Contact element and contact component with a contact element of this kind

Abstract

The invention relates to a contact element (24), which is used for electrically connecting an electrical line (8) to a bonding wire (22) and which comprises a main body (26), which extends in a longitudinal direction (L) from a connection region (28) for the electrical line (8) to an opposing contact portion (30) for electrically contacting the bonding wire (22). The main body (26) is open on its underside in the region of the contact portion (30) in the peripheral direction and is U-shaped, with a base (40) and two lateral limbs (38). The contact element (24) is located in a carrier housing (25) and forms therewith a contact component (16) and is held therein so as to be vibration-resistant and positionally fixed. For this purpose, the carrier housing (25) comprises in particular a support element (56) in the manner of a rib, which form-fittingly engages in the U-shaped region.

Description

[0001] Description

[0002] Contact element and contact component with such a contact element

[0003] The invention relates to a contact element and a contact component comprising such a contact element. The contact element serves to connect an electrical line to a bonding wire and has a base body extending from a connection area for the electrical line to an opposite contact section for electrically contacting the bonding wire.

[0004] From the German application, which was unpublished at the time of filing

[0005] According to German patent document 10 2023 200 967.6, a cell contact unit used to electrically connect a plurality of cells, particularly in a high-voltage battery of a vehicle, provides such a contact element for connecting a sensor line. A conventional crimp contact is used, to one end of which the conductor of the sensor line is crimped, and to the other end of which a bonding wire is attached by direct bonding. The contact element is located in a carrier housing, which, together with the contact element, forms a contact component that is suitably attached to the cell contact unit. The bonding wire is in turn routed to a voltage tap for measuring the cell voltage and is contacted, for example, at a cell connector.

[0006] In general, when contacting electrical components, particularly within large electromechanical assemblies, for example, those with a length of 1 m or more, where a large number of components must be connected in a confined space, certain requirements exist with regard to installation space, ease of assembly, and cost. An example of such an assembly is the cell contact unit mentioned above. Such a cell contact unit, specifically for a high-voltage battery, in particular for a traction battery of an electric motor-driven vehicle, often has a cable harness with numerous sensor lines that are used to tap the voltage of each cell as part of battery monitoring. For this purpose, the sensor lines must each be contacted to the cell, which is a complex process.

[0007] The bonding wire is a bare metal wire, often made of aluminum, alternatively copper or gold, which is directly connected to a connection point of the electrical component by bonding. The bonding wire is usually comparatively thin and has, for example, a maximum diameter of 500 pm, preferably up to a maximum of 250 pm and in particular up to a maximum of 100 pm. Diameters of up to 100 pm, preferably less than or equal to 75 pm, are used for what is known as thin wire bonding and are used in cases where only low electrical power needs to be transmitted. Diameters above this, for example up to 500 pm, are used for what is known as thick wire bonding, in particular for applications where higher electrical power needs to be transmitted.During bonding, electrical contact is established through a material-to-material connection, particularly without the need for additional auxiliary materials, such as soldering. Bonding is achieved primarily through welding, particularly ultrasonic welding, of the bond wire to the connection point.

[0008] A particular advantage of bonding is that no separate connection element is required to connect the wire to the connection point. This eliminates the need for an additional contact element between the bond wire and the component.

[0009] Vibrations typically occur during operation, particularly in motor vehicle applications. The electrical contact of such a bonding wire must therefore be vibration-proof. Due to the limited space available, such contact elements are designed to be very small. The contact elements preferably used according to 10 2023200 967.6 are standard nano-crimp contact elements that are typically less than 25 mm long and typically less than 3 mm wide and high. Due to this small size, their inherent rigidity is often low, making assembly and reliable vibration-proof fixing difficult. Such conventional nano-crimp contacts are usually completely coated on the base body, which is usually made of copper. This coating increases their strength at least somewhat.However, this involves additional costs.

[0010] Based on this, the invention is based on the object of specifying a contact element and a contact component with such a contact element, which is cost-effective and which can be fixed in a fixed position and vibration-proof within a carrier housing of the contact component.

[0011] The object is achieved according to the invention by a contact element for electrically connecting an electrical line, in particular a stripped conductor of the electrical line, to a bonding wire. The contact element has a base body that extends from a connection area for the electrical line to an opposite contact section for electrically contacting the bonding wire.

[0012] The object is further achieved according to the invention by a contact component which has a carrier housing with a housing base, wherein such a contact element is mounted in the carrier housing.

[0013] When connected, the bonding wire is directly attached to the contact section by bonding.

