Contact device and power module assembly

Abstract

To propose electric contact of two function components of a circuit and / or a partial circuit within a combined interface.SOLUTION: A contact device for electrically bringing into contact between two electric function components of a circuit and / or a partial circuit within a combined interface, and the contact device includes a plurality of power transmission rails, and the respective power transmission rails are electrically insulated and spaced apart. The power transmission rails include a contact area, and the contact area has a contact element. The contact device generates a current path between contact areas within the power transmission rails when a function element and both the power transmission rails are brought into electric contact in the contact element. Electric contact of a contact surface between the contact element and the function element can be formed in the form of galvanic applied contact, and the contact device causes compression force perpendicular to a contact surface to the contact element as contact force in a contact state between the contact device and the function element.SELECTED DRAWING: Figure 4a

Description

[Technical field]

[0001] The present invention relates to a contact device as well as a power module assembly, in particular for providing a phase current to an electric machine, comprising at least one power module and comprising at least one contact device that is in electrical contact with the power module within a coupling interface. [Background technology]

[0002] From the state of the art, power module assemblies are known in which a first coupling interface between at least one power module and a capacitor unit comprising at least one capacitor or a second coupling interface between at least one power module and a phase connection to an electric machine is realised by a welded joint.

[0003] To achieve this welded joint, a laser welding process is generally used with a corresponding expensive laser welding device. A corresponding laser welding head requires a very large free space in the power module assembly. In addition, the laser welding process also generates conductive particles, which can later cause short circuits in the installed power module assembly. Summary of the Invention

[0004] The problem underlying the present invention is to propose an inexpensive and technically simple to implement electrical contact of at least two electrical functional components of an electrical and / or electronic circuit and / or subcircuit within at least one coupling interface.

[0005] This problem is solved by a power module assembly, inter alia for providing a phase current to an electric machine, comprising a contact device as well as at least one power module and comprising at least one contact device that is in electrical contact with the power module in a coupling interface, with the features of the independent claims.

[0006] The invention takes as its starting point a contact device for electrically contacting at least two electrical functional components of an electrical and / or electronic circuit and / or subcircuit within at least one coupling interface. The two functional components to be electrically contacted are, for example, a power module and a capacitor as part of a commutation circuit for controlling an electric motor. The contact device comprises at least a first and a second power transmission rail, which are arranged electrically insulated and spaced apart from one another. Each power transmission rail comprises at least a first and a second contact area, which each have at least one contact element. The contact device is formed in such a way that, during circuit operation, a current path is generated between the first and second contact areas in both power transmission rails, respectively, when the functional component and each of the two power transmission rails are electrically contacted at the contact elements of the respective different contact areas. In this respect, the electrical contact between the contact element of the at least one contact area and at least one contact surface of the functional element can be made in the form of a forced galvanic contact, for which the contact device has means for bringing about a contact force, in the at least one contact element in the at least one contact area, a compressive force perpendicular to the contact surface, in the state of contact between the contact device and at least one of the functional elements. The galvanic contact is thus made by merely mechanically pressing together (and holding) the otherwise loosely overlapping contact surfaces of the contact counterparts with the application of force. The transmission rails are each made from a plate-shaped basic material having a plate thickness between two opposite outer faces. The transmission rails are thus preferably made from a sheet metal material as a plate material, more preferably from copper or a copper alloy. In this way, it is advantageous that the first and second transmission rails can each be produced as a punched part, which allows inexpensive mass production. Both transmission rails each have a rail section extending between the first and second contact areas and arranged parallel to one another over the track.Furthermore, a part or the entire rail section of each power transmission rail has at least one flange projection formed laterally, thereby forming a side rail section. The formed side rail section is arranged in a different plane than the rail sections of the respective power transmission rail. The side rail sections of the first and second power transmission rail are arranged parallel to each other, substantially overlapping each other. The overlapping is visible by a vertical view of at least one of the side rail sections arranged parallel to each other. During energization of the contact device with a current flow through both power transmission rails, the additional side rail section results in an overall very low inductance overall behavior of the contact device. In particular, the inductances that arise in the case of different potential application of the two power transmission rails are compensated for. This is all the more successful the more the faces of the power transmission rails are opposed to each other. Furthermore, the arrangement of the rail section and the side rail section in different planes leads to an increase in the structural rigidity, so that the contact device is better able to withstand loads under the action of differently oriented mechanical forces.

