Electrical connection assembly, in particular for use in electric vehicles or hybrid vehicles

Abstract

The invention relates to an electrical connection assembly (1), in particular for use in electric vehicles or hybrid vehicles, comprising a first electrical and / or electronic component (10) and a second electrical and / or electronic component (20), wherein: the first electrical and / or electronic component (10) is electrically connected to the second electrical and / or electronic component (20) by a first bus-bar connection (40) and by a second bus-bar connection (50); the first bus-bar connection (40) is electrically insulated from the second bus-bar connection (50); the first bus-bar connection (40) runs at least partly in parallel with the second bus-bar connection (50); the first bus-bar connection (40) is spaced apart from the second bus-bar connection (50) by an intermediate space (60); the connection assembly (1) also comprises an insulation part (30) which is disposed at least partly between the first bus-bar connection (40) and the second bus-bar connection (50) and which insulates the first bus-bar connection (40) from the second bus-bar connection (50) in the intermediate space (60). According to the invention, the first bus-bar connection (40) comprises a connection bus bar (41) which lies on a contact surface (31) of the insulation part (30) and which is fastened to the insulation part (30).

Description

[0001] Description

[0002] title

[0003] Electrical connection arrangement, particularly for use in electric vehicles or hybrid vehicles

[0004] State of the art

[0005] The invention relates to an electrical connection arrangement, in particular for use in electric vehicles or hybrid vehicles, having the features of the preamble of independent claim 1.

[0006] In power electronics, for example in electric vehicles or hybrid vehicles, electrical and / or electronic components that carry high electrical currents are connected to one another. Due to the high electrical currents, current-carrying elements through which the electrical and / or electronic components are connected to one another must have correspondingly low electrical resistances and thus large cross-sections. Repeated switching operations result in frequency-dependent high power losses due to alternating currents. It is known that planar and parallel current conduction and the magnetic interaction between current layers caused by opposite current directions result in a significant reduction in the inductance resulting from the switching operations and thus significantly reduced power losses. In such arrangements, current is carried via busbars.For example, two busbars with opposite current directions, a forward conductor and a return conductor, are routed directly above each other and parallel to each other at a short distance. For connections between different electrical and / or electronic components, this parallel and superimposed routing of the busbars is interrupted in the area where the busbars of a first electrical and / or electronic component are connected to the busbars of a second electrical and / or electronic component, to create a secure and fixed connection, for example, a screw connection or a welded connection.This interruption of the superimposed routing of the busbars leads to increased inductances and concomitant increased losses in the arrangement in the area in which the busbars of the first electrical and / or electronic component are connected to the busbars of the second electrical and / or electronic component.

[0007] Disclosure of the invention

[0008] According to the invention, an electrical connection arrangement is proposed, in particular for use in electric vehicles or hybrid vehicles. The connection arrangement comprises a first electrical and / or electronic component and a second electrical and / or electronic component, wherein the first electrical and / or electronic component is electrically conductively connected to the second electrical and / or electronic component by a first busbar connection and by a second busbar connection, wherein the first busbar connection is electrically insulated from the second busbar connection, wherein the first busbar connection runs at least partially parallel to the second busbar connection, wherein the first busbar connection is spaced from the second busbar connection by a gap, wherein the connection arrangement further comprises an insulating part,which is arranged at least partially between the first busbar connection and the second busbar connection and insulates the first busbar connection from the second busbar connection in the intermediate space. According to the invention, the first busbar connection comprises a connecting busbar that rests on a support surface of the insulating part and is fastened to the insulating part. Advantages of the invention,

[0009] Compared to the prior art, the electrical connection arrangement has the advantage that the connecting busbar is connected to the insulating part. This means that when assembling the connection arrangement, the connecting busbar and the insulating part can be positioned and mounted simultaneously as a single unit. The connecting busbar, together with the insulating part, forms an assembly that is mounted together in the electrical connection arrangement. The insulating part electrically insulates the connecting busbar from the second busbar connection. The insulating part allows the first busbar connection to be advantageously routed close to the second busbar connection. The insulating part with the connecting busbar can, for example, be placed onto the already welded second busbar connection. The connecting lugs of the connecting busbar can then be welded into the first busbar connection.In this way, an advantageously low-inductance connection between the first electrical and / or electronic assembly and the second electrical and / or electronic assembly can be achieved.

