Connection assembly, in particular for use in electric vehicles or hybrid vehicles

Abstract

The invention relates to a connection assembly (1), in particular for use in electric vehicles or hybrid vehicles, said connection assembly comprising: a first planar terminal contact (11) having a planar first contact surface (15) for electrically contacting a first electrical and / or electronic component; and a second planar terminal contact (21) having a second contact surface (25) for electrically contacting a second electrical and / or electronic component, the first planar terminal contact (11) and the second planar terminal contact (21) overlapping in an overlap region (5), the first contact surface (15) facing the second contact surface (25), the first planar terminal contact (11) and the second planar terminal contact (21) being connected by means of a connecting element (30) and the first contact surface (15) being pressed against the second contact surface (25) by the connecting element (30). According to the invention: a structure (17) is embossed in the first planar terminal contact (11) so that an edge (16) of the first planar terminal contact (11) projects out of the plane of the first contact surface (15), wherein the edge (16) projecting from the plane of the first contact surface (15) is pressed into the second contact surface (25) of the second planar terminal contact (21) by the connecting element (30).

Description

[0001] Description

[0002] title

[0003] Connecting arrangement, particularly for use in electric vehicles or hybrid vehicles

[0004] State of the art

[0005] The invention relates to a connecting arrangement, in particular for use in electric vehicles or hybrid vehicles, having the features of the preamble of independent claim 1.

[0006] In power electronics, for example, in electric or hybrid vehicles, electrical and / or electronic components that carry high electrical currents are interconnected. Due to the high electrical currents, the current-carrying elements that connect the electrical and / or electronic components must have correspondingly low electrical resistance and thus large cross-sections and / or materials with high electrical conductivity. For example, in such arrangements, current is carried via busbars, and the electrical and / or electronic components are connected via busbars.

[0007] To interconnect electrical and / or electronic components, flat connection contacts, such as busbars, which form electrical connections between the electrical and / or electronic components, are electrically connected to one another. The flat connection contacts overlap and are connected to one another, for example, by screwing, in the overlapping area. If high currents flow through the connection, maintaining a low electrical material resistance and a low electrical contact resistance is essential to minimize the overall electrical loss. Disclosure of the Invention

[0008] According to the invention, a connection arrangement, in particular for use in electric vehicles or hybrid vehicles, is proposed. 1. The connection arrangement comprises a first planar connection contact with a flat first contact surface for electrically contacting a first electrical and / or electronic component and a second planar connection contact with a second contact surface for electrically contacting a second electrical and / or electronic component, wherein the first planar connection contact and the second planar connection contact overlap in an overlap region, wherein the first contact surface faces the second contact surface, wherein the first planar connection contact and the second planar connection contact are connected by means of a connecting element and the connecting element presses the first contact surface against the second contact surface.According to the invention, a structure is embossed into the first planar connection contact such that an edge of the first planar connection contact protrudes from the plane of the first contact surface, wherein the edge protruding from the plane of the first contact surface is pressed into the second contact surface of the second planar connection contact by the connecting element.

[0009] Advantages of the invention

[0010] Compared to the prior art, the connecting arrangement with the features of the independent claim has the advantage that an advantageously low electrical contact resistance is achieved in the connection between the two flat connecting contacts. This advantageously prevents otherwise high heat generation and a high voltage drop at the contact point between the two flat connecting contacts. Due to the edge of the first flat connecting contact being pressed into the second contact surface of the second flat connecting contact, the edge is pressed through foreign layers on the second contact surface when the flat connecting contacts are mechanically fastened to one another, for example, when screwing.The foreign layer can, for example, be an oxide layer caused by corrosion of the second flat connection contact, which would lead to high contact resistance at the contact point between the two flat connection contacts. When the flat connection contacts are fastened to one another, the edge penetrates the foreign layer on the second contact surface. During the fastening of the flat connection contacts to one another, for example when tightening a screw connection, the embossed structure is flattened. This results in a relative movement of the edge on the second contact surface, with the edge being pushed over the second contact surface. Due to this relative movement, the foreign layer on the second contact surface is broken up by the edge and simultaneously the foreign layer on the edge is removed.The relative movement thus breaks up the foreign layers, which could be oxide layers, for example, on the two flat connection contacts. By securing the flat connection contacts, for example when tightening the screw connection, it is ensured that areas with an open foreign layer lie on top of one another and that no further foreign layer can form in the area where the areas lie on top of one another. This achieves an advantageously low and stable electrical resistance between the two connection contacts. At the beginning of the screwing process, there is line contact between the first flat connection contact and the second flat connection contact. The surface pressure in the area of ​​the line contact is advantageously high during the screwing process because the pressed area is very small (surface pressure = force / area).Thus, the very high local force can break up the foreign layer very well.

