Electrical contact between conductors of a conductor cable and a connection partner, cell connection system for a motor vehicle battery module, and method for manufacturing the cell system

Abstract

To provide an improved method for establishing an electrical contact with a conductor cable, especially a flexible flat conductor.SOLUTION: In a device having an electrical contact between a conductor 3 of a flat conductor cable 1 and an electrical connection partner 2, the conductor 3 is embedded in the contact plane of an insulating sheath 4 of a flat conductor cable 1, and the insulating sheath 4 is peeled off from the conductor 3 on at least one contact surface at a predetermined contact portion 5, and the contact portion 5 of the conductor is bent outward from the contact plane beyond the insulating sheath 4, and the contact surface of the contact portion 5 of the conductor 3 rests on the electrical connection partner side 2 and is directly connected on the electrical connection partner side 2.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an arrangement of electrical contact between the conductors of a conductor cable, in particular a flexible flat conductor cable, and an electrical connection counterpart, and to a method for manufacturing a device having electrical contact between the conductors of a conductor cable, in particular a flexible flat conductor cable, and an electrical contact.

[0002] The invention also relates to a cell connection system for an automotive battery module, in particular for electric or hybrid vehicles, comprising contact elements for receiving electrodes of at least one battery cell and a sensing cable comprising wires electrically and mechanically connecting the cell monitoring unit and the contact elements. The invention also relates to a method for attaching the sensing cable to the contact elements of such a cell connection system. [Background technology]

[0003] An electrical connection arrangement is known in which a flexible circuit arrangement is connected to a planar substrate, the flexible circuit arrangement comprising a circuit arrangement in the form of a flexible, flat strip, at least one longitudinal end of which is folded back on itself to form a resilient spring, with the top surface of the folded-back area positioned adjacent to the surface of the unfolded area of ​​the strip (EP 0 699 353 B1). The conductors have an uninsulated surface facing away from the folded surface, allowing them to be resiliently pressed against the conductive traces of the planar substrate. In a further embodiment, the flexible flat conductor cable has recesses in the direction of the contacts, the recesses being located above the contacts. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] European Patent No. 0699353B1 Summary of the Invention [Problem to be solved by the invention]

[0005] A first object of the present invention is to provide an improved device for making an electrical contact between the conductors of a conductor cable, in particular a flexible flat conductor cable, and a connection partner, and an improved method for establishing an electrical contact between the electrical contact and the conductor of a conductor cable, in particular a flexible flat conductor cable.

[0006] Cell connection systems are known in the art, for example from DE 102014219178 A1, and are used to connect multiple battery cells to one another in battery modules of electric or hybrid vehicles. To be able to monitor the state of the cells, parameters, such as cell temperature, capacity, or load state, must be monitored. To do this, a monitor unit is electrically connected to each of the cells via an electrical cable via contact elements of the cell connection system. The monitor unit can also be used to balance the cells. In this case, this unit may also be called a monitor and balancing unit.

[0007] To ensure a sufficiently long lifespan of the battery module, it is important to achieve connections that are electrically and mechanically stable, even when vibrations, shocks, etc., in daily use exert mechanical stress on the connections. The connection between the cable and the cell connection system is realized using ultrasonic welding.

[0008] Automotive manufacturing places strict requirements on the reliability of connections. A 90° peel tension test, well known in the art, is performed in which the connection must be able to withstand a force of at least 7 N before the connection breaks. In the 90° peel tension test, a pre-connected cable is bent 90° until it is perpendicular to the contact surface. The force at which the connection peels is measured. The mechanical capacity characteristic value Cmk is greater than 1.67.

[0009] It is therefore a second object of the present invention to improve the mechanical reliability and therefore the electrical condition and electrical connection, and thereby the monitorability of the battery. [Means for solving the problem]

[0010] This first object is achieved by a device having an electrical contact between a conductor of a conductor cable, particularly a flexible flat conductor cable, and a counterpart electrical connection. The conductor is embedded in the insulating sheath of the conductor cable at a contact plane. At least one contact surface of the conductor is stripped from the conductor at a predetermined contact point. The contact surface of the conductor is bent out of the contact plane, particularly beyond the insulating sheath. The contact surface of the conductor contact rests on the counterpart electrical connection and establishes direct electrical contact with the counterpart electrical connection. Furthermore, the contact surface of the conductor is connected to the counterpart electrical connection in the region of the contact point.

[0011] The connection can be implemented by a welded connection, in particular a laser welded connection, or an ultrasonic or ultrasonic welded connection.

[0012] The connection partner can be, for example, a conductive strip, a conductive plate, or any other type of contact element.

[0013] In the region of the contact area, the insulating sheath of the conductor cable is not bent toward the mating electrical connection. The conductor cable can, for example, be flat in the region of the contact area and transition to a planar longitudinal transition before and after the contact area to the adjacent region of the conductor cable. This prevents additional mechanical stress on the conductor cable and its other conductors in the region of the contact area. In this embodiment, since only the conductors are bent toward the mating electrical connection, the processing effort, especially the mechanical processing effort, for establishing the electrical contact is reduced. Furthermore, multiple electrical contacts of adjacent conductors that are offset from one another in the longitudinal direction of the conductor cable can be achieved in this way, since no bending of the conductor cable toward the mating electrical connection is required. The conductor cable can be configured to be planar and smooth in the area of ​​the contact, so that a fully planar support of the conductor cable is obtained on the connection partner.

[0014] In one embodiment, the contact portion of the conductor has a contact surface bent in a first direction from the contact plane beyond the outer surface of the insulating sheath. The contact surface of the contact portion of the conductor then rests on the electrical connection counterpart and is directly connected to the electrical connection counterpart. The conductor cable is bent in a second direction in the area of ​​the contact portion, i.e., in the insulating sheath of the conductor cable immediately outside the contact portion, where the second direction is opposite to the first direction. Due to the bending of the conductor cable, a preload is applied to the conductor in a direction opposite to the bend of the conductor. Therefore, a preload can be applied to the contact portion of the conductor in a direction toward the connection counterpart, and the contact portion can be pressed onto the electrical connection counterpart with a higher pressing force. In this way, the electrical connection between the conductor and the electrical connection partner can be established with higher quality and in a simpler manner. In particular, the conductor itself does not need to be pressed onto the electrical connection partner by a mechanical tool in the contact area. For example, in the case of laser-welded or ultrasonic-welded connections, the electrical and mechanical connection between the electrical connection partner and the conductor can be further improved in this way. Furthermore, in this embodiment, there is more free space in the contact area of ​​the conductor during assembly. Therefore, the connection between the conductor and the connection partner can be established more easily.

[0015] In a further embodiment, the bending of the contact can be realized in such a way that no stretching of the conductor occurs in the bent area, thereby preventing a reduction in the cross section and, as a result, mechanical damage to the contact.

[0016] In a further embodiment, the contact surface of the contact part is connected to the electrical connection partner by several contact points. In this way, the mechanical connection between the conductor and the electrical connection partner is improved. Furthermore, the electrical connection between the conductor and the electrical connection partner is also improved. For example, the contact points can be created with the aid of laser welding. In this embodiment, the contact points can be created by a laser weld seam formed in a spiral shape. However, other shapes and / or methods for realizing the contact points can also be used, such as ultrasonic welding.