[0014] The contact section extends over a predetermined section length, which is, for example, at least 1 / 4 or at least 1 / 3 of the total length of the contact element. The contact element and / or the contact component, in particular, comprise one or more measures and elements that serve to immobilize and thus provide a vibration-proof arrangement, as will become apparent from the following description and the subclaims.

[0015] The contact element is preferably - similar to conventional crimp contacts - a one-piece, in particular monolithic contact element, to whose base body a coating may also be applied. The entire contact element therefore ultimately consists of the monolithic base body, optionally with a coating applied thereto. The base body is in particular a bent sheet metal part. The contact element preferably has only a size similar to that of conventional nano crimp contacts. Its length is therefore preferably less than or equal to 30 mm, preferably less than or equal to 20 mm and in particular less than or equal to 15 mm. The width and height are in particular less than or equal to 5 mm and especially less than or equal to 2 mm.

[0016] According to the invention, the contact element is located in a carrier housing to form a contact component according to claim 14.

[0017] A preferred embodiment of the contact element results from the combination of features of claim 2. Individual features of this preferred combination of features can also be found in subclaims 3 to 13 and are explained in more detail below.

[0018] A preferred embodiment of the carrier housing results from the combination of features of claim 15. Individual features of this preferred combination of features can also be found in subclaims 16 to 27 and are explained in more detail below.

[0019] In a preferred embodiment, the base body is open on a circumferential underside at least in the area of ​​the contact section and, viewed in cross-section, is U-shaped with a base and two lateral limbs. The base forms an upper side of the contact element in the contact section.

[0020] The contact element is preferably open over its entire length in the circumferential direction towards its underside and is in particular U-shaped in cross section.

[0021] The connection area is preferably designed as a crimping area, i.e. in particular has crimping flanks that are mechanically bent to contact the conductor.

[0022] In conventional crimp contacts, the opposite connection area, referred to here as the contact section, is typically designed as a socket contact, ie a socket is formed in the area of ​​the contact section, so that in the area of ​​the contact section the base body forms a sleeve running around the circumference.

[0023] In contrast, the present contact element is open towards the bottom in the area of ​​the contact section and is U-shaped. This special design is adapted to the specific application of direct bonding of the bond wire in the contact section. By omitting a continuous base body in the contact section, material and thus costs are saved. At the same time, this enables reliable and vibration-proof fixation to a carrier housing in the contact section, as will be explained in more detail below in connection with the contact component.

[0024] The base body is preferably made of metal and in particular copper.

[0025] In the final assembled state, the electrical line is electrically connected at the connection area. The bonding wire, as defined above, is electrically connected and mechanically secured at the contact section by direct bonding. The other end of the bonding wire is electrically and mechanically connected to an electrical component, also in particular by direct bonding.

[0026] In a practical development, a coating is applied to the base body only in the contact section. This coating is a conventional, well-known coating, such as a nickel-nickel / phosphorus coating or nickel-gold coating. Therefore, coating the entire contact element is omitted.

[0027] Preferably, the coating is applied only to a portion of the contact section, specifically to an outer surface that serves as the contact surface for bonding the bond wire. Specifically, this surface is the base of the U-shaped contact section.

[0028] Alternatively, the contact element is completely coated in the contact section. For example, the contact element is immersed (only) with the contact section in a coating bath.

[0029] By only partially and selectively coating, coating material is saved. Furthermore, the risk of electrolytic corrosion resulting from the coating is minimized, as only a small area is coated. The loss of strength associated with the partial removal of the coating—compared to conventional, fully coated crimp contacts—is compensated for by the special shape and mounting in the carrier housing.

[0030] In a preferred embodiment, the contact element has at least one laterally projecting tab, which is in particular bent out from the base body. This serves as a locking tab or a clamping tab. Preferably, both a locking tab and a clamping tab are formed. The locking tab serves to secure the contact element in the carrier housing. The clamping tab, in contrast, serves to clamp the contact element in the carrier housing. The tabs are each elastic and, in particular, spring-elastic. "Protruding laterally" here means that a respective tab is arranged either in the region of the legs or the base and protrudes from the latter transversely to the longitudinal direction.

[0031] The tabs are formed in particular in an intermediate region of the contact element between the connection region and the contact section.

[0032] Preferably, the at least one tab is attached only to the base and thus to the top side. Due to the small size and the required compact design of the carrier housing, lateral partition walls, which form adjacent chambers for adjacently arranged contact elements, are very thin. With a lateral arrangement on the legs, there is therefore a risk that these thin partition walls would not be able to withstand the clamping force exerted by the clamping tab, and there would therefore be a risk of electrical contact between the two adjacently arranged contact elements. In addition, the arrangement on the top side also offers the particular advantage that the contact element is pressed in a defined manner towards the housing base.