[0011] Further advantageous embodiments and developments of the inventions are made possible by the features specified in the subclaims.

[0012] According to an advantageous exemplary embodiment, a first recess is formed in the first connection contact in the overlap region, the edge being formed by the edge of the first connection contact around the first recess, the connecting element protruding through the first recess in the first planar connection contact. The edge around the connecting element is thus used to establish the connection with the lower contact resistance. The recess, for example a hole for receiving a screw, is simultaneously used to establish the connection with advantageously low contact resistance with the edge around this recess. The edge running around the recess for the connecting element can advantageously be pressed all the way around into the second contact surface and produce an advantageously low electrical contact resistance between the two planar connecting elements.In this case, a head, such as a screw head of the connecting element, can press the edge all the way around, for example in a ring shape, into the second contact surface of the second flat connecting element when the connecting element is tightened. Due to the ring-shaped contact around the first recess, it is possible to create a connection with advantageously low electrical resistance even using small screws.

[0013] According to an advantageous embodiment, a funnel-shaped structure embossed around the first recess is formed in the first connection contact. Such a structure is advantageously easy to manufacture and particularly suitable for securing the flat connection elements to one another, for example, when tightening the connecting element, which may be designed as a screw, for example, to ensure good relative movement of the edge on the second contact surface. During tightening, the funnel-shaped structure is flattened, and the edge breaks up the foreign layers in the radial direction.

[0014] According to an advantageous exemplary embodiment, the connecting element is designed as a screw connection, and the first flat connection contact and the second flat connection contact are connected to one another and pressed together by means of the screw connection. The screw connection creates a particularly simple and, at the same time, good mechanical connection between the flat connection contacts. Furthermore, by tightening the screw, a force can be exerted on the flat connection contacts, which presses the edge firmly into the second contact surface and sufficient force can be applied to flatten the structure and break up the foreign layer on the second contact surface and the edge. A screw head can, for example, press all around the first recess onto the, for example, funnel-shaped structure, and thus press the edge all around the first recess into the second contact surface.The edge is pushed radially away from the connecting element over the second contact surface and thus breaks up the foreign layer on the second contact surface in a ring shape.

[0015] According to an advantageous embodiment, a second recess is formed in the second flat connection contact, through which the connecting element protrudes, wherein the edge around the first recess, in particular annularly, is pressed into the second contact surface surrounding the second recess. Thus, the connecting element can be arranged through both recesses, and the two flat connection contacts can be connected to one another in a simple manner.

[0016] According to an advantageous exemplary embodiment, it is provided that the first planar connection contact is designed as a busbar and / or the second planar connection contact is designed as a busbar. The busbars can be connected to one another particularly well in the manner shown; in particular, the busbars can advantageously be punched and embossed in a simple and inexpensive manner. The first recess in a busbar can advantageously be produced easily by punching. A punched recess then has, for example, a particularly sharp edge that can advantageously easily break through the foreign layer on the second contact surface. The embossed structure can be produced particularly easily on a first planar connection contact designed as a busbar.

[0017] Furthermore, a method for producing a connection arrangement is proposed. The method comprises a step for providing a first planar connection contact, in particular a busbar, with a flat first contact surface, a step for providing a second planar connection contact with a second contact surface, a step for embossing a structure into the first planar connection contact, wherein an edge of the first planar connection contact is pressed out of the plane of the flat first contact surface by the embossing of the structure, a step for arranging the first contact surface of the first planar connection contact on the second contact surface of the second planar connection contact, a step for fastening the first planar connection contact to the second planar connection contact by means of a connecting element,The first contact surface of the first planar connection contact is pressed against the second contact surface of the second planar connection contact, and the edge of the first planar connection contact is pressed into the second contact surface of the second planar connection contact. In this way, a connection arrangement with advantageously low electrical contact resistance between the planar connection contacts can be produced in a simple and cost-effective manner. The foreign layers on the two planar connection contacts are broken up at the contact points, creating a stable contact with low electrical contact resistance between the two planar connection contacts.

[0018] According to an advantageous embodiment, a first recess is formed in the first planar connection contact, wherein the edge of the first planar connection contact forms the edge around the first recess. When attaching the first planar connection contact to the second planar connection contact, the connecting element, in particular a screw connection, is inserted through the first recess. This allows a mechanically stable connection with simultaneously low electrical contact resistance to be established in a simple manner.

