be at least 2. This allows corresponding connection systems to be advantageously used in coupling leadframes to power supply systems.

[0020] In a further advantageous embodiment of this aspect, the first thickness can be at least 2 mm and / or in a range of 3 to 4 mm. In some illustrative examples herein, the first thickness can be at least 2.5 mm. This allows corresponding connection systems to be advantageously used in coupling with energy supply systems.

[0021] In a further advantageous embodiment of this aspect, the second thickness may be less than 2 mm and / or in a range from 0.6 to 1.2 mm. In some illustrative examples herein, the second thickness may be at most 1.5 mm. This allows corresponding connection systems to be advantageously used in coupling with lead frames. In at least some of the embodiments described above, busbar elements may be formed from copper or aluminum or Cuponal (i.e., a copper-clad aluminum bimetal).

[0022] In at least some of the embodiments described above, busbar elements may be at least partially coated with an insulating material for electrical insulation.

[0023] At least some of the embodiments described above may include an opening having a diameter that has a ratio to the thickness of the first busbar element of at least 0.9.

[0024] At least some of the above embodiments provide a connection system for contacting busbars of different thicknesses with geometric connections that offer very good conditions for a subsequent laser welding process.

[0025] Further advantages and illustrative embodiments of the aspects of the invention presented above are described below with reference to the accompanying figures, which are not drawn to scale and in which:

[0026] Fig. 1 schematically illustrates a first busbar element according to some illustrative embodiments;

[0027] Fig. 2 schematically illustrates a second busbar element according to some illustrative embodiments;

[0028] Fig. 3 schematically illustrates the second busbar element of Fig. 2 as a die-cut in an early manufacturing stage according to some illustrative embodiments;

[0029] Fig. 4 schematically illustrates an arrangement of two busbar elements, each corresponding to the second busbar element of Fig. 2, for implementing a capacitive component according to some illustrative embodiments; and Fig. 5 schematically illustrates a connection system in an exploded view according to some illustrative embodiments.

[0030] Fig. 1 shows a schematic perspective view of a first busbar element 1. The first busbar element 1 can represent a busbar or a section of a busbar or reworked busbar. The first busbar element 1 generally represents a rail-shaped element made of an electrically conductive material, for example copper and / or aluminum. The term “rail-shaped” means that the first busbar element 1 is elongated with a thickness d1, where elongated means that a length dimension (for example substantially parallel to a y-direction of an xyz coordinate system shown in Fig. 1), which is perpendicular to a width dimension (for example substantially parallel to an x-direction of the xyz coordinate system shown in Fig. 1) and to the thickness d1, is greater than the width dimension.The thickness d1 represents a constant or substantially constant or average dimension of the first busbar element 1 along a thickness dimension (for example, substantially parallel to a z-direction of the xyz coordinate system shown in Fig. 1), which is oriented perpendicular to the length dimension and the width dimension, respectively. In illustrative examples and as shown in Fig. 1, the width dimension may be greater than the thickness d1.

[0031] In illustrative embodiments, the thickness d1 can be at least 2 mm. For example, the thickness d1 can be at least 2.5 mm and / or in a range of 3 to 4 mm. Thus, the first busbar element 1 can be used in high-voltage or high-current applications, for example, as a supply rail that can be connected to or is connected to a power source.

[0032] In some examples, the busbar element 1 can be configured such that it has a thickness d1 only in one region thereof, and otherwise has a different thickness, such as a thickness less than d1. For example, the busbar element 1 can be provided with a variable thickness profile, wherein the thickness d1 is fixed only in one region thereof.

[0033] With further reference to Fig. 1, the first busbar element 1 has an opening 1a, which is illustrated as a through-hole. The opening 1a is formed in the region where the busbar element 1 has the thickness d1. For example, a diameter of the opening 1a can be at least 0.9*d1. The opening 1a can be circular in plan view and, in an advantageous machining process, can be easily formed by punching in the first busbar element 1. The busbar element 1 can be subjected to one or more bending processes and thus have a desired three-dimensional shape with at least one bend, so that partial sections of the first busbar element 1 extend along at least two different spatial directions.For example, subsections can run along a direction parallel to the length dimension and at least one direction parallel to the width direction and / or a direction parallel to the thickness. In this case, a direction oriented at any angle relative to a direction parallel to the length dimension can also run if this direction is understood as a superposition of multiple directions, for example, according to a definition of a scalar product formed in three-dimensional space, whereby an angle value is defined by taking into account individual directional components and their values, as is generally known to those skilled in the art.