[0033] In a useful embodiment, at least one and preferably exactly one clamping tab and at least one locking tab and preferably exactly one locking tab are formed, wherein the locking tab and the clamping tab are arranged one behind the other in the longitudinal direction of the contact element, in particular on the upper side, i.e. on the base.

[0034] In a preferred embodiment, the contact section is open at an end region, in particular on an upper side and preferably on opposite sides, i.e. both on the underside and on the upper side. The upwardly open design allows particularly reliable fixing of the contact element to be achieved - regardless of the U-shaped design - as will be explained in more detail below. The two legs are more or less exposed in this end region and are in particular connected neither at the upper side nor at the underside, especially not via the base in the U-shaped design. In a useful embodiment, this end region serves as a fastening section for fastening to the carrier housing, in particular via a form-fitting fastening with a holding element of the carrier housing, as will be explained in more detail below.By omitting the connection on the top side and especially on the base in this end area, it is possible for each leg to be positively encompassed from above by the holding element, thus ensuring reliable, vibration-proof fixation of the contact element in the carrier housing.

[0035] According to a preferred embodiment, the two legs are contoured in the end region toward the top of the contact element. The upwardly oriented free edge of the respective leg therefore does not extend in a straight line, but rather, for example, runs in a wave-like, crenellated shape, or has a bulge or elevation. This contoured design supports and improves the desired fixation.

[0036] Preferably, the two legs are designed as freely projecting legs in the end region, which are therefore not connected to each other.

[0037] According to an alternative preferred embodiment, the legs are connected to each other at the end face of the contact element via a transverse tab – regardless of the previously described configuration of the end region without a base. This tab essentially holds the two legs together, thus increasing rigidity.

[0038] The contact element described above is intended in particular for arrangement in the carrier housing to form the contact component. The carrier housing has special properties for vibration-proof fastening and with regard to simple assembly and simple, in particular automated, contacting of the bonding wire, as explained in more detail below. Firstly, the carrier housing has at least one upwardly oriented cutout for connecting the bonding wire. This cutout is therefore designed in the manner of a recess in the carrier housing, so that access to the contact element located in the carrier housing is possible, in particular from an upper side. In particular, this cutout makes the contact section and in particular its upper side, i.e. the base, freely accessible, so that the bonding wire can be connected to the base by bonding.

[0039] With regard to the desired vibration-proof fastening of the contact element in the carrier housing, the contact element is held in a form-fitting manner by at least one holding element. The form-fitting action acts in at least one direction, specifically in a vertical direction. The vertical direction extends from the underside to the top of the contact element. The contact element is therefore held against the housing base by means of the form-fitting action acting in the vertical direction. For this purpose, the holding element encompasses the contact element and in particular the previously described end region with the free legs. Preferably, a form-fitting action acting in or against the longitudinal direction is also additionally formed by the holding element. This is achieved, for example, in particular by the contoured design of the free legs described above, into which the holding element engages and thus secures the contact element in the longitudinal direction.

[0040] The retaining element is preferably formed as a formed section of the support housing. This means that, for fastening purposes, a portion of the support housing is formed to form the retaining element.

[0041] The forming is preferably carried out by what is known as hot staking, in which the material of the carrier housing is heated and formed by the application of force. The material is at least softened and formed in the process. During hot staking, a heated forming punch is usually pressed against the forming section of the carrier housing and deforms it. The at least one forming section is preferably designed in the manner of a pin which extends vertically upwards from the housing base. The pin is therefore designed in the manner of a freely protruding, bolt-shaped element and is in particular widened during forming and essentially forms a holding head or closing head which engages around the contact element. In particular, the holding element thus formed is, for example, T-shaped in cross-section.

[0042] Preferably, the retaining element is formed in the region of the previously described end region. Specifically, the two legs, or at least one of the legs, rest against the pin.

[0043] The tenon is preferably located centrally between the two legs, providing good lateral guidance for the two legs. In the formed state, the legs rest directly against the tenon.

[0044] As an alternative to a central arrangement, a useful embodiment provides two pins, each arranged laterally on an outer side next to a respective leg. Each of these pins is formed and forms a respective retaining element. Alternatively, the formed pins form a common retaining element.

[0045] Preferably, the carrier housing further comprises a support element on which the contact element rests with its base, in particular such that the legs are spaced apart from the housing base. The support element is designed and arranged in particular in the region of the U-shaped contact section. The U-shaped configuration thus provides the particular advantage of reliable, positionally secure support of the contact element in the contact section.