[0017] In a further embodiment, the contact portion of the conductor is divided into two partial sections perpendicular to the longitudinal direction of the conductor cable, in which at least one partial section of the conductor rests with its contact surface on a counterpart electrical connection and is mechanically and electrically connected to the counterpart electrical connection.

[0018] In a further embodiment, at least a portion of the electrical conductor contacts is embedded in an insulating material, in particular an electrically insulating potting material, thereby achieving both electrical insulation of the electrical conductor contacts and mechanical protection of the electrical conductor contacts.

[0019] In a further embodiment, the electrical connection partner and the conductor can be formed from different conductive materials, in particular, the electrical connection partner can be formed from aluminum and the conductor from copper. The inventive device described achieves good electrical contact between the conductor and the connection partner even when using different conductive materials, in particular when using copper and aluminum. Laser-welded or ultrasonically welded connections are particularly suitable for establishing a good electrical connection and a sufficient mechanical connection between aluminum and copper.

[0020] In one embodiment, the electrical connection counterpart is a contact of an electrical terminal of a battery, in particular an automobile battery, which may for example be part of an arrangement of several batteries, in which case the electrical conductor is used, for example, to perform a voltage measurement of the battery.

[0021] In a further embodiment, the contact area can be at least partially embossed on the mating side. Embossing has the advantage that the two components can be connected during manufacture without the need for an additional clamping step to hold the two components together. This allows for a more efficient manufacturing process while still achieving a sufficiently high mechanical strength.

[0022] In a further embodiment, the interface between the contact and the electrical connection partner can be positioned below the surface of the connection partner directly adjacent to the interface, in particular at most about 0.1 to 0.5 mm below the surface, more particularly at most about 0.2 to 0.3 mm below the surface, which further improves the mechanical strength.

[0023] In a further embodiment, the surface of the contact and the surface of the electrical connection partner may be provided with mating surface area-enhancing features. An embossing stamp with a structured surface, for example with a plurality of regularly arranged pyramidal protrusions on its surface, is used to transfer a pattern onto the contact, which extends all the way to the surface of the surface of the contact that mates with the connection partner. This can further improve the attachment force before the final connection step, for example by welding.

[0024] The second object of the present invention is achieved by a cell connection system for an automotive battery module for an electric or hybrid vehicle, comprising a device as described above, wherein the electrical connection counterpart comprises contact elements for receiving electrodes of at least one battery cell, and the conductor cable, in particular a flexible flat conductor cable, comprises a sensing cable with wires electrically and mechanically connecting the cell monitoring unit and the contact elements, characterized in that the surfaces of the wires and / or contact elements are provided with surface area-increasing features in the areas of contact with each other. The increased surface area compared to a smooth surface allows for increased mechanical contact forces due to a larger joining surface. This embodiment achieves the first and second objects of the present invention.

[0025] The second object of the present invention is also achieved by a cell connection system for an automotive battery module, in particular for an electric or hybrid vehicle, as set forth in claim 14. The cell connection system comprises contact elements for receiving electrodes of at least one battery cell and a sensing cable comprising wires electrically and mechanically connecting the cell monitoring unit and the contact elements. This is characterized in that the surfaces of the wires and / or the contact elements are provided with surface area-increasing features in the area of ​​contact with each other. The increased surface area compared to a smooth surface allows for increased mechanical contact forces due to a larger joining surface.

[0026] According to an inventive variant, the surface area increasing mechanism may comprise a plurality of bumps. By forming bumps on the surface, the contact surface area can be easily increased.

[0027] According to an inventive variant, the ridges extend in straight lines, in particular parallel to the long sides of the area of ​​contact. Such a pattern is easy to realize.

[0028] According to an inventive variant, the protuberances may have a pyramidal shape, in particular a sharp-pointed pyramidal shape, such a pattern providing a further increase in surface area and contact flanks in various directions.

[0029] According to an inventive variant, the pyramidal shape may have a rectangular, in particular square, base shape and a flank angle of approximately 30° to 60°, in particular 45°. According to an inventive variant, the ridges have a height of at most 0.5 mm, in particular at most 0.2 mm, more particularly at most 0.1 mm. According to an inventive variant, the apexes of directly adjacent ridges may be at a distance of at most 5 mm, in particular at most 0.2 mm, from each other. These dimensions result in improved contact forces compared to flat, smooth surfaces.

[0030] According to an inventive variant, the wire and the contact element can be welded together, in particular ultrasonically welded together. The surface area increasing mechanism allows for a higher material transfer between the welded parts, resulting in a higher and more stable welding force.

[0031] According to an inventive variant, the contact elements and the wires can be made of different materials, in particular aluminum and copper, respectively. The invention makes it possible to combine two different materials and obtain a satisfactory connection. When using a material with a thin electrically insulating oxide layer on its surface, it is preferable to realize a surface area-increasing mechanism at least on this material.

[0032] According to an inventive variant, the cell connection system can have a plurality of contact elements arranged in two rows that allow a series electrical connection of the battery cells, in which case one of the opposing contact elements is electrically and mechanically connected to the wires of the sensing cable.

[0033] According to an inventive variant, the sensing cable can comprise a plurality of parallel wires, in particular flat wires, embedded in an electrical insulating material, each one of the wires connected to a contact element being electrically and mechanically connected to another one of the contact elements, the electrical insulating material being removed in the area of ​​each contact.

[0034] Furthermore, in relation to the first object of the present invention, a method for producing a device having an electrical contact between conductors of a conductor cable, in particular a flexible flat conductor cable, and an electrical connection partner is provided according to claim 25. For this purpose, a conductor cable, in particular a flexible flat conductor cable, is provided, which comprises at least one, in particular several conductors embedded in the insulating sheath of the conductor cable at a contact plane. At least one of the conductors has its insulating sheath stripped off at a predetermined contact point on at least one contact surface. For example, the insulating sheath can also be stripped off from the entire surface of the conductor at the contact point. The method comprises the steps of: a) bending contact surfaces of the contact portions of the conductors out of the contact plane onto at least one outer surface of the insulating sheath, step b) placing a conductor cable, in particular a flexible flat conductor cable, on a connection counterpart, in particular after bending the conductors out of the contact plane, step c) placing the contact surfaces of the contact portions of the conductors on the electrical connection counterpart, and then step d) connecting the contact surfaces of the contact portions of the conductors to the electrical connection counterpart. In one embodiment, in step d) the contact surfaces of the conductors are welded to the electrical connection counterpart.

[0035] In this method, it is advantageous if the insulating sheath does not bend in the region of the contact towards the connection partner, which leaves more space for connecting the conductor to the connection partner. In the region of the contact, the insulating sheath of the conductor cable can either be arranged flat against the upper surface of the electrical contact or can have a bend extending away from the electrical connection partner. Both embodiments ensure a simple and reliable electrical contact between the conductor and the electrical connection partner.