[0010] Further advantageous embodiments and developments of the inventions are made possible by the features specified in the subclaims.

[0011] According to an advantageous exemplary embodiment, it is provided that the second busbar connection comprises a first busbar and a second busbar electrically connected to the first busbar, wherein the first busbar protrudes from the first electrical and / or electronic component and the second busbar protrudes from the second electrical and / or electronic component, wherein the first busbar connection comprises a connecting busbar, wherein the connecting busbar protrudes from the first electrical and / or electronic component, wherein an insulating element, in particular an insulating plate or an insulating film, is arranged between the connecting busbar and the first busbar, which electrically insulates the first busbar from the connecting busbar.This allows the first busbar connection and the second busbar connection to be arranged parallel to each other at a short distance, creating a beneficial low-inductance connection. The combination of the insulation element and insulation part allows for continuous electrical insulation between the busbar connections over the entire length.

[0012] According to an advantageous embodiment, it is provided that the insulating element protrudes, in particular in a direction perpendicular to the support surface, into a recess in the insulating part, wherein the first busbar extends over the insulating element and the insulating part in a bridge-like manner in the region in which the insulating element protrudes into the recess in the insulating part. The insulating element protrudes, in particular in the direction perpendicular to the support surface, beyond the connecting busbar and the first busbar and into the recess of the insulating part. Thus, the insulating element can be connected to the insulating part with regard to electrical insulation. Continuous electrical insulation can be achieved between the first busbar connection and the second busbar connection.

[0013] According to an advantageous exemplary embodiment, at least one first connecting lug and at least one second connecting lug are formed on the connecting busbar, wherein the first connecting lug and the second connecting lug protrude from the insulating part, in particular in opposite directions. The first connecting lug runs, for example, in a plane that is plane-parallel to the support surface of the insulating part. The second connecting lug runs, for example, in a plane that is plane-parallel to the support surface of the insulating part. The connecting lugs serve to connect the connecting busbar to connection points of the electrical and / or electronic components or to other busbars. The connecting lugs can, for example, be welded to connection points of the electrical and / or electronic components.The connecting lugs of the connecting busbar can, for example, be welded to other busbars. The connecting lugs form the electrical connections of the unit consisting of the insulating part and connecting busbar. The connecting busbar can thus be advantageously inserted into the electrical connection arrangement together with the insulating part and electrically integrated into the electrical connection arrangement by the connecting lugs. According to an advantageous embodiment, the connecting busbar spans the entire insulating part in a bridge-like manner.

[0014] According to an advantageous embodiment, a wall is formed on the insulating part, in particular on an edge of the insulating part, which wall protrudes from the support surface of the insulating part and projects beyond the connecting busbar in a direction perpendicular to the support surface. The wall increases the shortest connection between the connecting busbar and the second busbar connection around the insulating part. Thus, the air gap and / or the creepage distance between the connecting busbar and the second busbar connection is increased. The dimensions and, in particular, the height of the wall allow the electrical connection arrangement to be easily adapted to creepage distance specifications.

[0015] According to an advantageous embodiment, at least one recess is formed in the connecting busbar, with at least one connecting element being formed on the insulating part, which protrudes from the support surface of the insulating part, the connecting element protruding through the recess in the connecting busbar. The connecting element mechanically, in particular positively, fastens the connecting busbar to the insulating part. The fastening can be purely mechanical, for example, without additional adhesive.