[0034] In illustrative embodiments, the first busbar element 1 can have at least one further opening 1b, for example and without limitation, three openings 1b (in particular also one opening, two openings, or more than three openings), which are formed as blind holes or through holes in the first busbar element 1. The openings 1b can have a cylindrical shape with a diameter that is smaller than the diameter of the opening 1a. For example, the diameter of the openings 1b can be smaller than 0.5*d1.The openings 1b can be provided for positioning the first busbar element 1, so that the openings 1b can serve for positioning the first busbar element 1 relative to a busbar holder (not shown) by means of catch lugs (not shown) provided for this purpose on the busbar holder (not shown), wherein the catch lugs (not shown) are matched to the number of openings 1b and in each case a catch lug (not shown) of the busbar holder (not shown) engages in an associated opening 1b.

[0035] As shown in Fig. 1 and in some illustrative embodiments, the first busbar element 1 can have one or more additional openings, for example and without limitation the opening 1c and / or the opening 1d. The opening 1c can be designed corresponding to the opening 1a and represent, for example, a cylindrical through-opening. Alternatively, the opening 1c can be designed as a blind hole. The opening 1d is shown as a slot-shaped opening which is designed for plug-in connection with a flat and rail-shaped mating plug-in element (not shown). Although the opening 1d is shown as a through-opening for a push-through connection, this does not represent a limitation and alternatively the opening 1d can represent a blind opening.

[0036] Referring to Fig. 2, a second busbar element 2 is shown in a perspective view relative to an xyz coordinate system. Compared to the first busbar element 1 of Fig. 1, the second busbar element 2 has a smaller thickness d2, wherein the thickness d2 is understood as a material thickness and represents a dimension substantially parallel to the z-axis in Fig. 2. In this respect, the second busbar element 2 can be described as less rigid or less solid than the first busbar element 1.

[0037] In illustrative embodiments, the second busbar element 2 is formed from a busbar or, generally, from a conductive material that can be permanently and reversibly deformed into a desired shape. For example, the second busbar element 2 can be formed from a sheet metal or leadframe material. In illustrative examples, the thickness d2 can be less than 2 mm; for example, the thickness d2 can be at most 1.5 mm and / or in a range from 0.6 to 1.2 mm.

[0038] With reference to Fig. 2, the second busbar element 2 has a body portion 2a and a plug connector 2b formed integrally with the body portion 2a. For example, the plug connector 2b can be mechanically and electrically connected to the body portion 2a via a web portion 2b1. A plug connection portion 2b2 is formed at an end portion of the web portion 2b1 opposite the body portion 2a. For example, the plug connection portion 2b2 can be designed as a rolled socket. This is not a limitation, and the plug connection portion 2b2 can alternatively be designed as a rolled pin or round pin or in a shape generally functioning as a plug connector for engagement with a mating opening in another busbar element, in particular the first busbar element 1 from Fig. 1. The web portion 2b1 can be bent so that it extends substantially parallel to the z-axis.This does not represent a limitation and an orientation of the web section 2b1 relative to the body section 2a can be adjusted in such a way as is expedient for forming a plug connection with a further busbar element, in particular the first busbar element 1 from Fig. 1.

[0039] As shown in Fig. 2 and in some illustrative embodiments, the second busbar element 2 can have one or more additional openings 2c. The one or more openings 2c can be designed as a cylindrical through-opening or as a blind hole and can be provided for positioning the second busbar element 2, so that the openings 2c can serve to position the second busbar element 2 relative to a busbar holder (not shown) by means of catch lugs (not shown) provided for this purpose on the busbar holder (not shown), wherein the catch lugs (not shown) engage in the one or more openings 2c.

[0040] With reference to Fig. 3, a manufacture of the second busbar element 2 from Fig. 2 will now be described according to some illustrative embodiments. In an initial manufacturing phase, a starting material piece (not shown) can be provided, for example in the form of a metal piece such as a metal sheet, from which a busbar output element 2' is produced by means of one or more machining processes (cutting and / or punching processes and / or rolling processes, etc.), as schematically illustrated in the top view of Fig. 3. The busbar output element 2' is provided in a substantially flat shape, wherein the busbar output element 2' has a material thickness corresponding to the thickness d2 of the second busbar element 2 from Fig. 2. As shown, the busbar output element 2' has a body portion 2a' corresponding to the body portion 2a of the second busbar element 2 from Fig. 2.Furthermore, it has a substantially T-shaped section formed by a web section 2bT, which transitions substantially centrally into a web section 2b2' oriented substantially transversely thereto. This is not a limitation, and alternatively, a substantially L-shaped section can be provided in which the web section 2bT transitions off-center into the web section 2b2' oriented transversely thereto. In any case, the web sections 2bT and 2b2' are integrally formed with the body section 2a'.

