Electrically conductive high current connector

Abstract

The present invention relates to an electrically conductive high current connector for orthogonal electrical connection of a first high voltage busbar to a high voltage component or a second high voltage busbar. The electrically conductive high current connector takes the form of a plug connector element having at least one first plug connector end, wherein a resilient contact region is provided at the first plug connector end. This plug connector element enables simple contacting of components in a high voltage system in the vertical direction, i.e. in a direction steeply inclined or perpendicular to the longitudinal direction of the associated high voltage busbar. The invention further relates to a current conductor assembly having a high voltage busbar and an electrically conductive high current connector configured as a plug connector element, as well as to a method for producing an electrically conductive high current connector configured as a plug connector element and to the use thereof for a high voltage connection.

Description

[0001] Electrically conductive high-current connector

[0002] The present invention relates to an electrically conductive high-current connector for electrically connecting a first high-voltage busbar to a high-voltage component or a second high-voltage busbar. Furthermore, the invention relates to a conductor assembly comprising a high-voltage busbar and an electrically conductive high-current connector, as well as a method for producing an electrically conductive high-current connector and its use for an orthogonal high-voltage connection to a high-voltage busbar.

[0003] Modern electric vehicles are powered by electric motors that are supplied with electrical energy by a high-voltage or high-current system. In such a high-voltage system, a high-voltage storage unit is usually used as the electrical energy source. This storage unit is connected to a high-voltage power supply as well as to the associated power electronics and the electric drive via appropriate high-voltage busbars. In contrast to low-voltage systems, which are used in the automotive sector primarily in the on-board electrical system, a high-voltage system uses direct voltages of over 60 V up to 1.5 kV. Alternating voltages of over 30 V up to 1 kV are also referred to as high-voltage systems. Since high-voltage systems therefore exceed the limits for electrical hazards to people, suitable protective measures are necessary to prevent unintentional contact with the high-voltage system.In order to meet the short charging times now required by law for modern electric vehicles, the associated high-voltage systems must provide both high voltage and high current. This is the only technically feasible way to feed the necessary electrical power into the battery within a short time and then later retrieve it to power the electric vehicle. The resulting currents, at up to 750A, are almost 50 times higher than the maximum fuse of 16A commonly used in household electrical systems.

[0004] To connect a high-voltage storage unit to the high-voltage components of the power electronics and the electric drive, as well as to the components of the charging device, two connection technologies are generally known for transmitting the high currents in a high-voltage system. For example, the connections between the high-voltage components can generally be made using electrical cables and connectors. The advantage of electrical cables and connectors is the easy-to-implement protection against accidental contact and the ease of installation. However, connectors are generally only suitable for use up to certain currents due to their limited current-carrying capacity.An alternative option, which can also be used for very high currents and is therefore also commonly used in electric vehicles, are high-voltage busbars, which are connected to the high-voltage components via screw connections, whereby the screw connections have a relatively low contact resistance. However, with screw connections there is an increased risk of unintentional contact, so that trained specialist personnel and protective equipment are necessary for installation and especially for maintenance of the high-voltage system. Furthermore, with this type of connection, the time required for fastening and loosening is many times longer than for contacting via cables and connectors, which is particularly important in the automotive sector and the usual cost pressure for the components used and the assembly. The reason for this is the number of individual parts required for a high-current screw connection, i.e.Screw, lock washer, Schnorr washer, nut, and the necessary assembly equipment, ie socket for screwdriver, screwdriver with torque monitoring, as well as the associated additional costs for storage, order picking and administration.

[0005] For example, DE 102016 200 451 A1 discloses a high-current screw connection for a high-voltage system that provides electrical and mechanical contact between high-voltage storage devices or high-voltage components and a busbar. This touch-protected electrical screw connection has a multi-part cover designed to be electrically insulating to protect people from contact with the electrical voltage of the high-voltage system and from the electrical current flowing through the screw connector. In particular, sufficient protection is also ensured during assembly of the screw connection, as the fastening screw is provided with an electrically insulating protective layer.

[0006] The present invention is therefore based on the object of providing an improved connection of high-voltage components, with which a simplified and safe assembly of high-voltage systems as well as a safe electrical connection of the components of a high-voltage system is possible.

[0007] The object underlying the invention is achieved for a generic electrically conductive high-current connector in that the electrically conductive high-current connector is designed as a plug-in element with at least one first plug-in end for an orthogonal electrical connection between a first high-voltage busbar and a high-voltage component or a second high-voltage busbar, wherein a resilient contact region is provided on the first plug-in end. This plug-in element enables simple contacting of high-voltage components in a vertical direction, i.e. in a direction steeply inclined at more than 60°, preferably an orthogonal direction, to the longitudinal direction of the high-voltage busbar. The term high-voltage is used in the field of automotive technology for electrical systems that are operated with alternating voltages above 30 V or with direct voltages above 60 V.Accordingly, high-voltage systems are used in electrified vehicles, but also as stationary systems in the energy industry to smooth peak loads and ensure grid stability. Compared to low-voltage systems, high-voltage systems have the advantage of a higher electrical voltage, meaning that only a relatively lower electrical current is required to generate high electrical power to drive electric vehicles. This allows the cross-section of the busbars or conductors to be reduced, reducing material, weight, cooling requirements, and system complexity, while also avoiding very high currents. When using high-voltage storage systems, a high voltage can be easily achieved by connecting the individual battery modules in series.Unfortunately, high-voltage systems typically have a complex design when integrated into motor vehicles due to the limited space available. This also requires complex assembly, resulting in problems with automated and error-free installation. To connect the various components of the high-voltage systems, screwable high-current connectors or high-current plugs are used. These connectors are suitable for transmitting the currents of up to 750A that occur in a high-voltage system. The high-current connector of the present invention, designed as a plug-in element, enables both the rapid assembly of orthogonal high-voltage connections with little effort and the fast, safe, and error-free vertical connection of the components of a high-voltage system to one another.