[0007] Advantageous modifications and improvements of the contact device according to the invention are possible thanks to the measures recited in the dependent claims. In a further advantageous embodiment of the contact device, the side rail section of the respective power transmission rail is formed into the rail section at least over a partial section, preferably over the entire rail section, by at least one bend. The longer the partial section is selected, the more favorably this can affect the low inductance of the contact device. This also leads to an increase in the structural rigidity of the power transmission rail.

[0008] Great advantages arise in an embodiment of the contact device in which the rail sections and the side rail sections of the respective transmission rails are arranged, via two bends, as respective legs of a cross section of the transmission rail, in this case U-shaped, parallel or at an open angle to one another. The U-shaped cross section provides the best possible compactness with stiffness specifications against the action of mechanical forces from various spatial directions. The arrangement of the legs at an open angle to one another means that the legs, which are joined at the start, gradually move away from one another in a V-shape as the leg sections extend.

[0009] There are various possibilities for a particularly space-saving arrangement of the first and second transmission rails relative to one another. A preferred arrangement results in the u-shaped cross sections of the first and second transmission rails being arranged in opposite directions by 180°, with at least one leg of each of the transmission rails meshing between two legs of the respective other transmission rail. An alternative arrangement results in the u-shaped cross sections of the first and second transmission rails being arranged in the same direction, with the two legs of each of the transmission rails being spaced apart from one another more widely than the two legs of the respective other transmission rail. Furthermore, in this case the u-shaped cross section of the other transmission rail is accommodated between the more widely spaced legs of one transmission rail.

[0010] An embodiment of the contact device in which the rail sections and the side rail sections of both power transmission rails are arranged parallel to one another with substantial mutual shading has a particularly low inductance: due to the high degree of shading, the inductances due to the currents in both power transmission rails are particularly strong and act in the opposite direction to one another.

[0011] In a preferred embodiment of the contact device, each power transmission rail has an uninterrupted surface area over the running track from the first contact area of ​​the power transmission rail to the second contact area of ​​the power transmission rail, in which the normal vector of each surface point is oriented perpendicular to the force vector of the compression force. Due to such a defined provision, the particularly high bending stiffness of the power transmission rail can be utilized in the case of a constructional type of the contact device that is very compact overall. This allows high compression forces to be planned or formed as contact forces for electrical contact without mechanically overloading the contact device. In addition, the possibility of high compression forces as contact forces allows electrical contact by this contact device to be ensured with low electrical resistance and a long service life.

[0012] In an advantageous embodiment of the contact device, at least the first and second power transmission rails are embedded in a common, electrically insulating encapsulation, with at least one contact element of at least one first contact region of each power transmission rail and at least one contact element of at least one second contact region protruding from the encapsulation. Advantageously, this encapsulation forms a contact protection for the contact device, so that during operation of the contact device, even at high currents and / or high voltages, there is no direct danger to humans and the environment in the case of proper use. The encapsulation can be prepared, for example, by a casting material, for example made of ceramics, or by an injection-molded material, for example a moulding material, in particular of a polymer.

[0013] In one variant of the contact device, the means for generating a contact force comprises at least one elastic pressure element, which is configured to be preloaded by a mechanical force application part in order to generate a contact force. A contact force in a defined force value range or at a defined force value can be generated by application of force in the elastic region of the pressure element. The galvanic application contact to be generated can thus be designed to be reliable, both electrically and mechanically, over a given service life, taking into account the material-technical properties of the contact surface of the functional element to be electrically contacted. The at least one elastic pressure element can preferably fit into a recess in the electrically insulating encapsulation, so that the pressure element is protected against mechanical damage. In this case, the mechanical application is carried out, inter alia, by means of a screw or a nut, which preloads the at least one elastic pressure element with a force to generate a contact force. The elastic pressure element is configured, inter alia, as a pressure disk made of spring steel. This allows a particularly inexpensive implementation of the elastic pressure element. Of course, the at least one elastic pressure element can also have another suitable embodiment for generating the desired contact force, for example in the form of a clamping yoke.

[0014] In a particularly preferred embodiment of the contact device, at least one contact element of at least one first contact region and / or at least one contact element of at least one second contact region are each made as sharp teeth, which are further designed to be pressed into at least one contact surface of the functional element by a triggerable contact force in the form of a compressive force, so that a galvanic application contact is formed. A good electrical connection with a low contact resistance and a high current carrying capacity can be achieved in this way.