[0016] According to an advantageous embodiment, the connecting element has a widened end, wherein the connecting busbar and the insulating part are positively connected to one another by the widened end. The connecting busbar is firmly held to the insulating part by the widened end. The connecting element is fastened, in particular non-detachably, to the insulating part by the widened end of the connecting element. During production, the connecting element is inserted, for example, through the recess in the connecting busbar and then deformed to create a widened end that holds the connecting busbar to the insulating part. The deformation of the connecting element can be achieved, for example, by applying heat and force, for example by hot caulking.According to an advantageous embodiment, it is provided that the recess is formed as a hole, in particular a circular hole, in the connecting busbar.

[0017] According to an advantageous embodiment, two spaced-apart and, in particular, identically designed recesses are formed in the connecting busbar, wherein two spaced-apart, in particular, identically designed connecting elements are formed on the insulating part, which protrude from the support surface of the insulating part, wherein each of the connecting elements protrudes through one of the recesses. Each of the connecting elements then has a widened end, by which the connecting busbar is held to the insulating part.

[0018] Short description of the drawings

[0019] An embodiment of the invention is illustrated in the drawing and explained in more detail in the following description.

[0020] Fig. 1 shows an embodiment of the electrical connection arrangement,

[0021] Fig. 2 shows a cross section through the embodiment of the electrical connection arrangement from Fig.1,

[0022] Fig. 3 shows the insulating part and the first busbar of the embodiment of the electrical connection arrangement from Fig. 1,

[0023] Fig. 4 shows a cross-section through the insulating part and the first busbar from Fig. 3.

[0024] Embodiments of the invention The connection arrangement 1 can be used, for example, in systems that carry high currents, for example in power electronics, for example in electric vehicles or hybrid vehicles.

[0025] The connection arrangement 1 comprises a first electrical and / or electronic component 10 and a second electrical and / or electronic component 20. The electrical and / or electronic components 10, 20 can be or include, for example, inverters, converters, DC / DC converters, capacitors such as intermediate circuit capacitors, batteries, busbars, or, for example, other electronic and / or electrical components that are used, for example, in electric vehicles or hybrid vehicles or in other power electronics systems. In the exemplary embodiment illustrated in the figures, the first electrical and / or electronic component 10 is designed as an intermediate circuit capacitor, and the second electrical and / or electronic component 20 is designed as a signaled circuit breaker.

[0026] The first electrical and / or electronic component 10 is connected to the second electrical and / or electronic component 20 by a first busbar connection 40. The first busbar connection 40 can comprise one or more interconnected, flat busbars 41, 49. In the exemplary embodiment shown in the figures, the first busbar connection 40 comprises a connecting busbar 41 and a connecting busbar 49. The connecting busbar 49 protrudes from the first electrical and / or electronic component and is electrically connected thereto. The connecting busbar 49 is electrically connected to the connecting busbar 41, for example, welded thereto. The connecting busbar 49 is connected flat to the connecting busbar 41. The connecting busbar 41 is electrically connected to the second electrical and / or electronic component 20.The connecting busbar 41 is connected, for example welded, to an electrical connection point of the electrical and / or electronic component 20. The connection points of the second electrical and / or electronic component 20 can be formed, for example, on a power substrate, for example a DBC substrate, of the electrical and / or electronic component 20. The connecting busbar 41 is designed as a bent sheet. At least one first connecting tab 42 and at least one second connecting tab 43 are formed on the connecting busbar 41. In this exemplary embodiment, a plurality of, in particular four, first connecting tabs 42 are formed on the connecting busbar 41. The first connecting tabs 42 are separated from one another by slots in the connecting busbar 41. The first connecting tabs 42 extend flat, in particular in the same plane.Furthermore, in this exemplary embodiment, a second connecting lug 43 is formed on the connecting busbar 41. However, a plurality of second connecting lugs 43 can also be formed on the connecting busbar 41. The second connecting lug 43 extends flatly, in particular in a plane plane-parallel to the plane in which the first connecting lugs 42 extend. The first connecting lugs 42 and the second connecting lug 43 protrude from the insulating part 30, in particular in opposite directions. The first connecting lugs 42 extend towards the connecting busbar 49. The first connecting lugs 42 are electrically connected, in particular welded, to the connecting busbar 49. The second connecting lug 43 extends towards the second electrical and / or electronic component 20.The second connecting tab 43 is electrically connected to the second electrical and / or electronic component 20, in particular welded to a connection point of the second electrical and / or electronic component 20. The connection point of the second electrical and / or electronic component 20 can be formed, for example, on a power substrate, for example a DBC substrate, of the electrical and / or electronic component 20.