[0019] According to an advantageous embodiment, a funnel-shaped structure is embossed around the first recess, with the edge being pressed out of the plane of the first contact surface in a ring shape. Such a structure is particularly suitable when a screw head presses the first flat connection contact against the second flat connection contact. When the connection is tightened, the structure is evenly flattened, and the edge moves in the radial direction away from the connecting element, e.g., designed as a screw, over the second contact surface, breaking up the foreign layer on the second contact surface in a ring shape around the connecting element.

[0020] According to an advantageous embodiment, when attaching the first planar connection contact to the second planar connection contact, the edge is pressed into the second contact surface of the second planar connection contact in a ring shape, in particular surrounding a second recess in the second planar connection contact. This advantageously creates a good contact with low electrical contact resistance. Brief Description of the Drawings

[0021] An embodiment of the invention is illustrated in the drawing and explained in more detail in the following description.

[0022] Fig. 1 shows an embodiment of a first flat connection contact,

[0023] Fig. 2 shows a further view of the embodiment of the first flat connection contact,

[0024] Fig. 3 shows a cross section through the embodiment of the first flat connection contact,

[0025] Fig. 4 shows a cross section through an embodiment of the connection arrangement before fastening the first flat connection contact to the second flat connection contact,

[0026] Fig. 5 is an enlarged cross-section through the embodiment of the connecting arrangement when attaching the first flat connection contact to the second flat connection contact,

[0027] Fig. 6 shows a cross section through an embodiment of the connection arrangement after fastening the first flat connection contact to the second flat connection contact.

[0028] Embodiments of the invention

[0029] Fig. 1 to Fig. 3 show various views of an embodiment of a first planar connection contact 11. Fig. 4 to Fig. 5 show an embodiment of the connection arrangement 1 with the embodiment of the first planar connection contact 11 from Fig. 1 to Fig. 3. The connection arrangement 1 can be used in all applications in which high currents must be conducted via contact connections and power losses must be kept low. The connection arrangement 1 can be used, for example, in systems that carry high currents, for example in power electronics, for example in electric vehicles or hybrid vehicles. For example, the connection arrangement 1 can be used in power electronics, in converters or batteries.

[0030] The connection arrangement 1 comprises a first flat connection contact 11, which can be, for example, an electrical connection of a first electrical and / or electronic component. Furthermore, the connection arrangement 1 comprises a second flat connection contact 21, which can be, for example, an electrical connection of a second electrical and / or electronic component. The electrical and / or electronic components can be or include, for example, inverters, converters, DC / DC converters, capacitors, such as intermediate circuit capacitors, batteries, or, for example, other electronic and / or electrical components used in electric vehicles or hybrid vehicles.

[0031] The first electrical and / or electronic component is electrically conductively connected to the second electrical and / or electronic component. The electrically conductive connection between the first electrical and / or electronic component and the second electrical and / or electronic component is established via the planar connection contacts 11, 21. For this purpose, the first planar connection contact 11 is electrically conductively connected to the second planar connection contact 21. For this purpose, the first planar connection contact 11 rests flatly, in particular directly, on the second planar connection contact 21.

[0032] The flat connection contacts 11, 21 are made of an electrically conductive material, for example a metal, for example copper. Copper has an advantageously low material resistance. The first flat connection contact 11 can be made of the same material as the second flat connection contact 21. However, the first flat connection contact 11 and the second flat connection contact 21 can also be made of different materials. The flat connection contacts 11, 21 are essentially flat, at least in the area in which they overlap. In the overlap area 5, the flat connection contacts 11, 21 have flat contact surfaces 12, 22 against which the flat connection contacts 11, 21 abut one another, such that an electrically conductive connection is established between the flat connection contacts 11, 21.The flat connection contacts 11, 21 are arranged plane-parallel to one another with respect to their flat extension planes. In the illustrated embodiment, the flat connection contacts 11, 21 are designed as busbars 11, 21. In the context of the present application, a busbar 11, 21 is understood to be an electrically conductive flat conductor, for example an electrically conductive bar or an electrically conductive strip. A busbar can therefore be a busbar, for example. The busbars 11, 21 can, for example, be bent or curved, or run in a curved or stepped manner. The busbars 11, 21 are made of an electrically conductive material, for example a metal such as copper. The busbars 11, 21 are, for example, formed in one piece. The busbars 11, 21 are, for example, made entirely of the same material.The busbars 11, 21 are formed, for example, as stamped parts. For example, each of the busbars 11, 21 has a thickness of the busbar 11, 21 that is constant over a longitudinal extent of the busbars 11, 21, for example perpendicular to the current direction. For example, each of the busbars 11, 21 can have a width of the busbar 11, 21 that is constant over a longitudinal extent of the busbars 11, 21, for example perpendicular to the current direction. A first recess 12 is formed in the first planar connection contact 11. A second recess 22 is formed in the second planar connection contact 21. The first recess 12 in the first planar connection contact 11 has, for example, a larger surface area than the second recess 22 in the second planar connection contact 21.