[0015] The invention also extends to a power module assembly with at least one power module comprising a plurality of semiconductor switches and at least one external contact surface. The power module assembly further comprises at least one coupling interface comprising at least one contact device according to at least one of the aforementioned embodiments and at least one elastic pressure element. The elastic pressure element is preloaded by a mechanical force application, whereby a contact force is provided in the form of a compressive force, by which at least one contact element of at least one first contact area of ​​the power transmission rail is pressed towards the at least one external contact surface under the formation of a galvanically applied contact. The at least one coupling interface allows a low-inductance, rigid electrical or mechanical coupling between the at least one power module and the external supply terminals and / or the external load terminals by a simple mechanical application. The mechanical application is implemented, for example, by a screw connection. Such a coupling interface by a simple mechanical application can save structural space in the power module assembly. In addition, such a mechanical application can be cheaper and simpler than, for example, a laser welded joint.

[0016] In a further advantageous embodiment of the power module assembly, the first coupling interface comprises a first contact device and is made for electrically coupling at least one first external contact surface of the at least one power module with a first supply terminal and at least one second external contact surface of the at least one power module with a second supply terminal. The first coupling interface allows the corresponding power module to be electrically coupled in one working step with a supply terminal, which is provided, for example, by a capacitor unit. The power transmission rails of the first contact device can preferably be arranged parallel to each other at a certain distance. As the current directions of both power transmission rails are opposite to each other, the parasitic magnetic fields that occur can be largely or at least partially cancelled out by each other, so that a low-inductance coupling between the corresponding power module and the supply terminal can be realized with a high current-carrying capacity. The second coupling interface can comprise a further external contact device surrounded by an electrically insulating encapsulation and can be made for electrically coupling at least one third external contact surface of the at least one power module with a load terminal. By means of the second coupling interface, the corresponding power module can be electrically coupled, for example, to a phase terminal of an electric machine. The encapsulation, which is preferably formed by a hardened molding compound, can simplify the handling of the coupling interface and can ensure the position of the power transmission rail over the life of the power module assembly. In addition, the encapsulation protects the power transmission rail from external influences.

[0017] In a further advantageous embodiment of the power module assembly, the at least one power module can be molded with an encapsulation, which can have a cavity in the region of the at least one external contact surface, so that the at least one external contact surface is contactable. In the region of the at least one external contact element, an exposure can be applied to the encapsulation, for example by means of a laser, so that the at least one contact element is exposed and contactable.

[0018] In a further advantageous embodiment, the power module assembly may include three power modules. In this regard, at least one third external contact surface of the first power module may be electrically coupled to a load terminal made as a first phase terminal and may provide a first phase current to the electric machine. At least one third external contact surface of the second power module may be electrically coupled to a load terminal made as a second phase terminal and may provide a second phase current to the electric machine. At least one third external contact surface of the third power module may be electrically coupled to a load terminal made as a third phase terminal and may provide a third phase current to the electric machine. In addition, the three power modules may have respective first coupling interfaces electrically coupling the corresponding power module with the first supply terminal and the second supply terminal, and respective second coupling interfaces electrically coupling the corresponding power module with the corresponding load terminal. A power module assembly with three power modules may preferably be used as a power output stage for a three-phase electric motor.

[0019] Exemplary embodiments of the invention are illustrated in the drawings and explained in detail in the following description, in which like reference numbers refer to components or elements performing the same or similar functions.

[0020] Further advantages, features and details of the invention will become apparent from the following description of preferred exemplary embodiments and on the basis of the drawings. [Brief description of the drawings]