[0046] The support element is preferably designed in the manner of a rib formed on the housing base and extending, in particular, longitudinally. This rib engages the U-shaped contact element from below, in particular in a form-fitting manner. The contact element rests with its base on the rib, so that it is positioned in a defined vertical direction. The form-fitting reception of the rib preferably also holds the contact element precisely in the transverse direction.

[0047] Alternatively or in addition to this support element, the carrier housing has a transverse wall adjacent to the clearance, on which the contact section of the contact element is supported, in particular with its front side.

[0048] In a preferred embodiment, the transverse wall has a recess into which the contact element rests with one end face and against which the contact element is supported, particularly in the vertical direction and / or in the transverse direction. For example, the contact element rests in this recess with the previously described end-face transverse tab.

[0049] As an alternative to a recess, a rib projecting towards the contact element is formed on the transverse wall as a support element, as previously explained.

[0050] All of the support variants described above ensure in particular that the contact element is positioned in a defined and, in particular, twist-proof manner in the carrier housing. It is important to note that the undersides of the legs do not support each other, i.e. the lower edge of the legs is spaced from the housing base. Due to manufacturing tolerances, the two legs often have different lengths. If supported via the legs, there is a risk that the contact element will twist about its longitudinal axis and be tilted at an angle, so that the top side and thus the base, at which contact is made with the bonding wire, is not aligned plane-parallel. Such an inclined position of the base would impair contact reliability. In contrast, support on the support element ensures reliable plane-parallel alignment of the base of the contact section.In a preferred embodiment, the contact element is further supported on the housing via the previously described clamping tab, in particular in such a way that the contact element is pressed toward the housing base. This measure also ensures that the contact element, in particular the contact section, is reliably pressed against the previously described support element, thus ensuring a vibration-proof positioning of the contact section in the carrier housing.

[0051] In a preferred embodiment, the contact element is also secured to the support housing via the previously described locking tab, which for this purpose has at least one housing projection or a recess into which the locking tab snaps. Specifically, during assembly, the contact element is inserted longitudinally into a chamber of the support housing until the locking tab engages behind the housing projection.

[0052] In a preferred embodiment, the carrier housing has at least one fastening pin, specifically on its underside and thus preferably on the outside of the housing base, which serves for fastening to a carrier component. This fastening pin is in particular a formed section, which in the assembled state, i.e. when the carrier housing and the contact component are fastened to the carrier component, is connected to the carrier component by forming. This is preferably done by hot caulking, as previously described. A holding head is formed, which forms a reliable positive connection with the carrier component. This also achieves a vibration-proof fastening of the entire contact component.

[0053] In addition to such a forming section, a locking pin is preferably formed, which leads to additional rusting in the support component.

[0054] The described contact component is preferably used in a cell contact unit for a battery, especially for a high-voltage battery in a motor vehicle. The cable is, in particular, a sensor cable, and the bonding wire is generally connected to an electrical component. Specifically, the bonding wire serves to tap the cell voltage of a battery cell.

[0055] For this purpose, the bonding wire is connected to a suitable voltage tapping point, for example, a cell connector or a cell terminal, by direct bonding. Generally, the bonding wire is preferably connected to an electrical component by direct bonding, so that one end is bonded to the contact section and the other end is connected to the other electrical component.

[0056] An embodiment of the invention is explained in more detail below with reference to the figures. These show:

[0057] FIG 1 is a perspective view of a contact element according to a first embodiment,

[0058] FIG 2 is a perspective view of a bottom side of the contact element according to FIG 1,

[0059] FIG 3 is a perspective view of a contact element according to a second embodiment,

[0060] FIG 4 is a perspective view of a contact element according to a third embodiment,

[0061] FIG 5 is a perspective side view of a contact component with a carrier housing of a first type and a contact element embedded therein,

[0062] FIG 6 is a perspective view of the contact component according to FIG 5 from a different viewing direction with the carrier housing shown partially transparent,

[0063] FIG 7 is a side view of a contact component with a transparent carrier housing of a second type and contact elements embedded therein,

[0064] FIG 8 is a perspective front view of the contact component according to FIG 7 and FIG 9 is a partial perspective view of a cell contacting unit.

[0065] In connection with FIG 9, the preferred field of application is first explained, as it is also apparent in particular from the German application 10 2023 200 967.6, which was unpublished at the time of filing.

[0066] FIG. 9 shows a section of a cell contact unit 2 for a battery (not shown in detail here), which is preferably intended for an electric motor-driven motor vehicle and is also used there as a traction battery. Typically, the battery is composed of several modules that are interconnected. Each module, in turn, has a plurality of individual (battery) cells that are arranged in a row along an extension direction E and form a cell stack. The individual cells are often cuboidal / prismatic in shape. The cell contact unit 2 accordingly also extends along the extension direction E.