[0008] A preferred embodiment of the electrically conductive high-current connector provides that the plug element is designed as a separate component with at least a first plug end and a second plug end, wherein a resilient contact area is provided at the first plug end and at the second plug end. Such a separate plug element enables not only secure and simple contacting of high-voltage components but also compensation for manufacturing tolerances of the high-voltage components and thermal expansion during operation of the high-voltage system. For this purpose, the two plug ends of the separate plug element are each designed to be pluggable into corresponding connection openings in the high-voltage busbars or high-voltage components in order to provide secure electrical contact between the plug element and the high-voltage busbar and / or the high-voltage component, depending on the shape of the connection openings.Furthermore, a plug-in element designed as a separate component simplifies the complexity of high-voltage systems and their assembly, thus not only enabling automated and error-free assembly but also significantly reducing the costs of manufacturing a high-voltage system.

[0009] Advantageously, the plug element can be formed as a single piece, in particular as a hollow pin. This reduces the number of components required to provide and establish an orthogonal electrical connection between components of a high-voltage system, and identical components can be used for comparable high-voltage connections, thus reducing the costs of component production and inventory.

[0010] In a practical embodiment of an electrically conductive high-current connector, the plug element can be manufactured as a stamped and bent component, in particular as a stamped and bent or rolled hollow pin. Manufacturing a plug element as a stamped and bent component enables simple and cost-effective production of the plug element from a metal sheet or metal strip with good, consistent quality, even in high volumes. In the stamped and bent hollow pin as a plug element, the butt seam between the bent ends of the stamped sheet metal part runs essentially parallel to the longitudinal axis of the plug element.In a modification, the butt seam may additionally have at least one offset section extending substantially in the circumferential direction between two butt seam sections extending substantially in the longitudinal direction of the plug-in element in order to keep an angular offset between the bent ends as small as possible when producing a bent hollow pin.

[0011] For good mechanical properties, the plug element can be made of metal, preferably a copper alloy. For a plug element made from a stamped and bent component, the material is a metal sheet or a metal sheet strip that can be fed directly into a stamping device. In addition to steel and especially spring steel, which enable very good durability of the plug element and the plug connection to the high-voltage components and high-voltage busbars, a copper alloy can be used to ensure good electrical conductivity of the plug connection and the plug element itself, particularly high-performance alloys such as CuNiSi or CuCrZr, in order to provide good spring-elastic properties in addition to good electrical conductivity.

[0012] A special design provides for the resilient contact area of ​​the plug element to be resilient in the radial direction relative to the plug-in axis of the plug element. Accordingly, the direction of the spring action runs perpendicular to the longitudinal axis of the plug element or to the insertion direction of the plug element. This ensures good electrical contact with the corresponding connection openings in the high-voltage busbars and high-voltage components.

[0013] A useful variant of an electrically conductive high-current connector provides for the resilient contact area of ​​the plug element to have several lamellae extending side by side in the longitudinal direction of the plug element, with the lamellae being curved outward. A large number of individual lamellae, which are curved outwardly in the resilient contact area of ​​the plug element, in particular at least eight, preferably at least ten individual lamellae, enable not only good electrical contact evenly distributed over the inner circumference of a connection opening, but also good spring-elastic fixation of the plug element in the connection opening in the high-voltage component.The individual lamellae, which are curved radially outward and protrude from the inner circumference of the connection opening, can achieve relatively evenly distributed good mating behavior along the circumference of the connection opening, as well as good mechanical and electrical contact, thanks to the distribution of the individual lamellae around the circumference of the plug-in element. The individual parallel lamellae can run not only axially parallel to the longitudinal axis of the plug-in element, but also at an angle to it, for example, at an angle of 15° to the longitudinal axis.