[0021] [Figure 1] FIG. 1 is a schematic plan view of an exemplary embodiment of a power module assembly. [Diagram 2] FIG. 2 is a schematic plan view of an exemplary embodiment of a power module for the power module assembly of FIG. 1. [Diagram 3] FIG. 2 is a schematic cross-sectional view of the power module assembly of FIG. 1. [Figure 4a] 2 is a schematic exploded perspective view of one exemplary embodiment of a contact device in the power module assembly of FIG. 1; [Figure 4b] FIG. 4b is a schematic perspective view of both power transmission rails in the contact device of FIG. 4a. [Figure 4c] 4b shows further specifications of the contact device based on the second exemplary embodiment of FIG. 4a. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] In the figures, functionally identical parts are given the same reference numerals. As is evident from Figures 1 to 4c, the illustrated exemplary embodiment of a power module assembly 1 according to the invention comprises at least one power module 2, 2A, 2B, 2C, which comprises a number of semiconductor switches, not shown in more detail, and at least one external contact surface 2.1, 2.1A, 2.1B, 2.1C, as well as at least one coupling interface 10, 10A, 10B, which comprises at least one contact device 12, 12A, 12B and at least one elastic pressure element 22. The at least one coupling interface 10, 10A, 10B electrically couples the at least one external contact surface 2.1, 2.1A, 2.1B, 2.1C of the power module 2, 2A, 2B, 2C with at least one external supply terminal 32 or at least one external load terminal 34. The at least one external contact device 12, 12A, 12B comprises at least two power transmission rails 14, 14A, 14B each with at least one first contact area 16 contacting at least one external contact surface 2.1, 2.1A, 2.1B, 2.1C with at least one contact element 16.1 and at least one second contact area 18 contacting at least one external supply terminal 32 or at least one external load terminal 34 with at least one contact element 18.1. The at least one contact device 12, 12A, 12B is molded and encapsulated by an encapsulation 20 such that the at least one contact element 16.1 of the at least one first contact area 16 and the at least one contact element 18.1 of the at least one second contact area 18 protrude from the encapsulation 20.In this case, the mechanical force application part 24 applies a force to preload the at least one elastic pressure element 22, thereby causing a contact force K in the form of a compressive force D, which presses at least one contact element 16.1 of at least one first contact area 16 towards at least one external contact surface 2.1, 2.1A, 2.1B, 2.1C and at least one contact element 18.1 of at least one second contact area 18 towards at least one external supply terminal 32 or at least one external load terminal 34, thereby forming a galvanic application contact.

[0023] As is further evident from FIGS. 1-3, the illustrated exemplary embodiment of the power module assembly 1 comprises three power modules 2, 2A, 2B, 2C. In the illustrated exemplary embodiment of the power module assembly 1, each of the three power modules 2, 2A, 2B, 2C comprises a first circuit board, not shown in detail, on which at least two semiconductor switches, not shown in detail, are arranged. In this regard, at least one first semiconductor switch, also called high-side switch, is electrically loop-connected between a first external contact surface 2.1A, coupled to a first or positive external supply terminal 32A, and a third external contact surface 2.1C, coupled to at least one external load terminal 34. At least one second semiconductor switch, also called low-side switch, is electrically loop-connected between a second external contact surface 2.1B, coupled to a second or negative external supply terminal 32B, and a third external contact surface 2.1C, coupled to at least one external load terminal 34. The control terminals of the at least two semiconductor switches are each electrically coupled to at least one external contact element 2.2 arranged on a second circuit board, which is capable of contacting at least one control line of an external control contact device. The second circuit board is joined to the first circuit board by a solder joint, a sintered joint, a welded joint or an adhesive joint.

[0024] As can be further seen from Figures 1 to 3, the individual power modules 2, 2A, 2B, 2C are each molded and encapsulated by an encapsulation 3, which has a cavity 5 in the area of ​​the external contact surfaces 2.1, 2.1A, 2.1B, 2.1C, respectively, so that the external contact surfaces 2.1, 2.1A, 2.1B, 2.1C are contactable. In the area of ​​the external contact element 2.2, the encapsulation 3 is provided with an exposure 7, so that the contact element 2.2 is exposed and contactable.

[0025] As is further apparent from Figures 1-3 in particular, each power module 2A, 2B, 2C includes two first external contact surfaces 2.1A coupled to a first or positive external supply terminal 32A via a first coupling interface 10A, one second external contact surface 2.1B coupled to a second or negative external supply terminal 32B via the first coupling interface 10A, and two third contact surfaces 2.1C coupled to an external load terminal 34 via a second coupling interface 10B. Thus, the three power modules 2A, 2B, 2C have respective first coupling interfaces 10A electrically coupling the corresponding power module 2A, 2B, 2C to the first or positive supply terminal 32A and the second supply terminal 32B, and respective second coupling interfaces 10B electrically coupling the corresponding power module 2A, 2B, 2C to the corresponding load terminal 34. In this regard, the two third external contact surfaces 2.1C of the first power module 2A, which is arranged at the top in the figure, are electrically connected to the load terminal 34 made as the first phase terminal 34U and provide a first phase current to the electric machine. The two third external contact surfaces 2.1C of the second power module 2B, which is arranged in the middle in the figure, are electrically connected to the load terminal 34 made as the second phase terminal 34V and provide a second phase current to the electric machine. The two third external contact surfaces 2.1C of the third power module 2C, which is arranged at the bottom in the figure, are electrically connected to the load terminal 34 made as the third phase terminal 34W and provide a third phase current to the electric machine.