[0067] The individual cells of a module are electrically connected to each other in series via the cell contact unit 2. For this purpose, each cell pair is electrically connected to each other via a respective cell connector 4.

[0068] The entire battery usually has a battery management system which, among other things, is designed to monitor the current state of the battery and in particular also of the individual cells. The module and in particular the cells are generally equipped with a sensor system which is connected via a cable set 6 and is linked to the battery management system when installed. The cable set 6 has a large number of individual electrical lines 8, referred to as sensor lines. The cable set 6 has, for example, a multi-pin plug at one end, via which the cable set 6 can be connected, for example, to the battery management system. The cell contact unit 2 has a modular design in the exemplary embodiment. A large number of individual holders 10 made of insulating material are arranged next to one another in the direction of extension E. Each of the holders 10 accommodates a cell connector 4.In the center of the image, one holder is hidden to reveal the cell connector 4. The individual holders 1 are designed as (plastic) injection-molded parts and specifically as identical parts.

[0069] The individual holders 10 are lined up along two assembly lines 12. Specifically, the holders 10 are slid and / or clipped onto a respective assembly line 12 and held there in a form-fitting manner. In the exemplary embodiment, the assembly lines 12 are designed as profile rails, particularly made of metal. They are preferably designed as tensioning straps and ensure that, in the final assembled state, the individual cells are held clamped against one another in the direction of extension E.

[0070] The holders 10 and the respective cell contact unit 2 each have a rear side oriented toward the cells and an opposite front side. They form a kind of enclosure for the cell connector 4, in which it rests, protected from contact.

[0071] In the exemplary embodiment, the holder 10 is further designed to accommodate sensor elements, such as temperature sensors, pressure sensors, voltage taps, etc., which are each connected via the individual sensor lines 8. In particular, plug receptacles 14 are formed on the holder 10, in which a contact component 16 is located in the exemplary embodiment.

[0072] Each cell connector 4 has two contact tabs 18, which are opposite one another in the direction of extension E and are in particular approximately strip-shaped, and which are connected to one another via an intermediate part designed for length compensation and, in the exemplary embodiment, is in particular wave-shaped. Furthermore, the cell connector 4 has a connection area, in particular formed by a connection tab 20, which is used for a voltage tap and serves as a voltage tap point. The cell connector 4 also has two pole openings, in particular circular ones. These are in particular formed centrally in each contact tab 18.

[0073] The cell terminals of two adjacent cells are electrically contacted via a respective cell connector 4. The contact tabs 18 preferably lie flat against a respective cell terminal. For this purpose, the cell terminal is preferably approximately cuboid-shaped. It also preferably has an upwardly projecting contact pin with a typically circular cross-section, which, when assembled, is received by the respective terminal opening.

[0074] A sensor system is generally provided for monitoring the battery. The cell contact unit 2 is designed, in particular, to measure the voltage of each cell. For this purpose, the respective sensor line 8 is connected to the contact component 16, to which, in turn, a bonding wire 22 is connected. This bonding wire 22 is connected to the cell connector 4 for voltage tapping, in particular to the contact tab 18 as the voltage tapping point of the cell. The cell connector 4 and, in the assembled state, the cell indirectly connected via it form an electrical component connected to the bonding wire 22.

[0075] A specially designed contact element 24 is used to connect the bonding wire 22, as described in various embodiments in Figures 1 to 4. Furthermore, a specially designed carrier housing 25 is used, which, together with the at least one contact element 24 located therein, forms the contact component 16. This is shown in various variants in Figures 5 to 8.

[0076] The contact element 24 is based on a conventional crimp contact, in particular a nano-crimp contact, with the dimensions as previously described. The contact element 24 is formed by a metallic base body 26, in particular made of copper, which extends from a connection area 28, designed as a crimp area, for the electrical line 8 to a contact section 30 at the opposite end in the longitudinal direction L. An intermediate area 32 is formed between them, in which tabs bent out of the base body 26 are formed, namely at least one clamping tab 34 and at least one locking tab 36. As is usual with a crimp contact, crimp tabs are formed in the crimp area, which are bent over when contacting the electrical line.

[0077] It should be emphasized that the contact element 24 is U-shaped, particularly over its entire length and specifically in the contact section 30 as well as in the intermediate region 32, when viewed in cross-section, so that the contact element 24 is open on its underside. The base body 26 therefore has two opposite legs 38 which are spaced apart from one another in a transverse direction and are connected to one another via a base 40. The base 40 also defines an upper side. A vertical direction is defined in the present case by the direction from the underside to the upper side, in which the legs 38 also extend. The defined directions, namely the longitudinal direction L as well as the transverse direction and vertical direction, are oriented perpendicular to one another.