[0027] Furthermore, the first electrical and / or electronic component 10 is connected to the second electrical and / or electronic component 20 by a second busbar connection 50. The second busbar connection 50 can comprise one or more interconnected, flat busbars 51, 52. In this exemplary embodiment, the second busbar connection 50 comprises a first busbar 51 and a second busbar 52. The first busbar 51 is electrically connected, for example welded, to the second busbar 52. The first busbar 51 protrudes from the first electrical and / or electronic component 10. The first busbar 51 is electrically connected to the first electrical and / or electronic component 10. The second busbar 52 is electrically connected to the second electrical and / or electronic component 20.The second busbar 52 is electrically connected to the second electrical and / or electronic component 20, in particular welded to connection points of the second electrical and / or electronic component 20. The connection points of the second electrical and / or electronic component 20 can be formed, for example, on a power substrate, for example a DBC substrate, of the electrical and / or electronic component 20.

[0028] The connecting busbar 41, the connecting busbar 49, the first busbar 51 and the second busbar 52 are busbars 41, 49, 51, 52, respectively.

[0029] In the context of the present application, a busbar 41, 49, 51, 52 is understood to be an electrically conductive flat conductor, for example an electrically conductive bar, an electrically conductive strip or an electrically conductive sheet. A busbar 41, 49, 51, 52 can thus be a busbar, for example. The busbars 41, 49, 51, 52 can, for example, bent or curved or can run in a curved or stepped manner. The busbars 41, 49, 51, 52 are made of an electrically conductive material, for example a metal such as copper. The busbars 41, 49, 51, 52 are each formed in one piece. The busbars 41, 49, 51, 52 are each formed from the same material throughout.

[0030] The first busbar connection 40 is electrically insulated from the second busbar connection 50. The first busbar connection 40 runs, at least in sections, plane-parallel to the second busbar connection 50. The first busbar connection 40 is spaced from the second busbar connection 50 by a gap 60. The current flows in the first busbar connection 40 in the opposite direction to the second busbar connection 50. The first busbar connection 40 runs close to the second busbar connection 50, so that when current flows in opposite directions, a low-inductance connection exists between the first electrical and / or electronic component 10 and the second electrical and / or electronic component 20 due to electromagnetic interactions.

[0031] As shown in Fig. 2, the second busbar connection 50 is arranged directly below the first busbar connection 40. The first busbar 51 is arranged directly below the connecting busbar 41. The second busbar 52 is arranged directly below the connecting busbar 41. In the context of the present application, an object is understood to mean the first busbar connection 40, the second busbar connection 50, the connecting busbar 41, the connecting busbar 49, the first busbar 51, or the second busbar 52.If a first object is arranged directly beneath a second object, this is understood in the context of the present application to mean that the first object and the second object are arranged relative to one another such that a perpendicular projection of the first object onto the plane of the support surface 31 and a perpendicular projection of the second object onto the plane of the support surface 31 have at least an intersection. The connecting busbar 41 is spaced from the second busbar 52 by a minimum distance that is smaller than a width and / or a length of the connecting busbar 41.

[0032] The first busbar 51 has a first current-carrying region that runs plane-parallel to a second current-carrying region of the connecting busbar 49. Furthermore, the first busbar 51 has a first connection region that is connected, in particular welded, to the second busbar 52. The first connection region is angled, in particular by 90°, from the first current-carrying region. Furthermore, the connecting busbar 49 has a second connection region that is electrically connected, in particular welded, to the connecting busbar 41. The second connection region is angled, in particular by 90°, from the second current-carrying region. The first connection region of the first busbar 51 and the second connection region of the connecting busbar 49 are plane-parallel to one another, in particular in the same plane.The first connection region of the first busbar 51 and the second connection region of the connecting busbar 49 run plane-parallel to the support surface 31. The first current-carrying region of the first busbar 51 and the second current-carrying region of the connecting busbar 49 run perpendicular to the support surface 31. The first current-carrying region of the first busbar 51 and the second current-carrying region of the connecting busbar 49 run plane-parallel to one another.

