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

Abstract

A connection configuration (1), in particular a connection configuration (1) for use in an electric vehicle or a hybrid vehicle, comprising a first flat terminal contact (11) having a planar first contact surface (15) for making electrical contact with a first electrical and / or electronic component, and a second flat terminal contact (21) having a second contact surface (25) for making electrical contact with a second electrical and / or electronic component, wherein the first flat terminal contact (11) and the second flat terminal contact (21) overlap within an overlap region (5), the first contact surface (15) faces the second contact surface (25), the first flat terminal contact (11) and the second flat terminal contact (21) are connected by a connecting element (30), and the first contact surface (15) is pressed against the second contact surface (25) by the connecting element (30). Regarding the connection configuration (1), a structure (17) is embossed on the first flat terminal contact (11) such that an edge (16) of the first flat terminal contact (11) protrudes from the plane of the first contact surface (15), and it is proposed that the edge (16) protruding from the plane of the first contact surface (15) is press-fitted into the second contact surface (25) of the second flat terminal contact (21) by the connecting element (30).

Description

Technical Field

[0001] The present invention relates to a connection configuration having the features of the preamble of independent claim 1, in particular a connection configuration for use in an electric vehicle or a hybrid vehicle.

Background Art

[0002] For example, in power electronics in an electric vehicle or a hybrid vehicle, electrical and / or electronic components that conduct high current are interconnected. The current-carrying elements connecting the electrical and / or electronic components to each other must have a low electrical resistance corresponding to the high current, and thus must have a large cross-sectional area and / or a material with high electrical conductivity. Therefore, in such a configuration, the current is conducted, for example, via a conductive rail (also called a bus bar), and the electrical and / or electronic components are connected to each other via the conductive rail.

[0003] To connect electrical and / or electronic components to each other, flat terminal contacts that form electrical connections of the electrical and / or electronic components, for example, conductive rails, are electrically connected to each other. Here, the flat terminal contacts overlap and are connected to each other within the region where they overlap, for example, by screwing. When a high current flows through the connection, it is essential to maintain a low electrical material resistance and a low electrical contact resistance in order to minimize the overall electrical loss.

Summary of the Invention

[0004] According to the present invention, a connection configuration, in particular a connection configuration for use in an electric vehicle or a hybrid vehicle, is proposed. This connection configuration includes a first flat terminal contact having a planar first contact surface for electrically contacting a first electrical and / or electronic component, and a second flat terminal contact having a second contact surface for electrically contacting a second electrical and / or electronic component. At this time, the first flat terminal contact and the second flat terminal contact overlap within an overlapping region, the first contact surface faces the second contact surface, the first flat terminal contact and the second flat terminal contact are connected by a connecting element, and the first contact surface is pressed against the second contact surface by the connecting element. According to the present invention, the structure of the first flat terminal contact is embossed such that an edge of the first flat terminal contact protrudes from the plane of the first contact surface, and the edge protruding from the plane of the first contact surface is press-fitted into the second contact surface of the second flat terminal contact by the connecting element. [Advantages of the present invention] Compared with the prior art, the connection configuration with the features of the independent claim has the advantage that a preferably low electrical contact resistance is achieved in the connection between two flat terminal contacts. Thereby, preferably, the usually high heat generation and high voltage drop at the contact location between the two flat terminal contacts are prevented. By the edge of the first flat terminal contact being press-fitted into the second contact surface of the second flat terminal contact, during the mutual mechanical fixation of the flat terminal contacts, for example during screwing, the edge is press-fitted through the different layers on the second contact surface. The different layers can be, for example, oxide layers caused by the corrosion of the second flat terminal contact, and that oxide layer would result in a high contact resistance at the contact location between the two flat terminal contacts. During the mutual fixation of the flat terminal contacts, the edge penetrates into the different layers on the second contact surface. During the mutual fixation of the flat terminal contacts, for example during the tightening fixation of a screw connection, the shaped structure is flattened and crushed. Here, a relative movement of the edge on the second contact surface occurs, and the edge is slid on the second contact surface. By this relative movement, the different layers on the second contact surface are crushed by the edge, and at the same time the different layers at the edge are removed. Therefore, by this relative movement, the different layers (which can be, for example, oxide layers) at the two flat terminal contacts are crushed. By the fixation of the flat terminal contacts, for example during the tightening fixation of a screw connection, the regions with open different layers then overlap each other, and it is ensured that no different layers can be formed any more within this region where these regions overlap each other. Thereby, a preferably low and stable electrical resistance between the two terminal contacts is achieved. At the start of the screwing process, there is a line contact between the first flat terminal contact and the second flat terminal contact. During the screwing process, in the region of the line contact, since the pressed area is very small, preferably the surface pressure is high (surface pressure = force / area). Therefore, the different layers can be crushed very well by a locally very high force.