[0078] Particularly in the contact section 30, the contact element 24 has a U-shaped cross-section resembling a rectangle, with rounded corners. The base 40 runs parallel to the transverse direction. In contrast, in the connection area 38, the base 40 is significantly more rounded.

[0079] In the exemplary embodiment, a coating 41 is applied only in the contact section 30 and, furthermore, preferably exclusively on the base 40. The base 40 defines a contact surface for contacting the bonding wire 22. On this coated contact surface, the bonding wire 22 is therefore directly electrically contacted with the contact element 24 by direct bonding.

[0080] In the embodiment shown in Figures 1 and 2, several clamping tabs 34 are provided, each of which is attached, for example, at the same length position. One clamping tab 34 is arranged on the base 40 and one on each of the two legs 38. The locking tab 36 is attached to the base 40. In a preferred embodiment, however, the legs 38 are free of clamping tabs 34, so that only one clamping tab 34 is attached to the base, as is particularly illustrated in the embodiment shown in Figure 3.

[0081] In all embodiments, the clamping tabs 34 are preferably arranged directly adjacent to the contact section 30.

[0082] While in the embodiment according to Figures 1 and 2 the U-shaped section and thus also the base 40 extend to an end face, in the embodiments according to Figures 3 and 4 an end region 42 is formed in which the base 40 is not present, so that the two opposite legs 38 extend freely in the longitudinal direction L in the manner of a fork.

[0083] In the embodiment according to Figure 3, they are connected to one another at the end face via a transverse tab 44, whereas in the embodiment according to Figure 4 they project freely. The transverse tab 44 is preferably a bent-over section of at least one of the two legs 38. The transverse tab 44 is connected to the other leg 38 by form-fitting and / or material bonding.

[0084] In the embodiment variant according to Figure 4, the legs 38 have a contoured, particularly wave-shaped, design on their edge oriented toward the upper side. Specifically, a recess is formed in the center of the end region 42.

[0085] The various design features shown in the different variants can also be combined with one another. For example, the transverse tab 44 can also be formed in the embodiment shown in Figure 4. The embodiment shown in Figure 4 also preferably has the clamping tab 34 and locking tab 36 arranged one behind the other in the longitudinal direction, as shown in Figure 3. The contact elements 24 are preferably arranged in pairs in the special carrier housing 25, as shown in different embodiments in Figures 5 to 8.

[0086] The carrier housing 25 is made of plastic and has a respective chamber 46 for each contact element 24, extending in the longitudinal direction L, into which chamber the respective contact element 24 is inserted. The chamber 46 completely encloses each contact element in the circumferential direction. In the front area, however, the carrier housing 25 has a cutout 47 so that the contact section 30 arranged there is exposed and thus freely accessible. At the opposite end, the carrier housing 25 has an insertion opening through which the cable 8 is inserted. The connection area 28 is located in this end area and is completely surrounded by the insulating material of the carrier housing 25.

[0087] The support housing 25 generally has a housing base 48, which is particularly designed in the manner of a plate. Side walls and intermediate walls extend vertically upward from this base, which are connected to one another via an upper housing wall.

[0088] As can be seen particularly from Figure 7, fastening elements are formed on the underside of the support housing 25 and thus on the underside of the housing base 48, which are designed to fasten the support housing 25 to a support component. Of particular note here is a fastening pin 50 designed as a forming pin, which is formed, in particular, by hot-staking for mounting on the support component. In addition, a locking element 52 projecting vertically is also formed for locking to the support component.

[0089] In the embodiment shown in Figures 5 and 6, the carrier housing 25 has a transverse wall 54 in one of its end regions and adjacent to the contact section 30, against which the contact section is supported. In the exemplary embodiment of Figures 5 and 6, a support element 56 is formed which extends counter to the longitudinal direction L in the manner of a rib and extends from the transverse wall 54. This support element 56 preferably has a bevel at its end opposite the transverse wall 54, which serves to guide the contact element 24 when it is inserted. The rib formed by the support element 56 has a cross-sectional contour adapted to the LI shape of the contact element, such that the contact section 30 is securely guided and held in position. In particular, the contact section 30 rests with the base 40 on an upper side of the rib.In the illustrations of Figures 5 and 6, only one contact element 24 is shown in each case, so that one of the two support elements 56 can be clearly seen.

[0090] Alternatively or in addition to this support element 56, the transverse wall has a recess, not shown in detail here, into which the contact section 30 is inserted with its front end.