[0033] The recesses 12, 22 serve to accommodate a connecting element 30 for mechanically connecting the flat connection contacts 11, 21 to one another. The connecting element 30 is inserted through the recesses 12, 22. The connecting element 30 is tightened and thus presses the contact surfaces 12, 22 of the flat connection contacts 11, 21 against one another. The connecting element 30 establishes a mechanical connection between the first flat connection contact 11 and the second flat connection contact 21. The connecting element 30 can be designed, for example, as a screw 31. The screw 31 is guided through the connection contacts 11, 21 in the overlap region 5, in which the connection contacts 11, 21 overlap. For this purpose, a first recess 12 is formed in the first flat connection contact 11 and a second recess 22 is formed in the second flat connection contact 21.The screw 31 extends through the first recess 12 of the first flat connection contact 11 and through the second recess 22 of the second flat connection contact 21. The screw 31 is spaced apart from the first flat connection contact 11 and the second flat connection contact 21 in the recesses 12, 22 and does not touch them. A screw head 32 is formed at a first end of the screw 31. At the second end of the screw 31 facing away from the first end of the screw 31, the screw 31 is screwed into a mating thread 33. The mating thread 33 is formed in another component 35, for example a screw bushing, a screw nut, or a housing.The screw head 32 covers the first recess 12 in the first flat connection contact 11 and thus, when the screw 31 is screwed into the mating thread 33, exerts a force on the first flat connection contact 11 that presses the first contact surface 15 of the first flat connection contact 11 against the second contact surface 25 of the second flat connection contact 21. The screw head 32 has, for example, a larger diameter than the first recess 12. Thus, the screw 31 presses the first contact surface 15 of the first flat connection contact 11 against the contact surface 25 of the second flat connection contact 21. The two flat connection contacts 11, 21 are arranged between the screw head and the mating thread 33. The connecting element 30 can, for example, be made of a metal, for example steel.

[0034] 1 to 3 show an embodiment of the first planar connection contact 11. In this embodiment, the first planar connection contact 11 is designed as a busbar. The first planar connection contact 11 is made of an electrically conductive material, for example a metal, for example copper. The first electrical connection contact 11 is, for example, punched and / or bent and / or embossed from a sheet metal. The first planar connection contact 11 has a first contact surface 15. The first contact surface 15 is flat and thus extends in one plane. A first recess 12 for receiving a connecting element 30 is formed in the first connection contact 11. In this embodiment, the first recess 12 is punched in the first connection contact 11. The first recess 12 can, for example, be a hole for receiving a screw as the connecting element 30.Furthermore, a structure 17 is embossed into the first connection contact 11 around the first recess 12. The structure 17 is funnel-shaped. Due to the funnel-shaped structure 17, the edge of the first connection contact 11 is bent out of the plane of the first contact surface 15 around the first recess 12 and protrudes therefrom. This forms an edge 16 that presses into the second contact surface 22 during fastening, in particular during screwing, of the first flat connection contact 11 to the second flat connection contact 21.

[0035] Figures 4 to 6 illustrate how the electrically conductive and mechanical connection between the flat connection contacts 11, 21 of the connection arrangement 1 is established. Figure 4 shows a cross section through an embodiment of the connection arrangement 1 before the first flat connection contact 11 is attached to the second flat connection contact 21.

[0036] Fig. 5 shows an enlarged cross-section through the embodiment of the connection arrangement 1 when fastening the first flat connection contact 11 to the second flat connection contact 21. When the screw 31 is tightened, the edge 16 of the first flat connection contact 11 rests pointedly on the second contact surface 25 of the second flat connection contact 21. The edge 16 points in the direction of the second contact surface 25. If the screw 31 is tightened further, the structure 17 embossed into the first flat connection contact 11 is pressed flat and the edge 17 breaks through the foreign layer, for example the oxide layer, on the second contact surface 25. The arrow shows the direction of movement of the edge 17 on the second contact surface 25 when the screw is tightened and the structure 17 is pressed flat.