[0014] For the secure arrangement and pre-tensioning of the slats, the resilient contact area of ​​the plug-in element can have an end ring, wherein the outwardly curved slats are connected to the end ring and protrude outwards relative to the end ring. This enables secure arrangement and even distribution of the individual slats at the first and / or second plug-in end of the plug-in element and thus also secure electrical contact and mechanical fixation in the associated connection openings. Preferably, an annular section of the plug-in element is provided opposite the end ring, to which the outwardly curved slats are also connected. As a result, in addition to a secure and even distribution of the slats at the plug-in end, a good outwardly directed spring effect can be achieved. The width of the slats is essentially constant in the longitudinal direction of the plug-in element.Furthermore, the end ring can be designed as a complete ring element in order to securely connect the plurality of adjacently arranged slats. If the plug-in element is designed as a stamped and bent component, the end ring is designed to be closed, for example, except for the butt seam between the rolled-together ends of a stamped-out stamped part. A bevel can optionally be stamped onto the end ring to facilitate the insertion of the contact into the contact partner, even during automated mating processes. A useful embodiment provides that the plug-in element has a stop on at least the first mating end to limit the insertion depth of the mating end or the resilient contact area into a connection opening in the first high-voltage rail or the high-voltage component or the second high-voltage busbar.Such a stop enables the plug-in element to be secured in the connection opening in the insertion direction, reliably preventing any further unintentional insertion of the plug-in element into or through the connection opening, and safely removing the plug-in element from the connection through the connection opening is only possible in the opposite direction to the insertion direction. The provision of a stop to limit the insertion depth also allows a predetermined position of the plug-in element in the connection opening to be defined. This makes it possible to provide a busbar equipped with plug-in elements for final assembly of a high-voltage system and to connect this to one or more components or busbars of a high-voltage system by means of a further simple, vertical insertion process. This enables quick and cost-effective assembly of the high-voltage system, especially when assembling a vehicle with an electric drive.

[0015] Preferably, the stop can be designed as a holding contour on the resilient contact region, preferably as an annular circumferential depression or elevation on the adjacently arranged lamellae of the missing contact region at the first plug-in end of the plug-in element. After the first plug-in end of the plug-in element has been mounted in an associated connection opening, the lower section of the lamellae in the region of the annular circumferential depression / elevation protrudes from the connection opening and thus effectively prevents further pushing of the plug-in element or the resilient contact region through the connection opening. The annular circumferential depression creates a resistance or an increased holding force in the region of the edge of the connection opening, which is significantly greater than the insertion force required to insert a second plug-in end of the plug-in element into another connection opening.As an alternative to such a ring-shaped, circumferential recess on the adjacent lamellae, a lug protruding outwards in the shaft area of ​​the plug element can also be provided. While such a lug protruding outwards from the shaft area of ​​the plug element is very easy to manufacture and allows for a secure stop of the plug element, a lug protruding on one side can also cause the plug element to unintentionally tilt relative to the high-voltage component. Furthermore, such a stop usually requires a certain distance from a contact area formed from curved lamellae, so that a relatively large penetration depth of the contact area into the associated connection opening is necessary before such a stop limits the insertion depth of the plug end.The present invention further relates to a current conductor assembly with a first high-voltage busbar, a high-voltage component or a second high-voltage busbar and an electrically conductive high-current connector designed as a plug-in element as described above, wherein the first high-voltage busbar has a first connection opening into which the first plug-in end of the plug-in element is inserted, and the high-voltage component or the second high-voltage busbar has a second connection opening into which a second plug-in end of the plug-in element is inserted, and wherein the resilient contact regions on the first plug-in end and the resilient contact regions on the second plug-in end of the plug-in element form a high-voltage connection between the plug-in element and the first high-voltage busbar and between the plug-in element and the high-voltage component or the second high-voltage busbar.Accordingly, a direct electrical contact is created between the first high-voltage busbar and the high-voltage component or a second high-voltage busbar, via which high-voltage and high-amperage electrical current can be transmitted in a high-voltage system. Such a conductor assembly with an electrically conductive high-current connector designed as a plug-in element enables secure, orthogonal and permanent electrical contacting of high-voltage components despite its inherently simple design and minimal assembly effort.

[0016] A further embodiment provides that the axis of the first connection opening in the first high-voltage busbar and the axis of the second connection opening in the high-voltage component or in the second high-voltage busbar are formed substantially perpendicular to the longitudinal direction of the first high-voltage busbar. This enables a good vertical electrical connection between the high-voltage components and thus a compact design of the current conductor assembly and the entire high-voltage system. The inclination of the axes of the connection openings should be greater than 60°, in particular greater than 75°, to the longitudinal direction of the first busbar in order to enable a suitable vertical electrical connection of the high-voltage components. The axis of the first connection opening and the axis of the second connection opening can preferably run substantially coaxially, at least axially parallel to the longitudinal axis of the plug-in element.

[0017] A further modification of the current conductor assembly provides that the insertion depth of the resilient contact region on at least the first plug-in end or the second plug-in end of the plug-in element into the first or second connection opening is limited by a stop, preferably by a stop formed integrally with the plug-in element. This enables the plug-in element to be secured in at least one connection opening, so that incorrect positioning of the plug-in elements and also insertion of the plug-in elements through the connection openings are reliably prevented during assembly of the current conductor assembly. As a stop for limiting the insertion depth of the first or second plug-in end, either a recess or elevation formed in the resilient contact region, preferably in a ring-shaped circumferential direction, on the adjacently arranged lamellae can be provided, or alternatively a stop protruding outwards in the shaft region of the plug-in element.