[0091] In the embodiment according to Figures 5 and 6, the contact element 24 according to the embodiment according to Figures 1 and 2 is inserted, for example.

[0092] In the embodiment of the support housing according to Figures 7 and 8, in contrast to the previous example according to Figures 5 and 6, there is no transverse wall 54 or only a modified transverse wall 54. The contact sections 30 are also separated from one another by intermediate walls of the support housing 25, so that in this embodiment, two clearances 47 are formed. In the embodiment according to Figures 5 and 6, additional wall regions can also be provided in addition to the transverse wall 54, as shown in Figures 7 and 8.

[0093] In the embodiments according to Figures 7 and 8, two different variants of the contact element 24 are shown as examples, as they were described - at least with regard to the design of the end region 42 - for Figures 3 and 4.

[0094] What is noteworthy in the embodiment according to Figures 7 and 8 is the arrangement of pins projecting vertically from the housing base 48, each of which forms a forming section 58.

[0095] As can be seen in the right-hand half of Figure 8, in one embodiment the pin is mounted centrally between the two legs 38, whereas in an alternative embodiment, as shown in the left-hand half of Figure 8, two opposing pins are formed, each adjoining the outside of the legs 38. These formed sections 58 are subsequently deformed by hot staking so that they virtually enclose the end region 42 and thus the free legs 38 and form a holding head that covers the legs 38. Especially in the embodiment with the two pins, these are chamfered on their upper side to promote the desired formation of a common holding head that bridges the two legs 38.

[0096] As can be seen in particular from Figure 8, the carrier housing 25 generally has a housing section or housing projection on which the locking tab 36 is supported and with which it is secured.

[0097] The clamping tabs 34, which can be seen specifically in the transparent illustrations according to Figure 6, are each supported on a wall region of the carrier housing 25, so that they hold the contact section 30 in a defined position. In particular, the clamping tab 34 formed on the base 40 presses the base 40 against the support element 56. Preferably, only one clamping tab 34 is arranged on the base 40.

[0098] From Figure 8 it can also be seen that the carrier housing has a modified transverse wall 54 in which (compare the left half of the figure) a rib-shaped projection is formed, which can also represent a support element 56, for example.

[0099] As an alternative to the formation of support elements 56 starting from the transverse wall 54, a respective support element 56 is formed directly on the housing base 48 and independently of the transverse wall 54, in particular in the manner of a rib engaging in the U-shaped contact element 24.

[0100] List of reference symbols

[0101] 2 cell contact unit

[0102] 4 cell connectors

[0103] 6 Cable set

[0104] 8 electrical cable

[0105] 10 holders

[0106] 12 Assembly line

[0107] 14 connector sockets

[0108] 16 Contact component

[0109] 18 contact tabs

[0110] 20 connection tab

[0111] 22 bonding wire

[0112] 24 contact element

[0113] 25 carrier housings

[0114] 26 basic bodies

[0115] 28 Connection area

[0116] 30 Contact section

[0117] 32 Intermediate area

[0118] 34 clamping tab

[0119] 36 locking tab

[0120] 38 legs

[0121] 40 Base

[0122] 41 Coating

[0123] 42 End area

[0124] 44 Cross tab

[0125] 46 Chamber

[0126] 47 Postage paid

[0127] 48 Case back

[0128] 50 mounting pins

[0129] 52 locking element

[0130] 54 Cross wall 56 Support element

[0131] 58 Forming section

[0132] E Extension direction L Longitudinal direction

Claims

Claims 1 . Contact element (24) for electrically connecting an electrical line (8) to a bonding wire (22), which has a base body (26) which extends in a longitudinal direction (L) from a connection area (28) for the electrical line (8) to an opposite contact section (30) for electrically contacting the bonding wire (22).

2. Contact element (24) according to the preceding claim, characterized in that - the base body (26) is open in the circumferential direction on a lower side in the region of the contact section (30) and is U-shaped with a base (40) and two lateral legs (38), - the connection area (28) is designed as a crimping area, - it has a plurality of laterally projecting tabs, namely at least one locking tab (36) for locking the contact element (24) in a carrier housing (25) and at least one clamping tab (34) for supporting the contact element (24) in the carrier housing (25), the clamping tab (34) and the locking tab (36) are arranged one behind the other in the longitudinal direction (L), - the contact section (30) is open at one end region (42) on opposite sides, so that two end legs (38) are formed.

3. Contact element (24) according to one of the preceding claims, characterized in that the base body (26) is open in the circumferential direction on an underside in the region of the contact section (30) and is U-shaped with a base (40) and two lateral legs (38).

4. Contact element (24) according to the preceding claim, characterized in that it is open over its entire length in the circumferential direction on the underside.