[0036] In one embodiment, the contact surface of the electrical conductor is welded to the electrical connection partner with the aid of a laser. For example, one or more contact points or weld spots can be formed between the electrical conductor and the electrical connection partner. In particular, the laser can form a laser seam, which can be, for example, spiral-shaped, to form the contact point. Alternatively, ultrasonic welding can be used.

[0037] According to one embodiment, the method may include a step of using a pressure wave, particularly a liquid or solid-to-gas phase transition, and / or an explosion in a pressure-generating material to press the contact surfaces of the conductors against the electrical connection partner before welding. The creation of such a pressure wave to press the contact against the electrical connection partner has the advantage of enabling a manufacturing process without clamping or at least with reduced clamping, since clamping is only required to achieve the first weld spot at most. The pressure-generating material may be the same material as that used to achieve the connection, such as a welding material or adhesive. Alternatively, it may be a flammable material, such as CH3NO2.

[0038] According to some embodiments, the pressure wave generation step can include applying one or more laser pulses to a pressure-generating material, particularly using the same laser as for welding. In this case, the same laser used to achieve welding can be used to generate the pressure wave. A first shot can be used to ignite droplets of a combustible material, or one or more pulses can be used to vaporize small droplets of a phase-change material, such as a weld or adhesive. Subsequent pulses can then be used to achieve welding between the contact and the electrical connection partner.

[0039] According to certain embodiments, the pressure-creating material may be provided in the form of a droplet or cladding on or over the surface of the contact. By providing the pressure-creating material close to the contact, the depression effect that occurs after the generation of the pressure wave can be optimized.

[0040] Until the conductor is placed on the electrical connection partner and until the conductor is welded to the connection partner, the conductor cable, in one embodiment, is bent in a second direction in the area of ​​the contact, i.e., in the insulating sheath of the conductor cable immediately outside the contact. The second direction is opposite to the first direction in which the electrical connection partner is bent. By forming a bend in the conductor cable in a direction opposite to the conductor's bending direction, a preload is generated for the conductor, which allows for easier and better electrical contact between the conductor and the electrical connection partner. This means that a special hold-down system no longer needs to be used, at least partially or in some cases completely.

[0041] In a further embodiment, the contact portion of the electrical conductor is divided perpendicularly to the longitudinal direction into a first partial section and a second partial section. At least one first partial section of the electrical conductor is bent out of the contact plane. Depending on the embodiment selected, the electrical conductor can first be bent out of the contact plane, and then the electrical conductor can be divided into two partial sections in the region of the contact portion. At least one first partial section is placed on the connection partner and welded to the connection partner by means of the contact surface. Depending on the embodiment selected, both partial sections are placed on the electrical connection partner and connected to the electrical connection partner so as to be electrically conductive.

[0042] The advantages of dividing the conductor into two partial sections in the contact area are that the actual conductor cable can be laid out in a plane, the stripped conductor can be configured as a spring element that is hardly stretched and therefore does not reduce its cross section, and the conductor can be bent out of the contact plane more easily and with less mechanical stress. In this way, even thick conductors can be bent out of the contact plane with little stress. Thanks to the partial section, the conductor can be guided out of the insulating material of the conductor cable with little mechanical deformation, even in the case of a thick insulating sheath with a corresponding bend. This reduces the mechanical stress on the conductor in the contact area, especially in the case of a thicker insulating sheath. In this way, mechanical stresses and deformations of the conductor are reduced, which results in an improved electrical contact in terms of a long life cycle. In particular, the mechanical joint of the conductor can be protected in this way and can be less damaged when the conductor is bent out of the contact plane. This also improves the long-term stability of the electrical contact. Furthermore, the cross section of the conductor in the area of ​​the contact is less affected. In this case, the parameters for connecting the conductor to the electrical connection partner, in particular for welding, can be set more precisely. This also improves the quality of both the mechanical and electrical contact between the conductor and the electrical connection partner. Furthermore, this also results in an increased long-term stability of the electrical contact between the conductor and the electrical connection partner. This is particularly advantageous for applications in the automotive sector, since automobiles are exposed to mechanical vibration stresses during operation and thermal loads, especially strong temperature fluctuations. The quality of the mechanical and electrical connection between the electrical conductor and its electrical connection counterpart in the battery is particularly important when establishing contact with the electrical contacts of the automobile battery.

[0043] According to one embodiment, steps a) and c) can be realized simultaneously by embossing the contacts on the electrical connection partner. In this case, the conductor cable with the contacts is placed on the electrical connection partner, and then a pressing punch is used to bend the contacts towards the surface of the electrical connection partner and emboss them there. In this case, it is possible to hold the two parts together in one step, so that no additional clamping of the two parts before welding is necessary.

[0044] According to a variant, a pressing punch with a flat or structured surface can be used. A structured surface, for example a regularly arranged pyramidal shape, can be used to provide a surface pattern on the surface of the contact that actually faces the surface of the electrical connection counterpart. This pattern is then embossed in the same way to form a mating pattern on the surface of the counterpart. The larger surface area can improve the connection force between the two parts.

[0045] The second object of the present invention, combined with the first object, is achieved by a method as described above, in which a cell connection system according to the second object of the present invention is obtained, in which the surface area increasing features are realized using a press punch or scratching tool or by laser structuring, thus improving the electrical contact when the electrical connection between the two components is realized.

[0046] The second object of the present invention is also achieved by a method for attaching a sensing cable to a contact element of a cell monitoring system according to the embodiment described above, as claimed in claim 35. The method comprises the step of realizing surface area-increasing features using a press punch or scratching tool or by laser structuring. This method makes it possible to obtain an improved connection force compared to connections between smooth surfaces. At the same time, the structuring of the surface makes it possible to break down thin oxide layers on the surfaces of the wires and / or contact elements. Thus, when an electrical connection between the two components is realized, the electrical contact is improved.

[0047] According to an inventive variant, a pressing punch or scratching tool or laser structuring is applied to the faces of the wires and / or contact elements on which the electrical and mechanical connection is to be established.

[0048] According to an inventive variant, the electrical and mechanical connection can be achieved via welding, in particular ultrasonic welding. The surface area increasing mechanism allows for a higher material transfer between the welded parts, resulting in a higher and more stable welding force.

[0049] According to further variants, any embodiment and variants relating to the first inventive object may be combined with any embodiment and variants relating to the second inventive object.