[0041] In some illustrative embodiments, the busbar output element 2' can be formed by punching a piece of sheet metal and represents a stamped part. Punching represents a simple manufacturing process for the busbar output element 2', wherein a large number of pieces can be produced without great effort and with good reproducibility.

[0042] In a further processing step, the busbar output element 2' is subjected to a bending process so that the web section 2b2' is formed into the plug-in connection area 2b2. For example, the plug-in connection area 2b2 can be obtained by round-bending the web section 2b2' in Fig. 3. By adjusting the shape of the web section 2b2', a size of the plug-in connection area 2b2 to be produced is set, and it can be seen that a positive connection between the plug-in connector 2b of the second busbar element 2 from Fig. 2 and the opening 1a of the first busbar element 1 from Fig. 1 is achieved by coordinating the dimensions of the opening 1a and the plug-in connector 2b.

[0043] In some examples, the busbar output element 2' can be configured such that it has a thickness d2 only at the web section 2b2', and otherwise has a different thickness, such as a greater thickness. For example, the busbar output element 2' can be provided with a variable thickness profile, wherein the thickness d2 is fixed only at the web section 2b2'.

[0044] Referring to Fig. 4, an arrangement 3 comprising a plurality of second busbar elements 3a and 3b is shown, which can implement a capacitive component when the second busbar elements 3a and 3b are subjected to different potentials. As shown, the second busbar elements 3a and 3b can be substantially similar busbar elements, each of which can substantially correspond to the second busbar element 2 shown in Fig. 2. This does not constitute a limitation, and any desired shaped second busbar elements 3a and 3b can be provided.

[0045] Each of the second busbar elements 3a and 3b has a corresponding body portion 3a1 and 3b1 formed integrally with a corresponding connector 3a2 and 3b2. The second busbar elements 3a and 3b can be arranged on a carrier 3c, wherein the positioning and orientation of the second busbar elements 3a and 3b can be determined by catch lugs 3d formed in a surface 3d of the carrier 3c and engaging openings in the body portions 3a1 and 3b1.

[0046] In some illustrative embodiments, the carrier 3c can be formed from an electrically insulating material, so that the arrangement 3 represents a capacitive component as described above. This does not constitute a limitation, and the arrangement 3 can provide an electrical resistance component, provided the carrier 3c is formed from a suitable material that allows adjustment of a resistive current path between the busbar elements 3a and 3b. For example, an electrical resistance can be adjusted by the carrier 3c through a suitable choice of material and / or suitable dimensions. Alternatively, resistive paths can be inserted into the carrier 3c, which provide an electrical resistance between the busbar elements 3a and 3b.In specific examples herein, an ohmic material may be selected for the carrier 3c or at least in sections in the carrier 3c, for example for ohmic paths in the carrier 3c between the busbar elements 3a and 3b.

[0047] With reference to Fig. 5, a connection system 10 according to some illustrative embodiments is shown in a schematic exploded view. The connection system 10 is provided, as shown, for contacting busbars with different thicknesses. A busbar element 11a with a thickness d11a and with an opening 111a formed in the busbar element 11a is provided, which is electrically and mechanically coupled to a busbar element 13a with a thickness d13a. The busbar element 13a has a body portion 13a1 and a plug connector 13a2 formed integrally on the second busbar element 13a, which is configured for a plug-in connection with the opening 111a, wherein the thickness d11a is greater than the thickness 13a.For the electrical and mechanical coupling between the busbar element 11a and the busbar element 13a, the connector 13a2 is configured for a positive and non-positive connection to the opening 111a and is connected to the opening 111a. For example, the connector 13a2 is coupled to the opening 111a to form a push-through connection and is pressed into the opening 111a in a positive and non-positive manner.