[0005] The features presented in the dependent claims enable further advantageous forms and developments of the present invention.

[0006] According to an advantageous exemplary embodiment, a first cut-out is configured in the first terminal contact within the overlapping region, an edge is formed around the first cut-out by an edge of the first terminal contact, and it is contemplated that a connection element projects through the first cut-out of the first flat terminal contact. Thus, the edge extending over the entire circumference of the connection element is utilized to establish a connection with a lower contact resistance. The cut-out, for example, a hole for receiving a screw, is simultaneously utilized to establish a connection with an edge around this cut-out as an edge and advantageously a low contact resistance. The edge extending around the cut-out for the connection element can advantageously be press-fitted into the second contact surface in a circumferential shape, and an advantageously low electrical transition resistance between the two flat terminal elements can be established. Here, for example, the head of the connection element, for example, a screw head, can be press-fitted into the second contact surface of the second flat connection element, for example, annularly, over the entire circumference of the edge when the connection element is tightened. The annular contact around the first cut-out enables the establishment of a connection with an advantageously low electrical resistance even when using a small screw.

[0007] According to an advantageous exemplary embodiment, it is contemplated that a funnel-shaped structure is configured around the first cut-out by embossing on the first terminal contact. Such a structure is advantageously easily manufacturable and is particularly suitable for causing good relative movement of the edge on the second contact surface when the flat terminal elements are fixed to each other, for example, when the connection element configured as a screw, for example, is tightened and fixed. Here, when tightened and fixed, the funnel-shaped structure is flattened and crushed, and the edge radially fractures the different layers.

[0008] According to an advantageous exemplary embodiment, it is contemplated that the connecting element is configured as a screw connection, and the first flat terminal contact and the second flat terminal contact are connected to each other by the screw connection and pressed against each other. The screw connection establishes a particularly easy and at the same time good mechanical connection between the flat terminal contacts. Furthermore, by tightening the screw, a force can be exerted on the flat terminal contact, and this force can firmly press the edge against the second contact surface, flatten the structure and crush the different layers at the second contact surface and the edge, and sufficient force can be provided. Here, the screw head can, for example, abut against a funnel-shaped structure, for example, around the entire circumference of the first cutout, so that the edge can be press-fitted into the second contact surface around the entire circumference of the first cutout. The edge is slid radially from the connecting element on the second contact surface, thereby crushing the different layers on the second contact surface in a ring shape.

[0009] According to an advantageous exemplary embodiment, a second cutout is configured in the second flat terminal contact, the connecting element protrudes through the second cutout, and it is contemplated that the edge around the first cutout surrounds the second cutout, especially in a ring shape, and is press-fitted into the second contact surface. Therefore, the connecting element can be arranged through both cutouts, and the two flat terminal contacts can be easily connected to each other.

[0010] According to an advantageous exemplary embodiment, it is contemplated that the first flat terminal contact is configured as a conductive rail and / or the second flat terminal contact is configured as a conductive rail. The conductive rails can be connected to each other particularly well in the exemplified manner. In particular, the conductive rails can advantageously be easily and inexpensively punched and embossed. The first cutout of the conductive rail can advantageously be easily produced by punching. Here, the punched cutout has, for example, a particularly sharp edge, which can advantageously and well break down the different layers on the second contact surface. The embossed structure can be particularly easily produced in the first flat terminal contact configured as a conductive rail.

[0011] Furthermore, a method for manufacturing a connection configuration is proposed. This method includes the steps of providing a first flat terminal contact having a planar first contact surface, in particular a conductive rail; providing a second flat terminal contact having a second contact surface; embossing a structure onto the first flat terminal contact, wherein by the embossing of the structure, an edge of the first flat terminal contact is extruded from the plane of the planar first contact surface; placing the first contact surface of the first flat terminal contact onto the second contact surface of the second flat terminal contact; and fixing the first flat terminal contact to the second flat terminal contact by a connecting element, wherein the first contact surface of the first flat terminal contact is pressed against the second contact surface of the second flat terminal contact and the edge of the first flat terminal contact is press-fitted into the second contact surface of the second flat terminal contact. In this way, a connection configuration having advantageously low electrical contact resistance between the flat terminal contacts can be manufactured easily and with high cost-effectiveness. The different layers at the contact location between the two flat terminal contacts are broken up, and a stable contact having a low electrical contact resistance is created between the two flat terminal contacts.