[0050] The present invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which features of the invention are identified by reference characters. [Brief explanation of the drawings]

[0051] [Figure 1] 1 is a schematic perspective representation of a flexible flat conductor cable on an electrical contact. [Figure 2] 2 is a schematic, partially cross-sectional representation of the flexible flat conductor cable and electrical contacts according to FIG. 1; [Figure 3] 2 is a longitudinal cross-sectional view of the flexible flat conductor cable of FIG. 1. [Figure 4] 1A-1C illustrate an embodiment of a flexible flat conductor cable having conductors that are bent outward. [Figure 5] 5 is a top view of the flexible flat conductor cable according to FIG. 4, with the conductors resting on the electrical connection partner. [Figure 6] 1 is a top view of a partial section of a flexible flat conductor cable in which conductors are connected to their electrical connection counterparts by contact points or weld spots. [Figure 7] 4 is a schematic representation of a further embodiment of a flexible flat conductor cable, in which the conductor is connected with two partial sections of an electrical connection partner. [Figure 8] 1 is a perspective representation of a flexible flat conductor cable with two partial sections, looking at the underside of the flexible flat conductor cable, with the two partial sections of the conductors being pulled out of the insulating sheath. [Figure 9] 1 is a perspective representation of a flexible flat conductor cable with two partial sections of the conductor resting on an electrical connection partner. [Figure 10] FIG. 8 is a perspective view with two partial sections of the configuration of FIG. 7. [Figure 11] 8 is a partial cross-sectional representation of the flexible flat conductor cable and electrical contacts according to FIG. 7. [Figure 12] 12 shows the configuration of FIG. 11 in which partial sections of the conductors of the flexible flat conductor cable are embedded in insulation. [Figure 13]1 is a schematic representation of a battery with its electrical terminals in contact with the conductors of a flexible flat conductor cable. [Figure 14] 14a to 14e are schematic representations of a method for bending a contact onto an electrical connection counter element according to an embodiment of the present invention. [Figure 15] 15a to 15c are schematic representations of a method for embossing contacts into electrical connection counter elements according to an embodiment of the present invention. [Figure 16] 1 illustrates a cell connection system for an automotive battery module according to the present invention. [Figure 17a] 10A and 10B are schematic diagrams illustrating modified surface area increasing mechanisms according to the present invention. [Figure 17b] 10A and 10B are schematic diagrams illustrating modified surface area increasing mechanisms according to the present invention. [Figure 17c] 10A and 10B are schematic diagrams illustrating modified surface area increasing mechanisms according to the present invention. [Figure 18] FIG. 10 shows a pressing punch with sharp pyramids for forming surface area increasing features in the wire. [Figure 19] FIG. 1 illustrates the peel force of four working examples according to the present invention compared to a comparative example having a smooth surface. DETAILED DESCRIPTION OF THE INVENTION

[0052] 1 to 15 relate to an embodiment related to the first object of the present invention.

[0053] 1 shows a schematic representation of a conductor cable 1 resting on an electrical connection partner 2. Although a flexible flat conductor cable is used in this and subsequent embodiments, the invention is not limited thereto and any type of conductor cable having at least one conductor embedded in an insulating sheath may be used.

[0054] The flexible flat conductor cable 1 comprises several conductors 3, 10 embedded in an insulating sheath 4. In the embodiment shown, the flexible flat conductor cable 1 comprises nine conductors 3, 10 embedded in the insulating sheath 4. At the contact areas 5, the conductors 3 are stripped of their insulating sheath 4. This means that in the region of the contact areas 5, the conductors 3 are freed on all sides from the material of the insulating sheath 4. Furthermore, the conductors 3 rest with the contact areas and one contact surface on the electrical connection partner 2.

[0055] 2 shows the configuration of FIG. 1 in a schematic partial cross-sectional view along the conductor 3. It can be clearly seen that the conductor 3 is free of its insulating sheath 4 at the contact portion 5. Furthermore, the conductor 3 is placed with its contact portion 5 and one contact surface on the upper surface of the electrical connection counterpart 2. The remaining conductors 10 of the flexible flat conductor cable 1 are completely embedded in the insulating sheath. Depending on the embodiment selected, the insulating material of the insulating sheath can also be stripped from a further conductor 10 at the contact portion and this conductor 10 can be placed with one contact surface on the electrical connection counterpart 2. When viewed in the longitudinal direction of the flexible flat conductor cable 1, the stripped contact portions of the further conductors 10 can be located at the same height or in different longitudinal sections of the flexible flat conductor cable 1.

[0056] Figure 3 shows a schematic cross section of the arrangement of figure 1. The insulating sheath 4 is provided with a recess 9 in the area of ​​the contact area 5.

[0057] In FIG. 3 , it can be seen that the flexible flat conductor cable 1 rests laterally on the contact area 5, with the insulating sheath 4 resting on the upper surface 8 of the electrical connection partner 2 of the electrical contact. However, in the region of the contact area 5, the flexible flat conductor cable 1 is bent upward in a second direction 11 from the upper surface 8 of the electrical contact 2. Furthermore, in the region of the contact area 5, the conductor 3 is bent downward in a first direction 12 from the contact plane 13 of the insulating sheath 4 towards the electrical connection partner 2. The contact plane 13, in which the conductors 3, 10 of the flexible flat conductor cable are arranged within the insulating sheath 4, is typically formed in the center of the insulating sheath 4. The bending of the conductor 3 towards the connection partner 2 allows the contact surface 7 of the conductor 3 to rest firmly on the upper surface 8 of the electrical contact 2. Furthermore, the cable portion 14 that is bent upward in the second direction 11 can be used to pretension the contact portions 5 of the power transmission conductors 3 in the direction of the electrical connection counterpart 2. Additionally, this results in easier bending of the conductors 3 in the direction of the connection counterpart 2 without the need to deform the conductors 3.

[0058] Depending on the embodiment chosen, the flexible flat conductor cable 1 may also lie flat on the connection partner 2 in the region of the contacts 5. In this embodiment, however, the conductors 3 are deformed, in particular stretched, so as to be able to sag in the direction towards the connection partner 2.

[0059] 4 shows in a perspective representation a further embodiment of a flexible flat conductor cable 1, in which the conductors 3 are bent in a first direction 12 and emerge from the insulating sheath 4. At the same time, the cable portion 14, in the region of the contact portion 5, has a bent shape in a second direction 11, which is configured opposite to the first direction 12, relative to the remaining part of the flat flexible conductor cable 1 which extends in a plane.

[0060] 5 shows the flexible flat conductor cable 1 of FIG. 4 placed on the electrical connection partner 2. Here, the contact portions 5 of the conductors 3 rest on the upper surface 8 of the electrical connection partner 2. In this embodiment, the flexible flat conductor cable 1 comprises six conductors 3, 10, which are shown by dotted lines. The conductors 3 are not yet mechanically connected to the electrical connection partner 2 by their contact portions 5, but merely rest on the upper surface 8 of the electrical connection partner 2. In a subsequent method step, the contact portions 5 of the conductors 3 are connected to the upper surface 8 of the electrical connection partner 2. For example, a welded connection, an adhesive connection, or a soldered connection can be used for this purpose. The welded connection can in particular be a laser welded connection. The welding of the contact portion 5 of the electrical conductor 3 to the upper surface 8 of the electrical contact 2 is achieved by means of a laser beam. Depending on the embodiment selected, one or more weld spots 15 can be used, as shown in Figure 6. Ultrasonic welding can also be used instead of laser welding.

[0061] 6 shows an enlarged view of the configuration of FIG. 5 in detail, in which the electrical conductor 3 is welded to the electrical connection partner 2 using two welding spots 15, 16. Depending on the embodiment selected, only one welding spot or more than two welding spots can be used. Furthermore, instead of a round welding spot, an elongated, rectangular, or jagged weld connection can also be selected. For example, the weld connection can be created with the help of a laser beam guided in a spiral shape from the center point of the welding spot to the edge region of the welding spot.