[0018] Furthermore, the present invention relates to a suitable method for producing an electrically conductive high-current connector designed as a plug-in element, in particular for a current conductor assembly with a first high-voltage busbar and a high-voltage component or a second high-voltage busbar. This method comprises punching a flat punched part from a metal sheet including a contact region, in particular of adjacent lamellae, at at least a first end of the flat punched part, preferably a first and second contact region at a first and second end of the punched part, the subsequent embossing of the flat punched part to form the resilient contact regions and / or a plug-in stop, in particular to arch the adjacent lamellae towards the outside of the plug-in element, and the final bending or rolling of the punched part into a hollow pin.Such a punching and bending process allows for the very cost-effective production of plug-in elements suitable as electrically conductive high-current connectors. Such a process allows for the fully automated and cost-effective production of high-current connectors, enabling a secure electrical connection in an orthogonal direction between the components of high-voltage systems during assembly of high-voltage systems without additional components or with only a few additional components. When punching the flat punched part, the contact areas are provided on the end faces of the punched part and on the free rolling ends opposite the ends of the punched part in the rolling direction. Punching the flat punched part from a metal sheet does not automatically include the final separation of the punched part from the sheet metal strip. The actual cutting or punching of the punched part can take place either before or after stamping to form the resilient contact areas.The unrolled, unembossed form of the plug-in element is to be regarded as a flat stamped part or stamped blank.

[0019] Furthermore, the invention relates to the use of an electrically conductive high-current connector designed as a plug-in element for an orthogonal high-voltage connection between the components of a high-voltage system, in particular between a first high-voltage busbar and a high-voltage component, wherein the high-current connector designed as a plug-in element can be arranged between the first high-voltage busbar and the second high-voltage component and can be inserted into a first connection opening in the first high-voltage busbar and into a second connection opening in the second high-voltage component, preferably in a direction substantially perpendicular to the longitudinal direction of the first high-voltage busbar, in order to form a vertical electrical high-voltage connection between the first high-voltage busbar and the high-voltage component.

[0020] Non-limiting embodiments of the present invention are explained in more detail below with reference to exemplary drawings.

[0021] Figure 1 is a perspective view of a current conductor assembly of a high-voltage system from the prior art,

[0022] Figure 2 is a side view of a high-current connector according to the invention designed as a plug-in element,

[0023] Figure 3a-d various perspective views of a high-voltage busbar with several high-current connectors according to the invention,

[0024] Figure 4a-d side views of further embodiments of high-current connectors according to the invention and

[0025] Figure 5 is a plan view of a flat stamped part for bending a high-current connector according to the invention.

[0026] Figure 1 shows a current conductor assembly 1 for a high-voltage system according to the prior art, comprising a first high-voltage busbar 2, which is connected to a plurality of high-voltage components 3, in this case relays of the power electronics, by means of screw connections. In the conventional current conductor assembly 1 shown here, the screw connection between the first high-voltage busbar 2 and the high-voltage component 3 consists of suitable spacer sleeves 4 and washers 5, which are assigned to corresponding openings in the high-voltage busbar 2 and through which suitable fastening screws (not shown) extend in order to enable vertical electrical contact between the first high-voltage busbar 2 and the high-voltage component 3 or a second high-voltage busbar and to securely define the vertical spacing of these components of the high-voltage system.This electrical connection between a high-voltage busbar 2 and a high-voltage component 3 in a high-voltage system requires a multitude of components, including spacer sleeves 4, washers 5, and the screw connection, as well as possibly additional spacer elements and washers. These components must be arranged in the correct order and securely connected to one another during assembly of the high-voltage system. This creates the risk of component confusion and the inadvertent omission of components, which not only leads to incorrect assembly but also potentially endangers people.

[0027] In contrast, Figure 2 shows a plan view of an electrically conductive high-current connector 7 according to the invention for an orthogonal, electrical plug-in connection of the first high-voltage busbar 2 to the high-voltage components 3 or to a second high-voltage busbar 6. This high-current connector 7 according to the invention is designed as a separate, one-piece plug-in element 8. The plug-in element 8 has a first plug-in end 9 and a second plug-in end 10, as well as a shaft 11 that extends between the first plug-in end 9 and the second plug-in end 10. The plug-in element 8 is designed as a punched and bent hollow pin and, in the longitudinal direction of the plug-in element 8, has a butt seam 12 at which the two rolling ends 25 of the bent punched part 24 lie opposite one another. Typically, the two rolling ends 25 are not connected to one another, but together form the butt seam 12 of the hollow plug-in element 8, which is open in the radial direction.The butt seam 12 extends not only over the shaft 11, but also over the first plug end 9 and the second plug end 10 up to the end faces 13 of the plug element 8. The plug element 8 for the orthogonal electrical connection of high-voltage components of a high-voltage system has a resilient contact region 14 at each of the first plug end 9 and the second plug end 10. The resilient contact regions 14 are designed here as lamellar contacts with a plurality of lamellar blades 15 running next to one another in the longitudinal direction of the plug element 8, wherein the lamellar blades 15 are curved outwards and thus form a lamellar bead or a barrel-shaped lamellar element. The plurality of slats 15 running side by side are connected both to the shaft 11 and to an end ring 16 forming the end faces 13 of the first and second plug ends 9, 10 and are prestressed by the curvature projecting outwards relative to the end rings 16 and the shaft 11.The number of lamellae 15 running side by side in the longitudinal direction of the plug-in element 8 depends essentially on the requirements of the electrical contact with the connection openings 17 in the first and second high-voltage busbars 2, 6 and the high-voltage components 3. Typically, at least eight, preferably at least ten individual lamellae 15 are provided in order to enable good plug-in behavior and good electrical contact.