[0048] As shown in Fig. 5, the busbar element 11a may correspond to the first busbar element 1 of Fig. 1, the description of Fig. 1 being incorporated by reference at this point. In particular, the opening 111a in Fig. 5 is identified with the opening 1a in Fig. 1, and the thickness d11a in Fig. 5 is identified with the first thickness d1 in Fig. 1. Furthermore, the busbar element 13a in Fig. 5 may correspond to the second busbar element 2 of Fig. 2 or one of the busbar elements 3a and 3b in Fig. 4, the description of Fig. 1 being incorporated by reference at this point. In particular, reference symbols d13a, 13a1 and 13a2 are identified with corresponding reference symbols d2, 2a, 2b in Fig. 2 and with corresponding reference symbols 3a1, 3b1, 3a2 and 3b2 in Fig. 4.

[0049] With further reference to Fig. 5, the connection system 10 can further provide a busbar element 11b with a thickness d11b and with an opening 111b formed in the busbar element 11b, which is electrically and mechanically coupled to a busbar element 13b with a thickness d13b. The busbar element 13b has a body portion 13b1 and a plug connector 13b2 formed integrally on the second busbar element 13b, which is configured for a plug-in connection with the opening 111b, wherein the thickness d11b is greater than the thickness 13b. For the electrical and mechanical coupling between the busbar element 11b and the busbar element 13b, the plug connector 13b2 is configured for a positive and non-positive connection with the opening 111b and is connected to the opening 111b.For example, the connector 13b2 is coupled to the opening 111b to form a through-connection and is pressed into the opening 111b in a form-fitting and force-fitting manner.

[0050] As shown in Fig. 5, the busbar element 11b may correspond to the first busbar element 1 of Fig. 1, the description of Fig. 1 being incorporated by reference at this point. In particular, the opening 111b in Fig. 5 is identified with the opening 1a in Fig. 1, and the thickness d11b in Fig. 5 is identified with the first thickness d1 in Fig. 1. Furthermore, the busbar element 13b in Fig. 5 may correspond to the second busbar element 2 of Fig. 2 or one of the busbar elements 3a and 3b in Fig. 4, the description of Fig. 1 being incorporated by reference at this point. In particular, the reference symbols d13b, 13b1 and 13b2 are identified with corresponding reference symbols d2, 2a, 2b in Fig. 2 and with corresponding reference symbols 3a1, 3b1, 3a2 and 3b2 in Fig. 4.

[0051] The connection system 10 further comprises a carrier 13c having a surface 13d in which a plurality of catch lugs 13d are formed. The catch lugs 13d engage with openings in the body portions 13a1 and 13b1 to determine a positioning of the busbar elements 13a and 13b on the carrier and an orientation of the busbar elements 13a and 13b relative to one another. In illustrative examples, the catch lugs 13d can be provided by pins integrally formed on the carrier 13c. Thus, the busbar elements 13a and 13b fixed on the carrier 13c can provide a capacitive component 13, which is contacted by means of the busbar elements 11a and 11b in the connection system 10 and coupled to a power source (not shown).For example, in an illustrative and non-limiting application, the capacitive component 13 can implement a capacitive filter in an on-board system of an electric vehicle.

[0052] Although the connection system 10 is shown in Fig. 5 with two busbar elements 11a and 11b each, which are each coupled to a corresponding one of the busbar elements 13a and 13b, this does not represent a limitation and instead of the explicitly shown two busbar connection systems 11a, 13a and 11b, 13b, only one of the busbar connection systems 11a, 13a and 11b, 13b can be provided, as will now be described with regard to Fig. 5, wherein Fig. 5 shows a connection system 10 for contacting busbars with different thicknesses, wherein the connection system 10 comprises a first busbar element 11a or 13a with a corresponding first thickness d11a or d11b and a corresponding second busbar element 13a or 13b with a corresponding second thickness d13a or d13b. The first thickness d11a or d11b is greater than the second thickness d13a or d13b.Furthermore, the first busbar element 11a or 11b has an opening 111a or 111b formed in the first busbar element 11a or 11b, and the second busbar element 13a or 13b has a plug connector 13a2 or 13b2 formed integrally on the second busbar element 13a or 13b, which is configured for a plug connection with the opening 111a or 111b formed in the first busbar element 11a or 11b. This does not constitute a limitation, and alternatively, more than the two busbar connection systems 11a, 13a and 11b, 13b shown can be provided.

[0053] In summary, the following embodiments are described above with reference to Figs. 1 to 5.