[0033] The first current-carrying region of the first busbar 51 and the second current-carrying region of the connecting busbar 49 are spaced apart from one another. For this purpose, an insulating element 70 is arranged between the first current-carrying region of the first busbar 51 and the second current-carrying region of the connecting busbar 49. The insulating element 70 is designed, for example, as an insulating plate or insulating foil. The insulating element 70 protrudes beyond the connecting busbar 49 and the first busbar 51, in particular in a direction perpendicular to the support surface 31.

[0034] The electrical connection arrangement 1 further comprises an insulating part 30. The insulating part 30 is arranged between the first busbar connection 40 and the second busbar connection 50. The insulating part 30 is arranged in the intermediate space 60. The insulating part 30 insulates the first busbar connection 40 from the second busbar connection 50. The insulating part 30 is made of an electrically insulating material, for example a plastic. The insulating part 30 is, for example, formed in one piece. The insulating part 30 is, for example, formed continuously from the same material. The insulating part 30 is, for example, mirror-symmetrical. For example, both the connecting busbar 41 and the insulating part 30 are mirror-symmetrical with respect to the same mirror plane.

[0035] A support surface 31 is formed on the insulating part 30. The first connecting busbar 41 rests on the support surface. The support surface 31 is, for example, flat. The connecting busbar 41 runs essentially plane-parallel to the support surface 31 in one area, particularly in the area where the connecting busbar 41 rests on the support surface 31.

[0036] The connecting busbars 41 rests essentially flat against the support surface 31. In the illustrated embodiment, two connecting elements 33 are formed on the insulating part 30. The connecting elements 33 protrude from the support surface 31. The connecting elements 33 protrude through the connecting busbar 41. For this purpose, a recess 45 is formed in the connecting busbar 41 for each connecting element 33. To fasten the connecting busbar 41 to the insulating part 30, the ends of the connecting elements 33 are each widened. Thus, the connecting element 33 has a larger cross-section at its end in a plane parallel to the support surface 31 than the recess 45 through which the connecting element 33 protrudes in a plane parallel to the support surface 31. Thus, the connecting elements 33 create a positive connection between the insulating part 30 and the connecting busbar 41.The widened ends of the connecting elements 33 are produced, for example, by applying pressure and heat to the ends of the connecting elements 33. The connecting busbar 41 is, for example, hot-stitched to the insulating part 30 by means of the connecting elements 33.

[0037] A recess 37 is formed in the insulating part 30 on a side facing away from the support surface 31. The insulating element 70 projects, in particular in a direction perpendicular to the support surface 31, into a recess 37 of the insulating part 30. In the region in which the insulating element 70 projects into the recess 37 of the insulating element 30, the connecting busbar 41 has a bridge-like elevation. The bridge-like elevation. The connecting busbar 41 is arranged on the side of the insulating part 30 facing away from the recess 37 in the insulating part 30. The bridge-like, in particular locally formed, bridge-like elevation of the connecting busbar 41 runs over a region of the insulating part 30 and an edge of the insulating element 70 projecting into the recess 37 of the insulating part in a bridge-like manner. The insulating element 70, in particular an edge of the insulating element 70, projects into the bridge-like elevation of the connecting busbar 41.

[0038] A wall 32 is formed on the insulating part 30, in particular on one edge of the insulating part 30. The wall 32 protrudes from the support surface 31 of the insulating part 30. The wall protrudes beyond the connecting busbar 41 in a direction perpendicular to the support surface 31. In this exemplary embodiment, walls 32 are formed on two opposite edges of the insulating part 30. The walls 32 increase the air gap and / or the creepage distance between the first busbar connection 40 and the second busbar connection 50. Of course, further exemplary embodiments and mixed forms of the illustrated exemplary embodiments are also possible.