[0026] In the illustrated exemplary embodiment of the power module assembly 1, a capacitor unit 30 including a number of film capacitors (not shown) provides a first or positive supply terminal 32A and a second or negative supply terminal 32B supported by a plastic support element 36 to the three power modules 2, 2A, 2B, 2C. The three phase terminals 34U, 34V, 34W are each coupled to a three-phase electric motor (not shown in detail). In addition to this, the three power modules 2, 2A, 2B, 2C are each thermally coupled to a cooling device 9 via a metal structure 4 arranged on the underside of the respective power module 2, 2A, 2B, 2C in order to remove heat losses generated by the respective power module 2, 2A, 2B, 2C.

[0027] As is further evident from Figures 3 to 4c, the first coupling interface 10A of each one of the power modules 2, 2A, 2B, 2C in the illustrated exemplary embodiment comprises a first external contact arrangement 12A molded and sealed by an encapsulation 20, which electrically couples two first external contact surfaces 2.1A of the corresponding power module 2, 2A, 2B, 2C with a first supply terminal 32A and electrically couples the second external contact surface 2.1B of the corresponding power module 2, 2A, 2B, 2C with a second supply terminal 32B. For this purpose, the first contact arrangement 12A comprises at least two power transmission rails 14A, 14B each having at least one first contact area 16 and at least one second contact area 18.

[0028] As becomes clearer from Figures 4a and 4b, the contact elements 16.1 of the first contact area 16 of the first power transmission rail 14A are each made as sharp teeth 16.1A, which a contact force K in the form of an induced compressive force D presses into the first external contact surface 2.1A of both of the corresponding power modules 2A, 2B, 2C. The contact elements 18.1 of the second contact area 18 of the first power transmission rail 14A are also made as sharp teeth 18.1A, which a contact force K in the form of an induced compressive force D presses into the first or positive external supply terminal 32A. The first contact device 12A also includes a second power transmission rail 14B, which has a first contact area 16 and a second contact area 18, respectively. In this regard, the contact elements 16.1 of the first contact area 16 of the second power transmission rail 14B are also made as sharp teeth 16.1A, which a contact force K in the form of an induced compressive force D presses into the second external contact surface 2.1B of the corresponding power module 2A, 2B, 2C. The contact elements 18.1 of the second contact area 18 of the second power transmission rail 14B are also made as sharp teeth 18.1A, which a contact force K in the form of an induced compressive force D presses into the second or negative external supply terminal 32B.

[0029] As is further evident from Fig. 3 to Fig. 4c, at least the first and second power transmission rails 14A, 14B of the first contact device 12A are arranged parallel to one another at a certain distance a in order to reduce parasitic inductances. Each power transmission rail 14A, 14B of the first contact device 12A is preferably produced as a punched part, but may also be, for example, a laser-processed sheet metal bent part. In this respect, each power transmission rail 14A, 14B has an uninterrupted surface area 15 over the extension path E from the first contact area 16, 18 of the power transmission rail 14A, 14B, in which the normal vector NV of each surface point is oriented perpendicularly to the force vector KV of the compression force D. In this exemplary embodiment, the uninterrupted surface area 15 is produced as a purely by way of example rectangular sheet metal strip, extending over the extension area E with approximately a strip width b. This can be adapted accordingly depending on the contact situation. The minimum surface coverage distance remaining in the continuous surface area 15 is preferably several times the sheet metal thickness d, in particular more than 5 times, advantageously more than 10 times, preferably more than 15 times.

[0030] The first power transmission rail 14A is guided along a u-shaped extending track E. The second power transmission rail 14B is guided along a substantially o-shaped extending track E. The extending track E of the respective power transmission rail 14A, 14B may be embodied differently to suit the respective application, for example with a substantially i-shaped extending track. More than two power transmission rails 14A, 14B may also be provided. The illustrated exemplary embodiment of the first contact device 12A is adapted for application in the described power module assembly 1.