[0054] In a first embodiment, a connection system (cf. 10 in Fig. 5) for contacting busbars with different thicknesses is provided, comprising a first busbar element (cf. 1 in Fig. 1; 11a or 11b in Fig. 5) with a first thickness (cf. d1 in Fig. 1; d11a or d11b in Fig. 5) and with an opening formed in the first busbar element (cf. 1 in Fig. 1; 11a or 11b in Fig. 5) (cf. 1a in Fig. 1; 111a or 111b in Fig. 5) and a second busbar element (cf. 2 in Fig. 2; 3a or 3b in Fig. 4; 13a or 13b in Fig. 5) with a second thickness (cf. d2 in Fig. 2; d13a and d13b in Fig. 5) and with a plug connector (cf. 2b in Fig. 2; 3a2 or 3b2 in Fig. 4; 13a2 or 13b2 in Fig. 5) formed integrally on the second busbar element (cf. 2 in Fig. 2; 3a or 3b in Fig. 4; 13a2 or 13b2 in Fig. 5), which plug connector can be connected to the first busbar element (cf. 1 in Fig. 1; 11a or 11b in Fig.5) formed opening (cf. 1a in Fig. 1; 111a or 111b in Fig. 5), wherein the first thickness (cf. d1 in Fig. 1; d11a or d11b in Fig. 5) is greater than the second thickness (cf. d2 in Fig. 1; d13a or d13b in Fig. 5).

[0055] In a second embodiment, the connection system (cf. 10 in Fig. 5) according to the first embodiment is provided, wherein the first busbar element (cf. 1 in Fig. 1; 11a or 11b in Fig. 5) comprises a busbar or busbar for power supply. In a third embodiment, the connection system (cf. 10 in Fig. 5) according to the first or second embodiment is provided, wherein the second busbar element (cf. 2 in Fig. 2; 3a or 3b in Fig. 4; 13a or 13b in Fig. 5) comprises a leadframe.

[0056] In a fourth embodiment, the connection system (cf. 10 in Fig. 5) according to any one of the first to third embodiments is provided, wherein the opening (cf. 1a in Fig. 1; 111a or 111b in Fig. 5) is a hole punched in the first busbar element (cf. 1 in Fig. 1; 11a or 11b in Fig. 5).

[0057] In a fifth embodiment, the connection system (cf. 10 in Fig. 5) according to any one of the first to fourth embodiments is provided, wherein the connector (cf. 2b in Fig. 2; 3a2 or 3b2 in Fig. 4; 13a2 or 13b2 in Fig. 5) is formed as a rolled or bent plug.

[0058] In a sixth embodiment, the connection system (cf. 10 in Fig. 5) according to the fifth embodiment is provided, wherein the rolled or bent plug is provided in the form of a rolled or bent socket or a round pin.

[0059] In a seventh embodiment, the connection system (cf. 10 in Fig. 5) according to one of the first to the sixth embodiment is provided, wherein the plug connector (cf. 2b in Fig. 2; 3a2 or 3b2 in Fig. 4; 13a2 or 13b2 in Fig. 5) is designed for positive and non-positive connection with the opening (cf. 1a in Fig. 1; 111a or 111b in Fig. 5) and is connected to the opening (cf. 1a in Fig. 1; 111a or 111b in Fig. 5).

[0060] In an eighth embodiment, the connection system (cf. 10 in Fig. 5) according to any one of the first to seventh embodiments is provided, wherein a ratio of the first thickness (cf. d1 in Fig. 1; d11a or d11b in Fig. 5) to the second thickness (cf. d2 in Fig. 2; d13a and d13b in Fig. 5) is greater than 1.5, preferably at least 2.

[0061] In a ninth embodiment, the connection system (cf. 10 in Fig. 5) according to any one of the first to eighth embodiments is provided, wherein the first thickness (cf. d1 in Fig. 1; d11a or d11b in Fig. 5) is at least 2 mm, preferably at least 2.5 mm, and / or is in a range of 3 to 4 mm.

[0062] In a tenth embodiment, the connection system (cf. 10 in Fig. 5) according to any one of the first to the ninth embodiment is provided, wherein the second thickness (cf. d2 in Fig. 2; d13a and d13b in Fig. 5) is less than 2 mm, preferably at most 1.5 mm, and / or lies in a range of 0.6 to 1.2 mm.