[0028] Figure 3a shows a perspective view of a first high-voltage busbar 2, such as can also be used for a conventional conductor assembly 1 according to Figure 1. In contrast to the conductor assembly 1 shown in Figure 1, this high-voltage busbar 2 has a plurality of plug-in elements 8 in order to establish electrical contact with other components of a high-voltage system, for example a second high-voltage busbar 6 or other high-voltage components 3, for example the relays of the power electronics. The plug-in elements 8 are each inserted with the first plug ends 9 into associated connection openings 17 of the first high-voltage busbar 2. The individual lamellae 15 of the resilient contact regions 14 extend over the entire length of the connection opening 17, so that the lamellae 15 protrude both on the top side 18 of the high-voltage busbar 2 and on the bottom side 19, see also Figure 3b.As can be seen in the top view of the high-voltage busbar 2 in Figure 3c, the slats 15 of the resilient contact region 14 on the first plug-in end 9 protrude slightly on the upper side 18 relative to the circumference of the connection opening 17 (see also Figure 3d), so that good electrical contact is created between the slats 15 and the high-voltage busbar 2 over the entire thickness of the high-voltage busbar 2 at the circumference of the connection opening 17. At the same time, a good mechanical connection is also formed between the plug-in elements 8 and the high-voltage busbar 2, as a result of which the plug-in elements 8 protrude from the high-voltage busbar 2 essentially orthogonally, i.e. perpendicularly or only slightly inclined relative to the perpendicular to the longitudinal axis of the high-voltage busbar 2.The longitudinal direction of the high-voltage busbar 2 is the corresponding main direction of the high-voltage busbar 2 without any steps or inclined sections for adaptation to the structural boundary conditions of a high-voltage system.

[0029] In the perspective bottom view of the high-voltage busbar 2 in Figure 3b, various stops 20 of the plug elements 8 can also be seen, which prevent the plug elements 8 from being pushed through the connection openings 17 and thus both determine the position of the plug elements 8 in the high-voltage busbar 2 and ensure electrical contact between the lamellae 15 of the resilient contact area 14 and the connection opening 17. The specific design of the stops 20 will be explained in more detail below. The plug elements 8 connected to the first high-voltage busbar 2 enable the establishment of electrical contact with further high-voltage components 3 or a second high-voltage busbar 6 of the high-voltage system in a vertical direction by means of a direct plug connection via the numerous contact areas 14 of the second plug ends 10.

[0030] Various embodiments of plug-in elements 8 according to the invention are shown in Figures 4a-d. The plug-in element 8 from Figure 4a, similar to Figure 2, has an elongated shaft 11, a first plug-in end 9, and a second plug-in end 10. The resilient contact regions 14 on the first plug-in end 9 and on the second plug-in end 10 in turn have a plurality of lamellae 15 arranged next to one another in the longitudinal direction of the plug-in element, which lamellae 15 are each connected to the shaft 11 and the end rings 16 and extend outwardly between them in an outwardly curved manner. In the transition region between the shaft 11 and the first plug-in end 9, the butt seam 12 has an offset 21 in the radial direction, which connects the two sections of the butt seam 12 extending in the longitudinal direction of the plug-in element 8.This radial offset 21 of the butt seam 12 is essentially for manufacturing reasons and prevents the formation of large angles of inclination between the facing roller ends 25 when bending or rolling the punched and stamped part 24. Furthermore, the offset 21 reduces unintentional displacement of the roller ends 25 relative to one another in the event of uneven force application during the vertical insertion process. In the embodiment of the electrically conductive high-current connector 7 designed as a plug-in element 8 shown in Figure 4a, the lamellae 15 of the resilient contact area 14 at the first plug-in end 9 have an uneven curvature. This uneven curvature of the lamellae 15 results from an annular circumferential recess 22 or notches in the lamellae 15, each at the same distance from the shaft 11 or the end ring 16.The distance between the recesses 22 serving as stops 20 and the shaft 11 is significantly smaller, since the area of ​​the slats 15 between the recess 22 and the end ring 16 must be sufficiently long to establish adequate electrical contact in the connection opening 17 of the high-voltage busbar 2. After the first plug end 9 has been inserted into a corresponding connection opening 17 of a first high-voltage busbar 2, the recesses 22 radially surrounding the resilient contact area 14 rest against the edge of the connection opening 17 and prevent the plug element 8 from being pushed further through the connection opening 17, see also Figure 3b.

[0031] The embodiment of an electrically conductive high-current connector 7 designed as a plug-in element 8 shown in Figure 4b is very similar to the embodiment of the plug-in element 8 shown in Figure 4a. In contrast to this, this plug-in element 8 has a shortened shaft 11, on which there is also a resilient contact area 14 with a stop 20 at the first plug-in end 9 through the annular circumferential recesses 22 formed on the lamellae 15, and a resilient contact area 14 with uniformly outwardly curved circumferential lamellae 14 between the end ring 16 and the shaft 11 at the opposite second plug-in end 10. The butt seam 12 in the longitudinal direction of the plug-in element 8 between the two punched ends 9, 10 also has a radial offset 21 here.