[0031] At least a part of each of the power transmission rails 14A, 14B or the entire rail section 14.1A, 14.1B has at least one flange projection 14.12 formed laterally, which forms a respective side rail section 14.2A, 14.2B. The side rail section 14.2A, 14.2B is arranged in a different plane E1, E2 than the respective rail section 14.1A, 14.1B of the respective power transmission rail 14A, 14B. Furthermore, the side rail sections 14.2A, 14.2B of the first and second power transmission rails 14A, 14B are arranged parallel to each other, substantially overlapping each other. The flange projection 14.12 is formed in particular as a bend, for example as a sheet metal bend. This exemplary embodiment shows, purely by way of example, a power transmission rail 14A, 14B with two bends in the respective flange projection 14.12, in particular with two mutually parallel arranged legs A1, A2, B1, B2 of the in this case u-shaped cross section of the respective power transmission rail 14A, 14B. It is basically also conceivable that the opposite legs A1, A2, B1, B2 of the respective power transmission rail 14A, 14B are angled relative to one another, in particular like an open V. In the first contact device 12A, the respective u-shaped cross sections of the first and second power transmission rail 14A, 14B are arranged 180° opposite to one another. In this case, in a correspondingly alternating manner, the respective legs A1, B1 of one of the respective power transmission rails 14A, 14B mesh between two corresponding legs B1, B2, A1, A2 of the respective other power transmission rail 14A, 14B. Thereby, the rail sections 14.1A, 14.1B and the side rail sections 14.2A, 14.2B of both transmission rails 14A, 14B are arranged parallel to one another, substantially overlapping one another.

[0032] 4c additionally shows another possibility of the interlocking of the legs A1, A2, B1, B2 in a very schematic and exemplary cross-sectional view perpendicular to the running trajectory E of the transmission rails 14A, 14B. In this case, an arrangement of the two transmission rails 14A, 14B is selected in which the u-shaped cross-sections of the transmission rails 14A, 14B are arranged in the same direction relative to one another. Furthermore, the two legs A1, A2, B1, B2 of each of the transmission rails 14A, 14B are spaced apart from one another by a larger distance a1-a2, b1-b2 than the two legs A1, A2, B1, B2 of the other transmission rail 14A, 14B, respectively. That is to say, the u-shaped cross-section of this other transmission rail 14A, 14B is accommodated between the more widely spaced legs a1-a2, b1-b2 of the first transmission rail 14A, 14B.

[0033] As is further apparent from Figures 1 and 3, the second coupling interface 10B in the illustrated exemplary embodiment comprises a further second external contact arrangement 12B molded and sealed by the encapsulation 20 and electrically connects the two third external contact surfaces 2.1C of the corresponding power module 2, 2A, 2B, 2C with the corresponding load terminal 34. The second contact arrangement 12B differs from the first contact arrangement 12A only in that the respective extension tracks E of the at least two enclosed power transmission rails 14A, 14B as well as the respective number and specifications of the first and second contact areas 16, 18 are structurally adapted correspondingly to the contact of the two third external contact surfaces 2.1C of the corresponding power module 2, 2A, 2B, 2C.

[0034] As is further evident especially from Figures 3 to 4c, the elastic pressure element 22 as a pressure disk 22A is made from spring steel and is arranged in a recess 28 of the overmolded part 20 of the respective contact device 12A, 12B. In the illustrated exemplary embodiment, the mechanical force application part 24, which applies a force to and preloads the elastic pressure element 22, is made as a screw 24A. The screw 24A is screwed into a threaded hole 9.1 which is screwed into the base body of the cooling device 9.

[0035] In an alternative, not shown, exemplary embodiment, the mechanical force applicator 24 is made as a nut, which is screwed onto the threaded shaft and applies a force to the elastic pressure element 22 to preload it. [Explanation of symbols]

[0036] 1 Power Module Assembly 2, 2A, 2B, 2C Power Module 2.1, 2.1A, 2.1B, 2.1C contact surface 2.2 Contact Elements 3 encapsulation 4 Metal structure 5 Vacancies 7 Exposed part 9 Cooling device 9.1 Screw holes 10, 10A, 10B Combined Interface 12, 12A, 12B Contact device 14, 14A, 14B Power Rails 14.1A, 14.1B Rail Section 14.2A, 14.2B Side rail section 14.12 Flange protrusion 15 area 16 First Contact Area 18 Second Contact Area 16.1, 18.1 Contact Elements 20 Encapsulation 22 Pressure Elements 24, 24A mechanical force section 28 Recess 30 Capacitor Unit 32A First positive supply terminal 32B Second negative supply terminal 34 Load terminal 34U 1st phase terminal 34V Second phase terminal 34W 3rd phase terminal 36 Supporting elements A1, A2, B1, B2 legs D Compressive force E Extended track K Contact force KV Force Vector NV normal vector a1-a2, b1-b2 spacing