[0063] In an eleventh embodiment, the connection system (cf. 10 in Fig. 5) according to any one of the first to the tenth embodiments is provided, wherein the connection system (cf. 10 in Fig. 5) further comprises a third busbar element (cf. 11b in Fig. 5) having a third thickness (cf. d11b in Fig. 5) and an opening (cf. 111b in Fig. 5) formed in the third busbar element (cf. 11b in Fig. 5), a fourth busbar element (cf. 13b in Fig. 5) having a fourth thickness (cf. d13b in Fig. 5) and a plug connector (cf. 13b2 in Fig. 5) formed integrally on the fourth busbar element (cf. 13b in Fig. 5) which is adapted to be plugged into the opening (cf. 111b in Fig. 5) formed in the third busbar element (cf. 11b in Fig. 5). Fig. 5) and comprises a carrier (cf. 13c in Fig. 5) with a surface (cf. 13c1 in Fig. 5) in which a plurality of catch lugs (cf. 13d in Fig.5) are formed, through which the first and third busbar elements (cf. 13a and 13b in Fig. 5) are attached to the carrier (cf. 13c in Fig. 5).

[0064] In a twelfth embodiment, the connection system (cf. 10 in Fig. 5) according to the eleventh embodiment is provided, wherein the third thickness (cf. in Fig. 5: d1, d11a; d11b) is greater than the second and / or fourth thickness (cf. in Fig. 5: d2; d13a; d13b).

[0065] In a thirteenth embodiment, the connection system (cf. 10 in Fig. 5) according to the eleventh or twelfth embodiment is provided, wherein the catch lugs (cf. 13d in Fig. 5) are provided by pins formed integrally on the carrier (cf. 13c in Fig. 5) which engage with positioning and alignment openings (not provided with a reference number in Fig. 5) formed in the first and third busbar elements (cf. 13a and 13b in Fig. 5) so that the first and third busbar elements (cf. 13a and 13b in Fig. 5) are attached to the carrier (cf. 13c in Fig. 5) in a predetermined alignment and orientation to each other such that the first and third busbar elements (cf. 13a and 13b in Fig. 5) fixed on the carrier (cf. 13c in Fig. 5) form a capacitive component (see 13 in Fig. 5).

[0066] In a fourteenth embodiment, the connection system (cf. 10 in Fig. 5) according to any one of the eleventh to thirteenth embodiments is provided, wherein at least one of the third busbar element (cf. 11b in Fig. 5) and the fourth busbar element (cf. 13b in Fig. 5) is formed correspondingly to one of the first busbar element (cf. 11a in Fig. 5) and the second busbar element (cf. 13b in Fig. 5) in accordance with any one of the second to tenth embodiments, as indicated in various configurations below.

[0067] In a first embodiment of the fourteenth embodiments, the third busbar element (cf. 11b in Fig. 5) may comprise a busbar or busbar for power supply.

[0068] In a second embodiment of the fourteenth embodiments, the fourth busbar element (cf. 13b in Fig. 5) may additionally or alternatively comprise a leadframe.

[0069] In a third embodiment of the fourteenth embodiments, the opening (cf. 111b in Fig. 5) in the third busbar element (cf. 11b in Fig. 5) may additionally or alternatively be a hole punched in the third busbar element (cf. 11b in Fig. 5).

[0070] In a fourth embodiment of the fourteenth embodiment, the plug connector (cf. 13b2 in Fig. 5) of the fourth busbar element (cf. 13b in Fig. 5) can additionally or alternatively be designed as a rolled or bent plug. For example, the rolled or bent plug can be provided in the form of a rolled or bent socket or a round pin.

[0071] In a fifth embodiment of the fourteenth embodiments, additionally or alternatively, the plug connector (cf. 13b2 in Fig. 5) of the fourth busbar element (cf. 13b in Fig. 5) can be used for positive and non-positive connection with the opening (cf. 111b in Fig.

[0072] 5) in the third busbar element (cf. 11b in Fig. 5) and connected to the opening (cf. 111b in Fig. 5) in the third busbar element (cf. 11b in Fig. 5).

[0073] In a fifth embodiment of the fourteenth embodiments, additionally or alternatively, a ratio of the third thickness (cf. d11b in Fig. 5) to the second and / or fourth thickness (cf. d2 in Fig. 2; d13a and / or d13b in Fig. 5) may be greater than 1.5, preferably at least 2.