[0032] The embodiment of a plug-in element 6 according to the invention from Figure 4c, similar to the structure from Figure 2, has an elongated shaft 11 with a first plug-in end 9 and a second plug-in end 10, wherein the resilient contact regions 14 on the first plug-in end 9 and a second plug-in end 10 are of identical construction and consist of several outwardly curved lamellae 15 running side by side. The butt seam 12 between the two mutually facing roller ends 25 runs here without an offset 21 parallel to the plug-in axis of the plug-in element 8. In contrast, this plug-in element 8 has a stop 20, which here is designed as an outwardly projecting stop lug 23. As indicated in Figure 3b, the stop lug 23 rests against the underside 19 of a plug-in element 8 inserted into a high-voltage busbar 2 and prevents further insertion or pushing of the plug-in element 8 through the connection opening 17.The stop lug 23 can be easily formed during the punching and bending of this plug-in element 8, which is designed as a rolled hollow pin. The sheet metal section of the stop lug 23, which protrudes at an angle relative to the shaft 11, can be formed in its contour during the punching of the flat punched part 24 and can be inclined outward during the stamping of the punched part 24, so that the stop lug 23 is formed automatically during the bending of the punched part.

[0033] The embodiment of a plug-in element 8 according to the invention shown in Figure 4d is very similar to the embodiment with a short shaft 11 from Figure 4b. In addition to a butt seam 12 running continuously parallel to the plug-in axis of the plug-in element 8, this plug-in element 8 has a stepped shaft 11. While the structure of the resilient contact area 14 at the first plug-in end 9 essentially corresponds to the embodiment in Figure 4b, the diameter of the resilient contact area 14 at the second plug-in end 10 has a smaller diameter due to the stepped shaft 11. Despite the small diameter of the resilient contact area 14, the actual structural design is similar and again consists of several lamellae 15 running next to one another in the longitudinal direction of the plug-in axis, wherein the lamellae 15 are curved outwards and protrude outwards relative to the end ring 16.The different diameter of the resilient contact area 14 on the second plug end 10 facilitates the adaptation of the plug element 8 to different connection openings 17 of the components in a high-voltage system, in order to enable secure axial contact between a first high-voltage busbar 2 of a conductor assembly 1 with corresponding high-voltage components 3 or a second high-voltage busbar 6. Such plug elements 8 with a stepped shaft 11 are also used in the first high-voltage busbar 2 according to Figures 3a and 3b, in order to ensure secure axial contact in corresponding connection openings 17 with a smaller diameter in an associated high-voltage component 3 or a second high-voltage busbar 6.

[0034] The following describes a method for producing an electrical high-current connector 7 designed as a plug-in element 8 for an orthogonal electrical connection in a conductor assembly 1 between a first high-voltage busbar 2 and other components of a high-voltage system. A suitable material for producing the plug-in element 8 is, for example, a copper alloy, preferably a high-performance copper alloy, e.g., CuNiSi or CuCrZr, which is provided as a flat sheet or strip material. The flat, developed contour of the plug-in element 8 is then first punched from the sheet material. This flat punched part 24 or punched blank can be further connected to the sheet material to facilitate subsequent stamping, and punching can only take place after stamping. However, the flat punched part 24 can also be separated from the sheet material at the same time as the contour of the flat punched part 24 is punched.Figure 5 shows a view of the flat stamped part 24. Here, the adjacently arranged lamellae 15 of the resilient contact regions 14 on the first plug-in end 9 and second plug-in end 10 between the shaft region 11 of the subsequent plug-in element 8 and the end rings 16 of the first plug-in end 9 and the second plug-in end 10 can be clearly seen. Following the stamping of the flat stamped part 24, the flat stamped part 24 is embossed. During embossing, not only the adjacent lamellae 15 of the resilient contact regions 14 are formed or preformed, but also, if necessary, the circumferential recesses 22 on the lamellae 15, the stop lug 23 or an offset in the shaft 11 of the plug-in element 8.In particular, the embossing of the flat stamped part 24 serves to arch the adjacent slats 15 toward the outer side of the plug-in element 8 in order to form the resilient contact area 14 of the first and second plug-in ends 9, 10 of the plug-in element 8 for secure mechanical and electrical contact of the plug-in element 8 with the connection openings 17 of the first high-voltage busbar 2 and the high-voltage components 3 or other components of the high-voltage system. If the separation of the flat stamped part 24 from the metal sheet or strip material was not already integrated during the stamping of the flat sheet metal part 24, the separation of the flat stamped part 24 takes place after embossing.The embossed and punched flat punched part 24 is then bent into a hollow pin, wherein the curved, adjacent lamellae 15 on the outside of the plug-in element 8 designed as a hollow pin protrude relative to the end rings 16 of the first and second plug-in ends 9, 10. The rolling ends 25 provided on the outer edges of the shaft 11, the resilient contact regions 14, and the end rings 16 in the longitudinal direction of the plug-in element 8 face one another as a result of the bending of the plug-in element 8 and together form the butt seam 12 of the plug-in element 8, wherein the two rolling ends 25 are preferably arranged parallel to one another in the radial direction in the butt seam 12 of the hollow pin-shaped plug-in element 8.