[0012] According to an advantageous exemplary embodiment, a first cut-out is configured in the first flat terminal contact, and an edge of the first flat terminal contact around the first cut-out forms an edge. When fixing the first flat terminal contact to the second flat terminal contact, it is contemplated that a connecting element, in particular a screw connection, is inserted through the first cut-out. Thereby, a mechanically stable connection having at the same time low electrical contact resistance can be easily established.

[0013] According to an advantageous exemplary embodiment, a funnel-shaped structure is embossed around the first cut-out, and it is contemplated that the edge is extruded annularly from the plane of the first contact surface. Such a structure is particularly suitable when a screw head presses the first flat terminal contact against the second flat terminal contact. Here, when the connection is tightened and fixed, the structure is uniformly flattened and crushed, and the edge moves radially away from, for example, a connecting element configured as a screw on the second contact surface, and breaks up the different layers on the second contact surface annularly around the connecting element.

[0014] According to an advantageous exemplary embodiment, when fixing the first flat terminal contact to the second flat terminal contact, it is contemplated that the edge is press-fitted into the second contact surface of the second flat terminal contact by surrounding, in an annular manner, in particular the second cut-out of the second flat terminal contact. Thereby, an advantageously good contact with low electrical contact resistance is established.

[0015] An exemplary embodiment of the present invention is shown in the drawings and will be described in more detail in the following description.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Mode for Carrying Out the Invention

[0017] Figures 1 to 3 show various views of an exemplary embodiment of a first flat terminal contact 11. Figures 4 to 5 show an exemplary embodiment of a connection configuration 1 comprising the exemplary embodiment of the first flat terminal contact 11 from Figures 1 to 3. The connection configuration 1 can be used in all applications where high current is conducted through a contact connection and the power loss has to be kept low. The connection configuration 1 can be used, for example, in an electric vehicle or a hybrid vehicle, for example in a system for conducting high current, for example in power electronics. For example, the connection configuration 1 can be used in a converter or a battery in power electronics.

[0018] The connection configuration 1 includes a first flat terminal contact 11 which can be, for example, an electrical connection part of a first electrical and / or electronic component. Furthermore, the connection configuration 1 includes a second flat terminal contact 21 which can be, for example, an electrical connection part of a second electrical and / or electronic component. The electrical and / or electronic components can be, for example, an inverter, a converter, a DC / DC converter, a capacitor such as an intermediate circuit capacitor, a battery, or other electronic and / or electrical components used, for example, also in an electric vehicle or a hybrid vehicle, or can include them.

[0019] The first electrical and / or electronic component is conductively connected to the second electrical and / or electronic component. The conductive connection between the first electrical and / or electronic component and the second electrical and / or electronic component is established via the flat terminal contacts 11, 21. For this purpose, the first flat terminal contact 11 is conductively connected to the second flat terminal contact 21. For this purpose, the first flat terminal contact 11 is placed flatly, in particular directly, on the second flat terminal contact 21.

[0020] The flat terminal contacts 11, 21 are made of a conductive material, for example a metal, for example copper. Copper advantageously has a low material resistance. The first flat terminal contact 11 may be made of the same material as the second flat terminal contact 21. However, the first flat terminal contact 11 and the second flat terminal contact 21 can also be made of different materials. The flat terminal contacts 11, 21 are configured to be substantially flat at least within the region where they overlap. The flat terminal contacts 11, 21 have planar contact surfaces 15, 25 within the overlapping region 5, where the flat terminal contacts 11, 21 abut against each other, thereby establishing an electrical connection between the flat terminal contacts 11, 21. The flat terminal contacts 11, 21 are arranged parallel to each other with respect to their flat extending planes. In the illustrated exemplary embodiment, the flat terminal contacts 11, 21 are configured as conductive rails 11, 21. In the context of the present application, the conductive rails 11, 21 mean conductive flat conductors, for example conductive bars or conductive strips. Thus, the conductive rail can be, for example, a bus bar. The conductive rails 11, 21 may be, for example, bent or curved, or may extend in a curved or stepped manner. The conductive rails 11, 21 are made of a conductive material, for example a metal, such as copper. The conductive rails 11, 21 are, for example, composed of a single piece. For example, the conductive rails 11, 21 are made of exactly the same material. The conductive rails 11, 21 are, for example, configured as punched parts. For example, each of the conductive rails 11, 21 has a certain thickness of the conductive rail 11, 21 over the longitudinal extending region of the conductive rail 11, 21 perpendicular to the current direction. For example, each of the conductive rails 11, 21 may have a certain width of the conductive rail 11, 21 over the longitudinal extending region of the conductive rail 11, 21 perpendicular to the current direction. A first cutout 12 is formed in the first flat terminal contact 11. A second cutout 22 is formed in the second flat terminal contact 21. The first cutout 12 of the first flat terminal contact 11 has, for example, a larger planar spread than the second cutout 22 of the second flat terminal contact 21.