[0062] Figure 7 shows a perspective representation of a further device with electrical contact between the conductors 3 of a flexible flat conductor cable 1 and a counterpart electrical connection 2. The representation in Figure 7 is a schematic view from above on the flexible flat conductor cable 1, which is shown placed on the counterpart electrical connection 2. Recesses 9 are introduced in the insulating sheath 4 of the flexible flat conductor cable 1, such that the insulation of the insulating sheath 4 is stripped from the contact portions 5 of the conductors 3. Furthermore, the contact portions 5 of the conductors 3 are divided into a first partial section 17 and a second partial section 18. The first partial section 17 and the second partial section 18 are guided downwards relative to the flexible flat conductor cable 1, out of the contact plane of the insulating sheath 4, and rest on the upper surface 8 of the electrical connection partner 2. Furthermore, each partial section 17, 18 is electrically and mechanically connected to the electrical connection partner 2 by two corresponding welding spots 15, 16, respectively. The welding spots 15, 16 can be produced, for example, by laser welding.

[0063] 8 shows the flexible flat conductor cable 1 of FIG. 7 before it is placed on the electrical connection partner 2. Here, partial sections 17, 18 of the conductors 3 that are bent out from the insulating sheath 4 of the flexible flat conductor cable 1 are easily recognizable. Each of the partial sections 17, 18 is divided into a first section 19 and a second section 20. The first section 19 extends out from the contact plane 13 of the insulating sheath 4 and is inclined at an angle relative to the contact plane 13. The first section 19 transitions into the second section 20 via a bend 21. The second section 20 has a smaller inclination relative to the contact plane 13 and can be arranged, for example, parallel to the plane of the flexible flat conductor cable 1. The first partial section 17 and the second partial section 18 can have the same shape, in which case the first sections 19 each have the same angle to the plane of the flexible flat conductor cable 1, and the second sections 20 are arranged parallel to each other. This shape of the partial sections 17, 18 allows for a simpler and improved realization of electrical contact between the conductor 3 and the electrical connection partner 2.

[0064] Due to the shape of the partial sections 17, 18, the second sections 20 of the partial sections 17, 18 have a relatively large contact surface with the upper surface 8 of the electrical contact 2 when the flexible flat conductor cable 1 is placed on the electrical connection partner 2. The second sections 20 of the partial sections 17, 18 therefore extend in contact with the electrical connection partner 2 over a large area. A large contact surface is thus obtained. Furthermore, a large surface is available for forming the connection between the connection partner 2 and the partial sections 17, 18.

[0065] Figure 9 shows the flexible flat conductor cable 1 from Figure 8, which is placed on the electrical connection partner 2 so that the partial sections 17, 18 rest with the second section 20 on the top surface 8 of the electrical connection partner 2.

[0066] FIG. 10 shows the arrangement of FIG. 9 after the partial sections 17 , 18 have each been welded to the electrical connection partner 2 using welding spots 15 .

[0067] 11 shows a schematic, partially cross-sectional representation of the configuration of FIG. 10 in which the formation of the first section 19 and the second section 20 of the partial sections 17, 18 can be clearly seen. In the embodiment of FIG. 11, two welding spots 15, 16 are formed in the second section 20 of the partial sections 17, 18, which connect the partial sections 17, 18 to the electrical connection partner 2.

[0068] 12 shows a schematic partial cross-section through a further embodiment of FIG. 7. In this embodiment, the first partial section 17 and the second partial section 18 are embedded in an insulating material 22. The insulating material 22 can be formed, for example, from an electrically insulating potting material, for example a plastic material. For example, the partial sections 17, 18, from which the insulating sheath 4 has been stripped, can be at least partially, in particular completely, covered with the insulating material 22. Safe and reliable electrical insulation of the partial sections 17, 18 is thus achieved.

[0069] Similarly, the contact portions 5 of the embodiments of Figures 1 to 6 may be covered with an insulating material, in particular with an electrically insulating potting material.

[0070] Depending on the embodiment selected, the electrical connection partner 2 and the electrical conductor 3 can be made of different materials. For example, the electrical connection partner 2 can be made of aluminum. Furthermore, the electrical conductor 3 can be made of copper.

[0071] FIG. 13 shows, in a schematic representation, the configuration of a battery system having several batteries 23, 24, 25, each having an electrical terminal, several terminals 26, 27, 28 shown diagrammatically as rectangles. Furthermore, a flexible flat conductor cable 1 is routed through all of the batteries 23, 24, 25. The flexible flat conductor cable 1 comprises a conductor 3, a further conductor 10, and an additional conductor 29. Although the conductors 3, 10, 29 are shown diagrammatically as only partial segments, they are formed along the entire flexible flat conductor cable 1. In the illustrated embodiment, the conductor 3 is conductively connected to a first terminal 26 of the first battery 23, the further conductor 10 to a second terminal 27 of the second battery 24, and the additional conductor 29 to a third terminal 28 of the third battery 25, in accordance with one of the embodiments of FIGS. 1 to 12 already described. For example, this battery configuration may be provided in a vehicle. The battery's electrical terminals 26, 27, 28 correspond to electrical contacts. Depending on the embodiment selected, only one battery may be provided with electrical terminals that are connected to the conductors of the flexible flat conductor cable. The electrical contacts of the battery's electrical terminals may be used to sense the battery's voltage for balancing purposes and / or the battery's temperature. The battery has two terminals that are not shown in this schematic representation.

[0072] Figures 14a to 14e show further embodiments according to the invention. Reference will be made to features having the same reference numbers as already used in the description of the above figures, but they will not be described again in detail.

[0073] 14a shows a schematic cross-sectional side view of a conductor cable, here in the exemplary form of a flexible flat conductor cable 1, with its insulating sheath 4 arranged on the electrical connection partner 2. The conductors 3 are arranged over their entire length in a contact plane 13. The contact portions 5 have not yet been bent towards the surface 8 of the electrical connection partner 2. On the surface 33 of the layer opposite the contact surface 7, droplets 31 of welding material or a combustible or explosive material adhesive are arranged. Instead of a liquid material, it is also possible to use a suitable solid material, for example in the form of an explosive cladding provided on the surface 33 of the layer opposite the contact surface 7.

[0074] FIG. 14 b shows a laser pulse 35 emitted by a pulsed laser 37 striking a droplet 31 .

[0075] Depending on the material used, the droplets 31 will either vaporize immediately or burn or explode due to energy transfer. A single laser pulse may be sufficient for this. In some applications, multiple pulses may be required.

[0076] Following the phase transition, a pressure wave 39 is formed which rapidly expands and presses the contact surface 7 of the contact portion 5 towards the surface 8 of the electrical connection counterpart 2. This is shown in Figure 14c.

[0077] Next, as shown in FIG. 14d, while the contact portion 5 is still being pressed down by the pressure wave 39, a further laser pulse 41 is emitted by the laser 37, which strikes the contact portion 5 and welds it to the electrical connection partner 2 within the welding area 42.