[0035] The electrically conductive high-current connectors 7 of the present invention, designed as plug-in elements 8, are used to form an orthogonal electrical connection in a high-voltage system, in particular for an electrical and mechanical connection of a first high-voltage busbar 2 to other components of the high-voltage system, in particular high-voltage components 3 such as the relays of the power electronics of the high-voltage system or a second high-voltage busbar 6. The use of the plug-in element 8 enables simple contacting and, at the same time, a secure mechanical connection of components of the high-voltage system in a direction substantially orthogonal to the longitudinal direction of the high-voltage busbar 2.In contrast to a conventional connection of components of a high-voltage system in the longitudinal direction of the high-voltage busbar 2 to be connected, for example by means of an insulated and contact-protected high-voltage plug, an orthogonal electrical connection between the first high-voltage busbar 2 and the plug-in element 8, i.e. a plug-in connection with an inclination of the plug-in axis of the plug-in element 8 to the longitudinal direction of the high-voltage busbar 2 of at least 60°, preferably between 75° and 90°, enables quick and simple contacting of components of the high-voltage system in an orthogonal or vertical direction. In contrast to the complex screw connection known from the prior art between a high-voltage busbar 2 and the other components of a high-voltage system, the present invention enables simple, quick and cost-effective vertical contacting.

[0036] In a preferred use of the plug element 8 for producing a conductor assembly of a high-voltage system, the first high-voltage busbar 8 is equipped with a plurality of plug elements 8 according to Figures 3a-d. The length of the plug elements 8 is selected according to the vertical distance to the connection openings 17 of the high-voltage components 3 to be contacted. First, the corresponding plug elements 8 are inserted from the underside of the first high-voltage busbar 2 into the connection openings 17, with suitable stops 20 on the plug element 8 preventing the resilient contact areas 14 from being accidentally inserted too deeply or pushed through the connection opening 17.This assembly step of equipping the high-voltage busbar 2 with suitable plug-in elements 8 can take place spatially and temporally before the final assembly of an associated high-voltage system, and the high-voltage busbar 2 with orthogonally protruding plug-in elements 8 can be provided externally as a complete component of the final assembly of a high-voltage system. In a second assembly step, the high-voltage busbar 2 equipped with the plug-in elements 8 is plugged onto the associated high-voltage components 3 during the final assembly of the high-voltage system. This allows a suitable orthogonal electrical connection between a high-voltage busbar 2 and other components of a high-voltage system to be achieved with minimal assembly effort and at very low cost. Simultaneously with the electrical contact, the plug-in elements 8 also enable a secure mechanical connection that prevents the plug-in elements 8 from being accidentally released from the connection openings 17.

[0037] The stops 20 located on the underside 19 of the high-voltage busbar 2 for limiting the insertion depth of the first plug end 9 into the connection openings 17 of the high-voltage busbar 2 prevent, when inserting the second plug ends 10 of the plug elements 8 into the connection openings 17 of the associated high-voltage components 3, an undesired excessive insertion or pushing through of the spring-loaded contact areas 14 through the connection openings 17 of the high-voltage busbar 2, even in the case of a higher insertion resistance, and thereby simultaneously ensure secure insertion and secure contacting of the spring-loaded contact areas 14 of the second plug end 10 in the connection openings 17 of the high-voltage components 3.In contrast to conventional screw connections for an orthogonal electrical connection of the components of a high-voltage system to a first high-voltage busbar 2, which require, in addition to the actual screw bolt, several spacer sleeves 4, washers 5 and a thread in the associated connection opening 17, the present invention enables a vertical, electrical connection of components of a high-voltage system with a single component and with a single, simple assembly step. Inserting the plug element 8 into the connection openings 17 not only prevents errors during assembly, for example a canted or incorrect screwing of a screw bolt into the connection opening 17 or the missing orthe use of incorrect washers 5 and spacer sleeves 4, but also reduces the number of components required to create an orthogonal electrical connection, since spacer sleeves 4 and washers 5 can be dispensed with, and thus facilitates safe and quick assembly with a secure mechanical connection and a defined distance to the components of the high-voltage system to be connected.

[0038] List of reference symbols:

[0039] 1 conductor assembly

[0040] 2 first high-voltage power rail

[0041] 3 high-voltage components

[0042] 4 spacer sleeves

[0043] 5 slices

[0044] 6 second high-voltage power rail

[0045] 7 electrically conductive high-current connector

[0046] 8 plug-in element

[0047] 9 first plug end

[0048] 10 second plug end

[0049] 11 shaft

[0050] 12 Butt seam

[0051] 13 front sides

[0052] 14 springy contact area

[0053] 15 slats

[0054] 16 end ring

[0055] 17 Connection opening

[0056] 18 Top

[0057] 19 Bottom

[0058] 20 stops

[0059] 21 Offset

[0060] 22 Deepening

[0061] 23 Stop lug

[0062] 24 flat punched part

[0063] 25 rolling

Claims

Claims 1. Electrically conductive high-current connector (7) for an orthogonal, electrical connection of a first high-voltage busbar (2) to a high-voltage component (3) or to a second high-voltage busbar (6), characterized in that the high-current connector (7) is designed as a plug-in element (8) with at least one first plug-in end (9), wherein a resilient contact region (14) is provided on the first plug-in end (9) in order to provide an electrical contact between the first high-voltage busbar (2) and the high-voltage component (3) or the second high-voltage busbar (6).