5. Contact element (24) according to one of the preceding claims, characterized in that the connection area (28) is designed as a crimping area.

6. Contact element (24) according to one of the preceding claims, characterized in that a coating (41) is applied to the base body (26) exclusively in the contact section (30).

7. Contact element (24) according to the preceding claim, characterized in that in the region of the contact section (30) the coating (41) is applied only in a partial region on an outer surface.

8. Contact element (24) according to one of the preceding claims, characterized in that it has at least one laterally projecting tab which serves as a locking tab (36) or as a clamping tab (34) and which is in particular bent out of the base body (26).

9. Contact element (24) according to the preceding claim, characterized in that the at least one tab is formed only on the base (40).

10. Contact element (24) according to one of the two preceding claims, characterized in that the clamping tab (34) and the locking tab (36) are arranged one behind the other in the longitudinal direction (L) and are arranged in particular on the base (40).

11. Contact element (24) according to one of the preceding claims, characterized in that the contact section (30) is open at an end region (42) on opposite sides, so that two end legs (38) are formed, in particular such that in a U-shaped configuration the two legs (38) in the end region (42) are not connected via the base (40).

12. Contact element (24) according to the preceding claim, characterized in that the legs (38) are contoured in the direction of an upper side opposite the underside.

13. Contact element (24) according to one of the preceding claims, characterized in that on an end face of the contact section (30) it has a transverse tab (44), in particular such that in a U-shaped configuration the two legs (38) are connected to one another.

14. Contact component (16) with a carrier housing (25) with a housing base (48) and a contact element (24) arranged in the carrier housing (25) according to one of the preceding claims.

15. Contact component (16) according to the preceding claim, characterized in that - the carrier housing (25) has a clearance (47) for connecting the bonding wire (22), wherein the contact section (30) for contacting the bonding wire (22) is accessible via the clearance (47), - the contact element (24) is held in the carrier housing (25) in a form-fitting manner by a holding element which is formed by forming a forming section (58) of the carrier housing (25), - the carrier housing (25) has a support element (56) on which the contact element (24) is supported with its base (40), such that the legs (38) are spaced from the housing base (48), - the contact element (24) is supported by a clamping tab (34) on the support housing (25) and is thereby pressed towards the housing base (48), - the contact element (24) is secured to the carrier housing (25) by means of a locking tab (36).

16. Contact component (16) according to one of the two preceding claims, characterized in that the carrier housing (25) has a clearance (47) for connecting the bonding wire (22), wherein the contact section (30) for contacting the bonding wire (22) is accessible via the clearance (47).

17. Contact component (16) according to one of claims 14 to 16, characterized in that the contact element (24) is held in the carrier housing (25) in a form-fitting manner by a holding element which is formed by forming a forming section (58) of the carrier housing (25), in particular by hot caulking.

18. Contact component (16) according to the preceding claim, characterized in that the carrier housing (25) in the initial state has a pin as a forming section (58) which extends upwards from the housing base (48).

19. Contact component (16) according to one of the two preceding claims, characterized in that the forming section (58) encompasses the end region (42) of the contact element (24) according to one of claims 11 or 12.

20. Contact component (16) according to one of claims 14 to 19, characterized in that the carrier housing (25) has a support element (56) on which the contact element (24) is supported with its base (40), in particular such that the legs (38) are spaced from the housing base (48).

21. Contact component (16) according to the preceding claim, characterized in that the support element (56) is designed as a rib which is formed on the housing base (48).

22. Contact component (16) according to one of claims 14 to 21, characterized in that the carrier housing (25) has a transverse wall (54) adjoining the contact section (30) on which the contact section (30) is supported.

23. Contact component (16) according to the preceding claim, characterized in that the transverse wall (54) has a recess or a projecting rib for supporting the contact section (30).

24. Contact component (16) according to one of claims 14 to 13, characterized in that the contact element (24) is supported by the clamping tab (34) according to one of claims 8 to 10 on the carrier housing (25) and is thereby pressed in the direction of the housing base (48).

25. Contact component (16) according to one of claims 14 to 24, characterized in that the contact element (24) with the locking tab (36) according to one of claims 8 to 10 is secured to the carrier housing (25).

26. Contact component (16) according to one of claims 14 to 25, characterized in that the carrier housing (25) has at least one fastening pin (50) for fastening to a carrier component, which in the assembled state is preferably connected to the carrier component by forming and in particular by hot caulking.

27. Contact component (16) according to one of claims 14 to 26, characterized in that it is used in a cell contacting unit (2) for a battery and wherein the bonding wire (22) is connected in particular to a voltage tapping point for measuring a cell voltage.

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