[0078] Figure 14e shows the final result: the contact 5 is bent out of the contact plane 13 and is electrically and mechanically connected to the electrical connection counterpart 2. By pressing the contact 5 down at the moment of interaction with the laser, a high-quality weld 43 can be obtained.

[0079] Figures 15a to 15c show further embodiments according to the invention. Reference will be made to features having the same reference numbers as already used in the description of the above figures, but they will not be described again in detail.

[0080] 15a shows a schematic side cross-sectional view of a conductor cable, here in the exemplary form of a flexible flat conductor cable 1, with its insulating sheath 4 arranged on a counterpart electrical connection 2. The conductors 3 are arranged over their entire length in a contact plane 13. The contact portions 5 have not yet been bent towards the surface 8 of the counterpart electrical connection 2. A pressing punch 51 is arranged directly above the contact portions 5. The pressing surface 53 may be a flat surface with or without chamfered edges.

[0081] A variation of this embodiment is shown in the enlarged section 55. In this case, the pressing surface 57 has a structured surface 59, for example a plurality of pyramidal shapes 61 regularly arranged across the pressing surface 57.

[0082] 15b shows the result after the pressing punch 51 has been moved downwards and pressed against the contact 5 and the surface 8 of the electrical connection counterpart 2. Under the pressure of the pressing punch 51, at least a part 63 of the contact 5 is bent and embossed into the surface 65 of the electrical connection counterpart 2. The height 67 of the joining plane 69 of the imprint compared to the surface 8 directly adjacent to the embossed area 71 is of the order of 0.1 to 0.5 mm, preferably 0.2 to 0.4 mm.

[0083] The enlarged area 73 shows the mating surface 75 when using a pressing punch 51 having a structured surface 59 as shown in Figure 15a, where the contact part 5 and the electrical connection counterpart 2 have mating surface area increasing features 77 at the mating surface 75.

[0084] Embossing has the advantage that the two parts are positioned relative to each other without the need for additional clamping means, which simplifies the manufacturing process.

[0085] Next, as shown in Figure 15c, a laser 79 is used to weld the contact 5 to the electrical connection counterpart 2. One or more weld spots 81 can be realized within the embossed area 71, as in the previous embodiment. Alternatively, ultrasonic welding may be used instead.

[0086] Thus, in this embodiment, bending and positioning of the contact surface onto the surface 8 of the electrical connection partner 2 is achieved in one step.

[0087] FIG. 16 shows a cell connection system 100 used for a battery module, which is related to the second object of the present invention.

[0088] Such a cell connection system 100 is used in an electric or hybrid vehicle, and accepts battery cells connected in parallel and in series to provide energy to the vehicle's electric motor.

[0089] The cell connection system 100 comprises a support 103, typically made of plastic, on the surface of which are mounted, for example using a snap-fit ​​connection, two rows 105, 107 of contact elements 109 and 111, typically made of aluminum. The contact elements 109, 111 correspond to the electrical connection counterparts 2 of the above-described embodiment.

[0090] In this embodiment, each contact element 109 includes two contact element sections 109a, 109b, and each contact element 111 includes two contact element sections 111a, 111b. The two contact element sections 109a, 109b are electrically connected to each other. The contact element sections 111a, 111b are also electrically connected to each other.

[0091] In use, the battery cells are placed on the contacts with their positive and negative electrodes facing each other, with one battery cell on the contact element sections 109a, 111a and one battery cell on the contact element sections 109b, 111b. This results in the battery cells being arranged in parallel. In alternative embodiments, fewer or more than two cells may be arranged in parallel. The battery cells are typically welded to the contact element sections to ensure a reliable electrical and mechanical connection.

[0092] In column 105, adjacent contact elements 113 are electrically isolated from contact elements 109 via isolation elements 115, which are typically formed integrally with the support. In the opposing column, adjacent contact elements 117 are electrically connected to contact elements 111. Thus, battery cells mounted on contact elements 113 and 117 are mounted in series with battery cells mounted on contact elements 109 and 111. This configuration in which parallel battery cell pairs are connected in series with adjacent battery cell pairs is realized throughout columns 105 and 107. In this case, an electrically connected pair of contact elements is separated from the next electrically connected pair by isolation elements 115. In this embodiment, only contact element 109 in column 105 and contact element 149 in column 107 are not electrically connected to adjacent contact elements.

[0093] The cell connection system 100 is connected to adjacent cell connection systems or motors via bus bars 119 and 121 .

[0094] The cell connection system 100 further comprises a printed circuit board (PCB) 123 having a cell monitor unit 125. The monitor unit 125 on the PCB 123 is electrically connected to at least some of the contact elements 109, 111, 113, 115 to monitor parameters of the battery cells, such as temperature, capacitance, for example to balance the capacitance or its state of charge. The connection is realized using sensing cables, here flexible flat cables 127, 129, 131, and 133, which in the above embodiment are also called flexible flat conductor cables.

[0095] As can be seen in close-up view 135, flexible flat cable 133 comprises a plurality of parallel wires, here six, 137a-f, here copper wires, which are isolated from one another by electrical insulation 139 and, in this embodiment, embedded in extruded PVC. Three of the wires, 137c, 137d, and 137e, are electrically and mechanically connected to a single, exclusive contact element, here 145, 147, and 149. Furthermore, as can be seen in FIG. 1, only one wire is connected to each pair of opposing contact elements, such as wire 137d and contact element 147, while opposing contact elements in row 105 are not connected to flexible flat cable 127 for monitoring battery cell installation. As for the opposing contact elements 109a and 111a, both elements are connected to their corresponding flexible flat cables 129 and 131.

[0096] The flexible flat cable 133 has an exposed area 141 where a wire 143 corresponding to wire 137c is free of its electrical insulation. Wire 143 is welded to a contact element 145, typically by ultrasonic welding. To perform ultrasonic welding, the surface opposite to where contact with contact element 145 is made must also be free of electrical insulation 139, as can be seen in FIG. 1, because the sonotrode used to perform the welding must be positioned on the wire. Typically, the surface where the sonotrode was applied leaves a visible impression of the sonotrode's contact surface.

[0097] According to the present invention, the exposed area 141 facing the contact element 145 comprises surface area-increasing features such as ridges. In this context, surface area-increasing features means a surface with a larger area than the smooth surface of the copper wire, which surface is obtained after removal of the electrical insulation 139, for example using a CO2 laser and subsequent mechanical cleaning, such as with a metallic and / or plastic brush, e.g., a rotating brush.

[0098] 17a-17c show three different variations of surface area-enhancing features on exposed region 141 of wire 143 according to the present invention. The surface area-enhancing features are on the side of the wire that will come into contact with contact element 145, as shown in FIG.

[0099] Figure 17a shows the surface of the exposed region 151 of the wire 153 after application of the scratching tool. Scratch lines 155 are preferably provided across the entire surface of the exposed area, thereby increasing the surface area compared to a smooth surface.