[0074] In a sixth embodiment of the fourteenth embodiment, the third thickness (cf. d11b in Fig. 5) may additionally or alternatively be at least 2 mm, preferably at least 2.5 mm, and / or in a range from 3 to 4 mm. In a seventh embodiment of the fourteenth embodiment, the fourth thickness (cf. d13b in Fig. 5) may be less than 2 mm, preferably at most 1.5 mm, and / or in a range from 0.6 to 1.2 mm.

[0075] In the embodiments described above with reference to the figures, the second busbar element has the second thickness at least at the connector. For example, the second busbar element at the connector can have the second thickness as a constant or substantially constant thickness. If the second thickness at the connector represents an average thickness, a maximum thickness at the connector is smaller than the first thickness.

Claims

Claims Connection system (10) for contacting busbars with different thicknesses, comprising: a first busbar element (1 , 11a; 11 b) with a first thickness (d1 , d11a; d11 b) and with an opening (1 a, 111a; 111b) formed in the first busbar element (1 , 11a; 11b); and a second busbar element (2, 3a; 3b; 13a; 13b) with a second thickness (d2; d13a; d13b) and with a connector (2b, 3a2; 3b2; 13a2; 13b2) formed integrally on the second busbar element (2, 3a; 3b; 13a; 13b), which is configured to form a plug connection with the opening (1a, 111a; 111b) formed in the first busbar element (1, 11a; 11b), wherein the first thickness (d1, d11a; d11b) is greater than the second thickness (d2; d13a; d13b). Connection system (10) according to claim 1, wherein the first busbar element (1, 11a; 11b) comprises a power supply busbar.Connection system (10) according to claim 1 or 2, wherein the second busbar element (2, 3a; 3b; 13a; 13b) comprises a leadframe. Connection system (10) according to any one of claims 1 to 3, wherein the opening (1a, 111a; 111b) is a hole punched in the first busbar element (1, 11a; 11b). Connection system (10) according to any one of claims 1 to 4, wherein the connector (2b, 3a2; 3b2; 13a2; 13b2) is formed as a rolled or bent plug. Connection system (10) according to claim 5, wherein the rolled or bent plug is provided in the form of a rolled or bent socket or a round pin. Connection system (10) according to one of claims 1 to 6, wherein the connector (2b, 3a2; 3b2; 13a2; 13b2) is for positive locking and force locking connection with the. Opening (1a, 111a; 111b) is formed and connected to the opening (1a, 111a; 111b). Connection system (10) according to any one of claims 1 to 7, wherein the ratio of the first thickness (d1, d11a; d11b) to the second thickness (d2; d13a; d13b) is greater than 1.5, preferably at least 2. Connection system (10) according to any one of claims 1 to 8, wherein the first thickness (d1, d11a; d11b) is at least 2 mm, preferably at least 2.5 mm, and / or is in the range of 3 to 4 mm. Connection system (10) according to any one of claims 1 to 9, wherein the second thickness (d2; d13a; d13b) is less than 2 mm, preferably at most 1.5 mm, and / or is in a range of 0.6 to 1.2 mm.Connection system (10) according to any one of claims 1 to 10, further comprising: a third busbar element (11b) with a third thickness (d11b) and with an opening (111b) formed in the third busbar element (11b); a fourth busbar element (13b) with a fourth thickness (d13b) and with a connector (13b2) integrally formed on the fourth busbar element (13b), which is configured to form a plug connection with the opening (111b) formed in the third busbar element (11b); and a carrier (13c) with a surface (13c1) in which a plurality of retaining lugs (13d) are formed, by means of which the first and third busbar elements (13a, 13b) are attached to the carrier (13c).Connection system (10) according to claim 11, wherein the third thickness (d1 , d11a; d11 b) is larger than the second and / or fourth thickness (d2; d13a; d13b) Connection system (10) according to claim 11 or 12, wherein the locking lugs (13d) are provided by pins integrally formed on the carrier (13c) which engage with positioning and alignment openings formed in the first and third busbar elements (13a, 13b) such that the first and third busbar elements-. Elements (13a, 13b) are attached to the carrier (13c) in a predetermined alignment and orientation relative to each other such that the first and third busbar elements (13a, 13b) fixed on the carrier (13c) provide a capacitive component (13). Connection system (10) according to one of claims 11 to 13, wherein at least one of the third busbar element (11b) and the fourth busbar element (13b) is configured according to one of the first busbar element (1, 11a; 11b) and the second busbar element (2, 3a; 3b; 13a; 13b) in accordance with one of claims 2 to 10.

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