2. Electrically conductive high-current connector (7) according to claim 1, characterized in that the plug element (8) is designed as a separate component with at least the first plug end (9) and a second plug end (10), wherein a resilient contact region (14) is provided on the first plug end (9) and on the second plug end (10) in order to provide electrical contact between the first high-voltage busbar (2) and the high-voltage component (3) or the second high-voltage busbar (6).

3. Electrically conductive high-current connector (7) according to claim 2, characterized in that the plug element (8) is formed in one piece, in particular as a hollow pin.

4. Electrically conductive high-current connector (7) according to claim 2 or 3, characterized in that the plug element (8) is manufactured as a punched and bent component, in particular as a punched and bent hollow pin.

5. Electrically conductive high-current connector (7) according to one of claims 2 to 4, characterized in that the plug element (8) is made of metal, preferably of a copper alloy.

6. Electrically conductive high-current connector (7) according to one of claims 1 to 5, characterized in that the resilient contact region (14) of the plug-in element (8) is resilient in the radial direction to the plug-in axis of the plug-in element (8).

7. Electrically conductive high-current connector (7) according to one of claims 1 to 6, characterized in that the resilient contact area (14) of the plug element (8) has a plurality of slats (15) running next to one another in the longitudinal direction of the plug-in element (8), the slats (15) being curved outwards.

8. Electrically conductive high-current connector (7) according to claim 7, characterized in that the resilient contact region (14) of the plug element (8) further comprises an end ring (16), wherein the outwardly curved lamellae (15) are connected to the end ring (16) and project outwards relative to the end ring (16).

9. Electrically conductive high-current connector (7) according to one of claims 1 to 8, characterized in that the plug element (8) has a stop (20) on at least the first plug end (9) for limiting the insertion depth of the first plug end (9) or the resilient contact area (14) into a connection opening (17) of the first high-voltage busbar (2) or the high-voltage component (3) or the second high-voltage busbar (6).

10. Electrically conductive high-current connector (7) according to claim 9, characterized in that the stop (20) is designed as a holding contour on the resilient contact region (14), preferably an annular circumferential depression (22) or elevation on the adjacent lamellae (15) of the resilient contact region (14) at the first plug-in end (9) of the plug-in element (8). 11.Current conductor assembly (1) with a first high-voltage busbar (2), a high-voltage component (3) or a second high-voltage busbar (6) and an electrically conductive high-current connector (7) designed as a plug-in element (8) according to one of claims 1 to 10, characterized in that the first high-voltage busbar (2) has a first connection opening (17) into which the first plug-in end (9) of the plug-in element (8) is inserted, and the high-voltage component (3) or the second high-voltage busbar (6) has a second connection opening (17) into which a second plug-in end (10) of the plug-in element (8) is inserted, wherein the resilient contact regions (14) on the first plug-in end (9) and the resilient contact regions (14) on the second plug-in end (10) of the plug-in element (8) form a high-voltage connection between the plug-in element (8) and the first high-voltage busbar (2) and between the plug-in element (8) and the high-voltage component (3) or the second high-voltage busbar (6).

12. Conductor assembly (1) according to claim 11, characterized in that the axis of the first connection opening (17) in the first high-voltage busbar (2) and the axis of the second connection opening (17) in the High-voltage component (3) or in the second high-voltage busbar (6) are formed substantially perpendicular to the longitudinal direction of the first high-voltage busbar (2).

13. Conductor assembly (1) according to claim 11 or 12, characterized in that the insertion depth of the resilient contact region (14) on at least the first plug-in end (9) or the second plug-in end (10) of the plug-in element (8) into the first or second connection opening (17) is limited by a stop (20), preferably by a stop (20) formed integrally with the plug-in element (8).

14. A method for producing an electrically conductive high-current connector (7) designed as a plug-in element (8), in particular for a current conductor assembly (1) with a first high-voltage busbar (2) and a high-voltage component (3) or a second high-voltage busbar (6), comprising the steps: - punching a flat punched part (24) from a metal sheet including a contact region (14), in particular of lamellae (15) running side by side, at at least a first end of the punched part (24), preferably a first and second contact region (14) at a first end and a second end of the punched part (24); - embossing the flat stamped part (24) to form the resilient contact areas (14) and / or a stop (20), in particular to arch the adjacent slats (15) towards the outside of the plug-in element (8); and - Bending the punched part (24) into a hollow pin.

15. Use of an electrically conductive high-current connector (7) designed as a plug-in element (8) for an orthogonal high-voltage connection between a first high-voltage busbar (2) and a high-voltage component (3) or between the first high-voltage busbar (2) and a second high-voltage busbar (6), wherein the high-current connector (7) designed as a plug-in element (8) can be arranged between the first high-voltage busbar (2) and the high-voltage component (3) or the second high-voltage busbar (6) and can be plugged into a first connection opening (17) in the first high-voltage busbar (2) and into a second connection opening (17) in the high-voltage component (3) or in the second high-voltage busbar (6), preferably in a direction substantially perpendicular to the longitudinal direction of the first high-voltage busbar (2), in order to create a high-voltage connection between the first high-voltage busbar (2) and the high-voltage component (3) orthe second high-voltage busbar (6) to form an electrical high-voltage connection.

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