[0100] FIG. 17b shows the surface of exposed region 161 of wire 163 after application of a pressing punch, resulting in patterned surface area-increasing features in the form of linear ridges 165 extending along the long sides of exposed region 161. In a further variation, linear ridges 165 may extend along the short sides or may be oblique. In this embodiment, all linear ridges 165 have the same shape. In a variation, they may differ, for example, increasing in height towards the edges. The linear ridges 165 have a height of at most 0.5 mm, in particular at most 0.2 mm, more particularly at most 0.1 mm. Furthermore, the peaks of directly adjacent ridges are at a distance of at most 5 mm, in particular at most 0.2 mm, from each other.

[0101] 17c shows the surface of exposed region 171 of wire 173 after application of a pressing punch 181 as shown in FIG. 18, resulting in a patterned surface area-increasing feature in the form of an array of pyramids 175 covering the entire exposed region 171. In this embodiment, pyramids 175 are acute-pointed pyramids with an essentially rectangular, particularly essentially square-based, shape and side angles of approximately 30° to 60°, particularly 45°. Pyramids 175 have a height of at most 0.5 mm, particularly at most 0.2 mm, more particularly at most 0.1 mm. Furthermore, the apexes of directly adjacent pyramids are at a distance of at most 5 mm, particularly at most 0.2 mm, from each other.

[0102] As shown in FIG. 18, a pressing punch 181 has an array of regularly arranged pyramids 183.

[0103] Instead of embossing the surface area increasing features into the surface of wire 163 or 173, a laser patterning process can also be used.

[0104] The present invention also relates to a method for attaching a sensing cable to a contact element of a cell connection system as described above, comprising the steps of removing the electrical insulation 139 from the flexible flat cables 127-133 to form exposed areas 141, 151, 161, 171 and cleaning the exposed areas. This step is followed by a step of forming surface area-increasing features using a press punch or scratching tool or by laser structuring to obtain one of the structures shown in Figures 17a, 17b or 17c. An electrical and mechanical connection is then achieved between the exposed areas 141, 151, 161, 171 of the wires 143, 153, 163, 173 by welding, in particular ultrasonic welding waves or laser welding.

[0105] According to a variant, a configuration such as that shown in FIGS. 17a to 17c may also or alternatively be provided on the surface of the contact element 145.

[0106] Figure 19 shows the results obtained after a 90° peel tension test as described above, which met Cmk > 1.67, showing individual measurements and average values.

[0107] All samples used the same materials, ie, aluminum for the contact elements and copper for the wires, and were subjected to the same ultrasonic process.

[0108] Sample 191 corresponds to the comparative sample with a smooth surface. As can be seen, this peel tension test is satisfactory, as the average value of 8.625 N is higher than the required 7 N. See the horizontal dotted line. One of the measurements was below 7 N.

[0109] Sample 193 corresponds to surface area-enhancing features in the form of sharp pyramids, as shown in Figure 17c. These were obtained using a press punch as shown in Figure 18. The sharp pyramids on the wire exhibit essentially square contact surfaces along the 0° and 90° directions, and exhibit, on average, a 0.4 mm apex-to-apex distance, a 0.2 mm height, and a 45° side angle. The average peel force obtained was 13.154 N, with all measurements exceeding 7 N.

[0110] Sample 195 corresponds to surface area-enhancing features in the form of linear ridges as shown in Figure 17b, with a peak-to-peak distance of 0.2 mm, a height of 0.1 mm, and a side angle of 45°. The average peel force obtained was 9.482 N, with all measurements exceeding 7 N.

[0111] Sample 197 corresponds to surface area-enhancing features in the form of sharp pyramids, as shown in Figure 17c. These were obtained using a press punch as shown in Figure 18. The sharp pyramids on the wire exhibit essentially square contact surfaces along the 0° and 90° directions, and exhibit, on average, a 0.2 mm apex-to-apex distance, a 0.1 mm height, and a 45° side angle. The average peel force obtained was 15.56 N, with all measurements exceeding 7 N.

[0112] Sample 199 corresponds to a surface area increasing mechanism in the form of scratch lines. The average peel force obtained is 12.598 N, with all measurements exceeding 7 N.

[0113] All samples according to the invention have a higher peel force compared to the wire with a smooth surface, with the best results being obtained for sample 197, which shows an improvement of about 80% over the comparative sample.

[0114] Although several embodiments of the present invention have been described, it will be understood that various modifications and improvements can be made without departing from the scope of the following claims. In particular, by combining an embodiment relating to the first object of the present invention with an embodiment relating to the second object of the present invention, an additional embodiment of the present invention can be realized. [Explanation of symbols]

[0115] 1 Conductor cable, here a flexible flat conductor cable 2 Electrical connection counterpart 3 Conductors 4. Insulating sheath 5 Contact area 7 Contact surface 8 Top of electrical contact 9 Recess in insulating sheath 10 Further Conductors 11 The Second Direction 12 First Direction 13 Contact plane 14 Cable section 15 First welding spot 16 Second welding spot 17 First partial section 18 Second partial section 19 First Section 20 Second Section 21 Bend 22 Insulation material 23 First Battery 24 Second Battery 25 Third Battery 26 First terminal 27 Second terminal 28 Third Terminal 29 Additional Conductors 31 droplet 33 Surface 35 laser pulses 37 Laser 39 Pressure Waves 41 More laser pulses 42 Welding Area 43 Welded section 51 Press punch 53 Press Surface 55 Expansion Area 57 Press Surface 59 Structured Surface 61 Pyramid shape 63 Part of contact portion 5 65 Embossed surface of electrical connection mating part 2 67 Indentation height 69 Joint plane 71 embossed areas 73 Expansion Area 75 Joint surface 77 Surface area increasing mechanism 79 Laser 81 Welded parts 100 Cell Connection System 103 Support part Column 105 107 Second Column 109 Contact Elements 109a Contact element section 109b Contact element section 111 Contact Elements 111a Contact element section 111b Contact element section 113 Adjacent Contact Elements 115 Blocking Elements 117 Adjacent Contact Elements 119 Busbar 121 Busbar 123 Printed Circuit Board (PCB) 125 Cell monitor unit 127 Flexible Flat Cable 129 Flexible Flat Cable 131 Flexible flat cable 133 Flexible flat cable 135 Enlarged view 137a~f Wire 139 Electrical insulating materials 141 Exposure area 143 Wires in exposed areas 145 Contact Elements 147 Contact Elements 149 Contact Elements 151 Exposure area 153 Wire 155 Surface Scratch Lines as a Mechanism for Increasing Surface Area 161 exposed area 163 Wire 165 Linear ridges as a mechanism for increasing surface area 171 Exposed area 173 Wire 175 Sharp pyramids as a mechanism for increasing surface area 181 Press punch with sharp pyramid 191 Comparative Example 193 Large embossed pyramid 195 Embossed linear ridges 197 Embossed small pyramid 199 Scratching surface area increasing mechanism

Claims

1. A device comprising an electrical contact between a conductor (3) of a conductor cable (1) and an electrical connection counterpart (2), said conductor (3) being embedded in a predetermined position (13) in an insulating sheath (4) of said conductor cable (1), At a predetermined contact portion (5), the insulating sheath (4) is peeled off from the conductor (3) on at least one contact surface (7), The contact portion (5) of the conductor (3) is bent outward in a first direction (12) such that the contact surface (7) extends from the predetermined position (13) and extends beyond the outer surface of the insulating sheath (4); The contact surface (7) of the contact portion (5) of the conductor (3) rests on the electrical connection counterpart (2) and is directly connected to the electrical connection counterpart (2); the conductor cable (1) is bent in a second direction (11) in the area of ​​the contact portion (5); The second direction (11) is opposite to the first direction (12). device.