[0021] The cut-out portions 12, 22 are used to receive a connection element 30 for mechanically connecting the flat terminal contacts 11, 21 to each other. The connection element 30 is inserted through the cut-out portions 12, 22. The connection element 30 is fastened and fixed, thereby pressing the contact surfaces 15, 25 of the flat terminal contacts 11, 21 against each other. The connection element 30 establishes a mechanical connection between the first flat terminal contact 11 and the second flat terminal contact 21. The connection element 30 can be configured as, for example, a screw 31. The screw 31 is inserted through the terminal contacts 11, 21 within the overlapping region 5 where the terminal contacts 11, 21 overlap. For this purpose, a first cut-out portion 12 is configured in the first flat terminal contact 11, and a second cut-out portion 22 is configured in the second flat terminal contact 21. The screw 31 projects through the first cut-out portion 12 of the first flat terminal contact 11 and the second cut-out portion 22 of the second flat terminal contact 21. The screw 31 is spaced apart from and does not contact the first flat terminal contact 11 and the second flat terminal contact 21 within the cut-out portions 12, 22. A screw head 32 is configured at the first end of the screw 31. At the second end of the screw 31, which is opposite to the first end of the screw 31, the screw 31 is screwed into a mating thread 33. The mating thread 33 is configured in another component 35, for example, a screw bushing, a screw nut, or a housing. The screw head 32 covers the first cut-out portion 12 of the first flat terminal contact 11, and thus, when the screw 31 is screwed into the mating thread 33, exerts a force on the first flat terminal contact 11, and this force presses the first contact surface 15 of the first flat terminal contact 11 against the second contact surface 25 of the second flat terminal contact 21. The screw head 32 has, for example, a diameter larger than that of the first cut-out portion 12. Thus, by the screw 31, the first contact surface 15 of the first flat terminal contact 11 is pressed against the contact surface 25 of the second flat terminal contact 21. The two flat terminal contacts 11, 21 are arranged between the screw head and the mating thread 33. The connection element 30 may be made of, for example, a metal, such as steel.

[0022] Examples of an exemplary embodiment of the first flat terminal contact 11 are shown in FIGS. 1 to 3. The first flat terminal contact 11 in this exemplary embodiment is configured as a conductive rail (also called a bus bar). The first flat terminal contact 11 is composed of a conductive material, such as a metal, such as copper. The first electrical terminal contact 11 is, for example, punched and / or bent and / or embossed from sheet metal. The first flat terminal contact 11 has a first contact surface 15. The first contact surface 15 is configured in a planar shape and thus extends within a single plane. The first terminal contact 11 is configured with a first cutout 12 for receiving the connection element 30. In this exemplary embodiment, the first cutout 12 is punched in the first terminal contact 11. The first cutout 12 may be, for example, a hole for receiving a screw as the connection element 30. Further, around the first cutout 12, a structure 17 is embossed on the first terminal contact 11. The structure 17 is configured in a funnel shape. Due to the funnel-shaped structure 17, the edge of the first terminal contact 11 is bent so as to protrude from the plane of the first contact surface 15 around the first cutout 12. Thereby, an edge 16 is formed that is press-fitted into the second contact surface 25 when the first flat terminal contact 11 and the second flat terminal contact 21 are fixed, especially when screwed.

[0023] FIGS. 4 to 6 show how the conductive and mechanical connection between the flat terminal contacts 11 and 21 of the connection configuration 1 is established. FIG. 4 shows a cross-sectional view through an exemplary embodiment of the connection configuration 1 before fixing the first flat terminal contact 11 to the second flat terminal contact 21.

[0024] FIG. 5 shows an enlarged cross-sectional view through an exemplary embodiment of the connection configuration 1 when fixing the first flat terminal contact 11 to the second flat terminal contact 21. When tightening the screw 31, the edge 16 of the first flat terminal contact 11 abuts at its tip against the second contact surface 25 of the second flat terminal contact 21. The edge 16 faces the direction of the second contact surface 25. When the screw 31 is further tightened, the structure 17 embossed on the first flat terminal contact 11 is flattened and crushed, and the edge 16 breaks through different layers, for example an oxide layer, on the second contact surface 25. The arrow indicates the moving direction of the edge 16 on the second contact surface 25 when the screw is tightened and fixed and the structure 17 is flattened and crushed.