[0037] Fig. 6 shows a cross-section through the exemplary embodiment of the connection arrangement 1 after the first flat connection contact 11 has been fastened to the second flat connection contact 21. After the screw has been tightened, the foreign layers, which may be oxide layers, for example, on the two flat connection contacts 11, 21 in the region of the edge 16 are broken up by the relative movement of the edge 17 on the second contact surface 25. The edge 16 is pressed into the second contact surface 25. The structure 17 is largely or completely flattened by the force of the screw connection, particularly in the region under the screw head 32.

[0038] Of course, further embodiments and mixed forms of the embodiments shown are also possible.

Claims

Claims 1. Connection arrangement (1), in particular for use in electric vehicles or hybrid vehicles, comprising a first planar connection contact (11) with a flat first contact surface (15) for electrically contacting a first electrical and / or electronic component and a second planar connection contact (21) with a second contact surface (25) for electrically contacting a second electrical and / or electronic component, wherein the first planar connection contact (11) and the second planar connection contact (21) overlap in an overlap area (5), wherein the first contact surface (15) faces the second contact surface (25), wherein the first planar connection contact (11) and the second planar connection contact (21) are connected by means of a connecting element (30) and the first contact surface (15) is pressed against the second contact surface (25) by the connecting element (30), characterized in thatthat a structure (17) is embossed in the first planar connection contact (11) such that an edge (16) of the first planar connection contact (11) protrudes from the plane of the first contact surface (15), wherein the edge (16) protruding from the plane of the first contact surface (15) is pressed into the second contact surface (25) of the second planar connection contact (21) by the connecting element (30).

2. Connection arrangement according to claim 1, characterized in that a first recess (12) is formed in the overlap area (5) of the first connection contact (11), wherein the edge (16) is formed by the edge of the first connection contact (11) around the first recess (12), wherein the connecting element (30) projects through the first recess (12) in the first planar connection contact (11).

3. Connection arrangement according to one of the preceding claims, characterized in that a funnel-shaped structure (17) is formed in the first connection contact (11) around the first recess (12).

4. Connection arrangement according to one of the preceding claims, characterized in that the connecting element (30) is designed as a screw (31) and the first planar connection contact (11) and the second planar The connecting contacts (21) are connected to each other and pressed together by means of the screw (31).

5. Connection arrangement according to one of claims 2 to 4, characterized in that a second recess (22) is formed in the second planar connection contact (21) through which the connecting element (30) projects, wherein the edge (16) around the first recess (12), in particular in a ring-like manner, is pressed circumferentially into the second contact surface (25) of the second recess (22).

6. Connection arrangement according to one of the preceding claims, characterized in that the first planar connection contact (11) is designed as a busbar and / or the second planar connection contact (21) is designed as a busbar.

7. Method for producing a connection arrangement, comprising the steps: - Providing a first planar connection contact (11), in particular a busbar, with a flat first contact surface (15), - Providing a second planar connection contact (21) with a second contact surface (25), - Embossing a structure (17) into the first planar contact (11), wherein an edge (16) of the first planar contact (11) is pushed out of the plane of the planar first contact surface (15) by embossing the structure (17), - Arranging the first contact surface (15) of the first planar terminal contact (11) on the second contact surface (25) of the second planar terminal contact (21) - Attaching the first planar terminal contact (11) to the second planar terminal contact (21) by means of a connecting element (30), wherein the first contact surface (15) of the first planar terminal contact (11) is pressed against the second contact surface (25) of the second planar terminal contact (21) and the edge (16) of the first planar terminal contact (11) is pressed into the second contact surface (25) of the second planar terminal contact (21).

8. Method according to claim 7, characterized in that a first recess (12) is formed in the first planar connecting contact (11), wherein the edge of the first planar contact (11) around the first recess (12) forms the edge (16), wherein when attaching the first planar connecting contact (11) to the second planar connecting contact (21) the connecting element (30), in particular a screw (31), is inserted through the first recess (12).

9. Method according to claim 8, characterized in that a funnel-shaped structure (17) is formed around the first recess (12), wherein the edge (16) is pushed out of the plane of the first contact surface (15) in a ring shape.

10. Method according to claim 8 or 9, characterized in that when attaching the first planar connection contact (11) to the second planar connection contact (21), the edge (16) is pressed ring-shaped, in particular a second recess (22) in the second planar connection contact (21) circumferentially, into the second contact surface (25) of the second planar connection contact (21).

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