2. The conductor cable (1) is a flexible flat conductor cable. The device of claim 1 .

3. The contact surface (7) of the contact portion (5) of the electrical conductor (3) is connected to the electrical connection partner (2) by several contact points (15, 16).

3. A device according to claim 1 or 2.

4. The contact portion (5) of the conductor (3) is divided into two partial sections (17, 18), At least one partial section (17, 18) of the electrical conductor (3) rests with the contact surface (7) on the electrical connection partner (2) and is connected to the electrical connection partner (2). A device according to any one of claims 1 to 3.

5. The contact portion (5) of the conductor (3) is embedded in an insulating material (22) or in an electrically insulating potting material; A device according to any one of claims 1 to 4.

6. The electrical connection partner (2) and the conductor (3) are made of different conductive materials. A device according to any one of claims 1 to 5.

7. The electrical connection partner (2) is made of aluminum and the conductor (3) is made of copper. The device of claim 6.

8. the electrical connection counterpart (2) is a contact of an electrical terminal (26, 27, 28) of a battery (23, 24, 25) or a contact of an electrical terminal (26, 27, 28) of a car battery; A device according to any one of claims 1 to 7.

9. The electrical conductor (3) is connected to the electrical connection partner (2) by a welded connection, a laser welded connection or an ultrasonic welded connection. A device according to any one of claims 1 to 8.

10. the contact portion is at least partially embossed on the electrical connection partner; A device according to any one of claims 1 to 9.

11. a mating surface between the contact portion and the electrical connection partner is disposed below a surface of the electrical connection partner directly adjacent to the mating surface; The device of claim 10.

12. The surface of the contact portion and the surface of the electrical connection counterpart are provided with surface area increasing features that fit together at the mating surfaces.

12. A device according to claim 10 or 11.

13. A device according to any one of claims 1 to 12, the electrical connection partner comprises contact elements (109, 111) for receiving electrodes of at least one battery cell, The conductor cable comprises a sensing cable (127, 129, 131, 133) having wires (137a-e) electrically and mechanically connecting a cell monitor unit (125) and the contact elements (109, 111), characterized in that the surfaces of the wires and / or the contact elements are provided with surface area increasing features (155, 165, 175) in the area of ​​contact with each other; Cell connection system.

14. The cell connection system is a cell connection system for an automobile battery module for an electric vehicle or a hybrid vehicle. The cell connection system of claim 13.

15. the surface area increasing features (165, 175) comprise a plurality of ridges; 15. The cell connection system according to claim 13 or 14.

16. The ridges (165) extend linearly or parallel to the long sides of the area of ​​contact; 16. The cell connection system of claim 15.

17. The protuberance has a pyramidal shape (175).

16. The cell connection system of claim 15.

18. The pyramidal shape (175) has a rectangular base shape or a square base shape and a side angle of about 30° to 60°.

18. The cell connection system of claim 17.

19. The ridges (155, 165, 175) have a maximum height of 0.1 mm to 0.5 mm.

19. A cell connection system according to any one of claims 15 to 18.

20. the apexes of directly adjacent ridges (165, 175) are at most 0.2 mm to 5 mm apart from each other; 20. A cell connection system according to any one of claims 15 to 19.

21. the wires (153, 163, 173) and the contact elements (145) are welded together; 21. A cell connection system according to any one of claims 13 to 20.

22. The contact elements (145) and the wires (153, 163, 173) are made of different materials; 22. The cell connection system of claim 21.

23. a plurality of contact elements arranged in two rows (105, 107) that allow for the series electrical connection of the battery cells; one of the opposing contact elements is electrically and mechanically connected to the wire of the sensing cable (127, 129, 131, 133); 23. The cell connection system of claim 22.

24. the sensing cable (127, 129, 131, 133) comprises a plurality of parallel wires (137a-f) embedded in an electrical insulating material (139) or a plurality of parallel flat wires embedded in an electrical insulating material (139); each one of the wires connected to a contact element is electrically and mechanically connected to another one of the contact elements; the electrical insulation being removed in the area of ​​each contact; 24. The cell connection system of claim 23.

25. 25. A method for producing a device according to any one of claims 1 to 24, wherein the conductors of a conductor cable or a flexible flat conductor cable are embedded in predetermined positions in an insulating sheath of the conductor cable, and at predetermined contact points, the insulating sheath is stripped from the conductors on at least one contact surface, comprising: a) bending the contact portion of the electrical conductor out of the predetermined position onto at least one outer surface of the insulating sheath; b) placing the conductor cable onto the electrical connection counterpart; c) placing the contact surface of the contact portion of the electrical conductor on the electrical connection counterpart; and then d) directly connecting the contact surface of the contact portion to the electrical connection partner.

26. the contact surface of the electrical conductor is welded to the electrical connection partner; 26. The method of claim 25.

27. using a pressure wave formed by inducing a phase transition from a liquid or solid phase to a gas phase in a pressure-generating material and / or an explosion to press the contact surface of the conductor down toward the electrical connection partner before welding.

27. The method of claim 26.

28. forming the pressure wave includes applying one or more laser pulses to the pressure-producing material; 28. The method of claim 27.

29. the pressure-generating material is provided in the form of a droplet or cladding on or covering the surface of the contact area (5); 29. The method of claim 27 or 28.

30. the contact portion of the conductor is bent so that the contact surface protrudes in a first direction from the predetermined position beyond the outer surface of the insulating sheath, The conductor cable is then moved in a direction toward the electrical connection partner, and the contact surface of the contact portion of the conductor is placed on the electrical connection partner and directly connected to the electrical connection partner.

30. The method of any one of claims 25 to 29.

31. the conductor cable is bent in a second direction in the region of the contact portion before placing the conductor on the electrical connection counterpart and before welding, The second direction is opposite to the first direction.

31. The method of claim 30.

32. the contact portion of the electrical conductor is divided into a first partial section and a second partial section; At least the first partial section is bent out of the predetermined position; the first partial section is placed on the electrical connection partner and connected to the contact surface of the electrical connection partner.

32. The method of any one of claims 25 to 31.

33. Steps a) and c) are realized simultaneously by embossing the contact portions (5) on the electrical connection partner (2), 33. The method of any one of claims 25 to 32.

34. The embossing is achieved using a pressing punch (51) with a flat or structured surface; 34. The method of claim 33.

35. said surface area increasing features are realized using a pressing punch (181) or a scratching tool or by laser structuring; 35. A method according to any one of claims 25 to 34 for obtaining a cell connection system according to claim 13.

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