[0025] FIG. 6 shows a cross-sectional view through an exemplary embodiment of the connection configuration 1 after fixing the first flat terminal contact 11 to the second flat terminal contact 21. After the screw is tightened and fixed, the different layers (which may be, for example, oxide layers) at the two flat terminal contacts 11, 21 are crushed in the region of the edge 16 due to the relative movement of the edge 16 on the second contact surface 25. The edge 16 is press-fitted into the second contact surface 25. Here, the structure 17 is flattened and crushed almost or completely by the force of the screw connection, especially in the region under the screw head 32.

[0026] Of course, further embodiments and combinations of the illustrated exemplary embodiments are also possible.

Claims

1. A connection configuration (1), in particular a connection configuration (1) for use in an electric vehicle or a hybrid vehicle, comprising a first flat terminal contact (11) having a planar first contact surface (15) for making electrical contact with a first electrical and / or electronic component, and a second flat terminal contact (21) having a second contact surface (25) for making electrical contact with a second electrical and / or electronic component, wherein the first flat terminal contact (11) and the second flat terminal contact (21) overlap within an overlapping region (5), the first contact surface (15) faces the second contact surface (25), the first flat terminal contact (11) and the second flat terminal contact (21) are connected by a connecting element (30), and the first contact surface (15) is pressed against the second contact surface (25) by the connecting element (30). In the connection configuration (1), a structure (17) is embossed on the first flat terminal contact (11) such that an edge (16) of the first flat terminal contact (11) protrudes from a plane of the first contact surface (15), and the edge (16) protruding from the plane of the first contact surface (15) is press-fitted into the second contact surface (25) of the second flat terminal contact (21) by the connecting element (30), characterized in that it is a connection configuration (1).

2. A first cutout (12) is formed in the first terminal contact (11) within the overlapping region (5), the edge (16) is formed around the first cutout (12) by an edge of the first terminal contact (11), and the connecting element (30) protrudes through the first cutout (12) of the first flat terminal contact (11). The connection configuration according to claim 1, characterized in that

3. A funnel-shaped structure (17) embossed around the first cutout (12) is formed in the first terminal contact (11). The connection configuration according to claim 1 or 2, characterized in that

4. The connecting element (30) is configured as a screw (31), and the first flat terminal contact (11) and the second flat terminal contact (21) are connected to each other and pressed against each other by the screw (31). The connection configuration according to any one of claims 1 to 3, characterized in that

5. A second cutout portion (22) is formed in the second flat terminal contact (21), the connection element (30) protrudes through the second cutout portion (22), and the edge (16) around the first cutout portion (12) surrounds the second cutout portion (22), particularly in an annular shape, and is press-fitted into the second contact surface (25). The connection configuration according to any one of claims 2 to 4, characterized in that.

6. The connection configuration according to any one of claims 1 to 5, characterized in that the first flat terminal contact (11) is configured as a conductive rail and / or the second flat terminal contact (21) is configured as a conductive rail.

7. A method for manufacturing a connection configuration, comprising: preparing a first flat terminal contact (11) having a planar first contact surface (15), particularly a conductive rail; preparing a second flat terminal contact (21) having a second contact surface (25); embossing a structure (17) on the first flat terminal contact (11), wherein by the embossing of the structure (17), the edge (16) of the first flat terminal contact (11) is extruded from the plane of the planar first contact surface (15); placing the first contact surface (15) of the first flat terminal contact (11) on the second contact surface (25) of the second flat terminal contact (21); fixing the first flat terminal contact (11) to the second flat terminal contact (21) by a connection element (30), wherein the first contact surface (15) of the first flat terminal contact (11) is pressed against the second contact surface (25) of the second flat terminal contact (21), and the edge (16) of the first flat terminal contact (11) is press-fitted into the second contact surface (25) of the second flat terminal contact (21); A method, including.

8. A first cutout portion (12) is formed in the first flat terminal contact (11), the edge of the first flat terminal contact (11) around the first cutout portion (12) forms the edge (16), and when the first flat terminal contact (11) is fixed to the second flat terminal contact (21), the connection element (30), particularly a screw (31), is inserted through the first cutout portion (12). The method according to claim 7, characterized in that.

9. The method according to claim 8, characterized in that a funnel-shaped structure (17) is embossed around the first cut-out part (12), and the edge (16) is extruded annularly from the plane of the first contact surface (15).

10. When fixing the first flat terminal contact (11) to the second flat terminal contact (21), the edge (16) surrounds, in an annular manner, in particular the second cut-out part (22) of the second flat terminal contact (21), and is press-fitted into the second contact surface (25) of the second flat terminal contact (21), the method according to claim 8 or 9.

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