Claims

Claims 1. An electrical connection arrangement (1), in particular for use in electric vehicles or hybrid vehicles, comprising a first electrical and / or electronic component (10) and a second electrical and / or electronic component (20), wherein the first electrical and / or electronic component (10) is electrically conductively connected to the second electrical and / or electronic component (20) by a first busbar connection (40) and by a second busbar connection (50), wherein the first busbar connection (40) is electrically insulated from the second busbar connection (50), wherein the first busbar connection (40) runs at least partially parallel to the second busbar connection (50), wherein the first busbar connection (40) is spaced from the second busbar connection (50) by an intermediate space (60), wherein the connection arrangement (1) further comprises an insulating part (30),which is arranged at least partially between the first busbar connection (40) and the second busbar connection (50) and in the intermediate space (60) separates the first busbar connection (40) from the second busbar connection, (50) insulated, characterized in that the first busbar connection (40) comprises a connecting busbar (41) which rests on a support surface (31) of the insulating part (30) and is fastened to the insulating part (30).

2. Electrical connection arrangement according to claim 1, characterized in that the second busbar connection (50) comprises a first busbar (51) and a second busbar (52) electrically connected to the first busbar (51), wherein the first busbar (51) protrudes from the first electrical and / or electronic component (10) and the second busbar (52) protrudes from the second electrical and / or electronic component (20), wherein the first busbar connection (40) comprises a connecting busbar (49), wherein the connecting busbar (49) protrudes from the first electrical and / or electronic component (10), wherein an insulating element (70), in particular an insulating plate or an insulating film, is arranged between the connecting busbar (49) and the first busbar (51), which insulating element (51) is electrically insulated from the connecting busbar (49).

3. Electrical connection arrangement according to claim 2, characterized in that the insulating element (70), in particular in a direction perpendicular to the support surface (31), projects into a recess (37) of the insulating part (30), wherein the first busbar (51) in the region in which the insulating element (70) projects into the recess (37) of the insulating part (30), runs over the insulating element (70) and the insulating part (30) in a bridge-like manner.

4. Electrical connection arrangement according to one of the preceding claims, characterized in that at least one first connecting tab (42) and at least one second connecting tab (43) are formed on the connecting busbar (41), wherein the first connecting tab (42) and the second connecting tab (43) protrude from the insulating part (30), in particular in mutually opposite directions.

5. Electrical connection arrangement according to one of the preceding claims, characterized in that the connecting busbar (41) overlaps the entire insulating part (30) in a bridge-like manner.

6. Electrical connection arrangement according to one of the preceding claims, characterized in that a wall (32) is formed on the insulating part (30), in particular on an edge of the insulating part (30), which wall projects from the support surface (31) of the insulating part (30) and projects beyond the connecting busbar (41) in a direction perpendicular to the support surface (31).

7. Electrical connection arrangement according to one of the preceding claims, characterized in that at least one recess (45) is formed in the connecting busbar (41), wherein at least one connecting element (33) is formed on the insulating part (30) and projects from the support surface (31) of the insulating part (30) from the insulating part (30), wherein the connecting element (33) projects through the recess (45) in the connecting busbar (41).

8. Electrical connection arrangement according to claim 7, characterized in that the connecting element (33) has a widened end (34), wherein the connecting busbar (41) and the insulating part (30) are positively connected to one another by the widened end (34).

9. Electrical connection arrangement according to one of claims 7 or 8, characterized in that the recess (45) is designed as a hole, in particular a circular hole, in the connecting busbar (41).

10. Electrical connection arrangement according to one of claims 7 to 9, characterized in that two recesses (45) spaced apart from one another and in particular identically designed are formed in the connecting busbar (41), wherein two connecting elements (33) spaced apart from one another and in particular identically designed are formed on the insulating part (30), which connecting elements (33) protrude from the support surface (31) of the insulating part (30), wherein each of the connecting elements (33) protrudes through one of the recesses (45).

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