Claims

1. A contact device (12, 12A, 12B) for electrically contacting at least two electrical functional components (2, 2A, 2B, 2C, 30) of an electrical and / or electronic circuit and / or subcircuit in at least one coupling interface (10, 10A, 10B), comprising at least a first and a second power transmission rail (14, 14A, 14B), said power transmission rails (14, 14A, 14B) being arranged electrically insulated and spaced apart from each other, each power transmission rail (14, 14A, 14B) being electrically insulated and spaced apart from each other, The rails (14, 14A, 14B) have at least first and second contact areas (16, 18), the contact areas (16, 18) each including at least one contact element (16.1, 18.1), and the contact device (12, 12A, 12B) is arranged such that the functional element (2, 2A, 2B, 2C, 30) and each of the two power transmission rails (14, 14A, 14B) are connected to each other through the contact elements (16.1, 18.1) of the respective different contact areas (16, 18). a contact element (16.1, 18.1) of at least one contact area (16, 18) and at least one contact surface (2.1, 2.1A, 2.1B, 2.1C) of a functional element (2, 2A, 2B, 2C, 30) are formed to generate a current path between the first and second contact areas (16, 18) in both power transmission rails (14, 14A, 14B) when the contact element (16.1, 18.1) of at least one contact area (16, 18) and at least one contact surface (2.1, 2.1A, 2.1B, 2.1C) of a functional element (2, 2A, 2B, 2C, 30) are electrically connected to each other by a galvanic force applied to the contact area (16.1, 18.1). the contact device (12, 12A, 12B) can be formed in a shape such that the contact device (12, 12A, 12B) has means for exerting a compressive force (D) perpendicular to the contact surface (2.1, 2.1A, 2.1B, 2.1C) on the at least one contact element (16.1, 18.1) in the at least one contact area (16, 18) as a contact force (K) in a contact state between the contact device (12, 12A, 12B) and at least one of the functional elements (2, 2A, 2B, 2C, 30), the power transmission rails (14, 14A, 14B) are each formed from a plate-like basic material having a plate thickness (d) between two opposite outer faces, the at least two power transmission rails (14, 14A, 14B) each having rail sections (14.1A, 14.1B) arranged parallel to one another over an extending track (E) between the first and second contact areas (16, 18), the rail sections (14.1A, 14.1B) of each power transmission rail (14, 14A, 14B) having laterally formed flange projections (14.12); This forms side rail sections (14.2A, 14.2B) that are arranged in a different plane (E1, E2) than the respective rail sections (14.1A, 14.1B) of the respective power transmission rails (14, 14A, 14B), and the side rail sections (14.2A, 14.2B) of the first and second power transmission rails (14, 14A, 14B) are arranged parallel to one another, substantially obscuring one another.

2. 2. The contact device according to claim 1, characterized in that the side rail section (14.2A, 14.2B) of each power transmission rail (14, 14A, 14B) is molded into the rail section (14.1A, 14.1B) by at least one bend, at least over a partial section, preferably over the entire rail section (14.1A, 14.1B).

3. 3. The contact device according to claim 2, characterized in that the rail sections (14.1A, 14.1B) and the side rail sections (14.2A, 14.2B) of each power transmission rail (14, 14A, 14B) are arranged parallel to one another or at an open angle via two bends as respective legs (A1, A2, B1, B2) of a cross section of the power transmission rail (14, 14A, 14B) which is formed in a U-shape in this case.

4. 4. The contact device according to claim 3, characterized in that the U-shaped cross sections of the first and second power transmission rails (14, 14A, 14B) are arranged in opposite directions by 180° to each other, in which case at least one leg (A1, A2, B1, B2) of each one of the power transmission rails (14, 14A, 14B) meshes between two legs (A1, A2, B1, B2) of each other power transmission rail (14, 14A, 14B).

5. 4. The contact device according to claim 3, characterized in that the u-shaped cross sections of the first and second power transmission rails (14, 14A, 14B) are arranged in the same direction relative to one another, with the two legs (A1, A2, B1, B2) of each one of the power transmission rails (14, 14A, 14B) spaced apart from one another by a greater distance (a1-a2, b1-b2) than the two legs (A1, A2, B1, B2) of each of the other power transmission rails (14, 14A, 14B), and the u-shaped cross section of the other power transmission rail (14, 14A, 14B) is received between the more widely spaced legs (A1, A2, B1, B2) of the one power transmission rail (14, 14A, 14B).

6. 6. The contact device according to claim 1, wherein the rail sections (14.1A, 14.1B) and the side rail sections (14.2A, 14.2B) of both power transmission rails (14, 14A, 14B) are arranged parallel to one another, substantially overlapping one another.

7. 7. The contact device according to claim 1, wherein each transmission rail (14, 14A, 14B) has an unbroken surface area (15) over the elongated track (E) from the first contact area (16, 18) of the transmission rail (14, 14A, 14B) and in which the normal vector (NV) of each surface point is oriented perpendicular to the force vector (KV) of the compression force (D).

8. 8. A contact device according to claim 1, characterized in that at least the first and the second power transmission rails (14, 14A, 14B) are embedded in a common electrically insulating encapsulation (20), with the at least one contact element (16.1) of the at least one first contact area (16) and the at least one contact element (18.1) of the at least one second contact area (18) of each power transmission rail (14, 14A, 14B) protruding from the encapsulation (20).

9. 9. A contact device according to claim 1, characterized in that the means for inducing the contact force (K) comprises at least one elastic pressure element (22), the pressure element (22) being formed to be preloaded by a mechanical force applicator (24, 24A) in order to induce the contact force (K).

10. 10. A contact device according to claim 1, characterized in that the at least one contact element (16.1) of the at least one first contact region (16) and / or the at least one contact element (18.1) of the at least one second contact region (18) are each made as sharp teeth (16.1A, 18.1A) and are configured to be pressed into the at least one contact surface (2.1, 2.1A, 2.1B, 2.1C) of the functional element (2, 2A, 2B, 2C, 30) by the induceable contact force (K).

11. A power module assembly (1) comprising at least one power module (2, 2A, 2B, 2C) comprising a plurality of semiconductor switches and at least one external contact surface (2.1, 2.1A, 2.1B, 2.1C) and at least one coupling interface (10, 10A, 10B) comprising at least one contact device (12, 12A, 12B) according to any one of claims 1 to 10, comprising at least one elastic pressure element (22), said elastic pressure element (22) being mechanically a contact element (16.1) of the first contact area (16) of at least one of the power transmission rails (14, 14A, 14B) is preloaded by a force application portion (24, 24A) such that a contact force (K) is provided in the form of a compressive force (D), by which at least one contact element (16.1) of the first contact area (16) of at least one of the power transmission rails (14, 14A, 14B) is pressed towards the at least one external contact surface (2.1, 2.1A, 2.1B, 2.1C) under formation of a galvanically applied contact.

12. 12. Power module assembly (1) according to claim 11, characterized in that the first coupling interface (10, 10A) comprises a contact device (12, 12A) and is made for electrically coupling at least one first external contact surface (2.1, 2.1A) of the at least one power module (2, 2A, 2B, 2C) with a first supply terminal (32A) and for electrically coupling at least one second external contact surface (2.1, 2.1B) of the at least one power module (2, 2A, 2B, 2C) with a second supply terminal (32B).

13. 13. The power module assembly (1) according to claim 11 or 12, characterized in that the second coupling interface (10, 10B) comprises a further contact device (12, 12B) and is made to electrically couple at least one third external contact surface (2.1, 2.1C) of the at least one power module (2, 2A, 2B, 2C) with a load terminal (34).

14. 14. The power module assembly (1) according to claim 11, characterized in that the at least one power module (2, 2A, 2B, 2C) comprises at least one circuit board on which at least two semiconductor switches are arranged, in which at least one first semiconductor switch is electrically connected in a loop between a first external contact surface (2.1, 2.1A) coupled to a first external supply terminal (32) and a third external contact surface (2.1, 2.1C) coupled to the at least one external load terminal (34), and at least one second semiconductor switch is electrically connected in a loop between a second external contact surface (2.1B) coupled to a second external supply terminal (32) and the third external contact surface (2.1C) coupled to the at least one external load terminal (34).

15. 15. The power module assembly (1) according to claim 11, characterized in that there are three power modules (2), wherein the at least one third external contact surface (2.1C) of a first power module (2A) is electrically coupled to a load terminal (34) made as a first phase terminal (34U) and provides a first phase current to an electric machine, the at least one third external contact surface (2.1C) of a second power module (2B) is electrically coupled to a load terminal (34) made as a second phase terminal (34V) and provides a second phase current to the electric machine, and the at least one third external contact surface (2.1C) of a third power module (2C) is electrically coupled to a load terminal (34) made as a third phase terminal (34W) and provides a third phase current to the electric machine.

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