Busbar assembly, on-board electrical system for a motor vehicle, and production method for a busbar assembly

Abstract

The invention relates to a busbar assembly (100). The busbar assembly (100) has a first busbar (110). In addition, it has a second busbar (120) which is arranged at a distance from the first busbar (110). The busbar assembly (100) has at least one connecting element (130) which electrically conductively connects the first busbar (110) and the second busbar (120) to one other and is mechanically more flexible than the first busbar (110) and / or the second busbar (120). The invention additionally relates to an on-board electrical system for a motor vehicle and to a production method for a busbar assembly (100).

Description

[0001] Busbar arrangement, electrical system for a motor vehicle, and manufacturing method for a busbar arrangement

[0002] Technical field

[0003] The present invention relates to an electrical busbar arrangement. Furthermore, the invention relates to an electrical system for a motor vehicle with such a busbar arrangement. The invention also relates to the manufacture of such an electrical busbar arrangement.

[0004] State of the art

[0005] It is known from practical experience that two or more busbars can be connected to form an electrical busbar assembly. Such a busbar assembly can be used in a variety of applications, for example in the automotive sector, or similar fields. In the automotive sector, such a busbar assembly can be used, for example, in the electrical system of a vehicle, e.g., a motor vehicle, and serve to conduct current.

[0006] In such a busbar arrangement, it may be desirable to mount comparatively rigid busbar assemblies. The rigidity can result, for example, from a correspondingly large cross-section of the respective busbars. Description of the invention

[0007] One objective of the invention is therefore to achieve the best possible mountability of an electrical busbar arrangement using the simplest possible means in terms of construction.

[0008] The problem is solved by the subject matter of the independent claims. Advantageous embodiments of the invention are specified in the dependent claims, the description, and the accompanying figures.

[0009] According to a first aspect, an electrical busbar arrangement is proposed. The busbar arrangement comprises a first busbar. Furthermore, the busbar arrangement comprises a second busbar, which is arranged at a distance from the first busbar. The busbar arrangement also includes at least one connecting element. This at least one connecting element electrically connects the first busbar and the second busbar. Moreover, this at least one connecting element is designed to be mechanically more flexible than the first busbar and / or the second busbar.

[0010] With this configuration, the proposed busbar arrangement offers particularly good ease of assembly, as the at least one connecting element, through its flexible design, can compensate for movements, tolerances, or similar factors that may occur within the busbar arrangement. Ideally, the at least one connecting element can be flexible with respect to several, e.g., all, of the three spatial axes, i.e., x-axis, y-axis, and z-axis, in order to compensate for movements, tolerances, etc., around these axes. Likewise, the flexible design of the at least one connecting element can also compensate for and / or bridge relative positions between the first and second busbars that are limited by the installation space. In other words, the busbar arrangement can ensure good ease of assembly and prevent mechanical stresses within a current path, e.g.,Charging path, accomplish. The busbar arrangement requires less installation space. Furthermore, tolerance compensation is possible in each spatial axis. As used herein, the busbar arrangement can serve to conduct and / or distribute electrical energy, although this is not limited here. For example, it can serve for the mechanical force decoupling of a high-voltage busbar, e.g., a high-voltage double busbar, from connection points, e.g., a charging socket and / or battery. The busbar arrangement has at least partially the two busbars, i.e., the first busbar and the second busbar. These can be designed to be at least substantially rigid or inflexible. That is, they cannot deform, at least substantially, under their own weight, disregarding long-term cold yielding. For example, the first busbar and / or the second busbar can be of sheet metal construction.The first busbar and / or the second busbar can be made of an electrically conductive metal. For example, the first busbar and / or the second busbar can be made of an aluminum alloy, such as pure aluminum or an aluminum alloy. The first busbar and the second busbar can have the same or different cross-sectional shapes and / or sizes. For example, a rectangular cross-section can be used. It has been shown that the busbar arrangement is particularly advantageous with comparatively larger cross-sectional sizes for the first busbar and / or the second busbar. By way of example only, the cross-sectional size of the first busbar and / or the second busbar can be at least 120 mm². 2 , in particular at least 180 mm 2 , in particular at least 210 mm 2 , or about 240 mm2 The distance between the first and second busbars can, for example, refer to the distance between the respective edges, butt surfaces, narrow sides, or similar features of the first and second busbars, which are arranged in a common plane or in approximately parallel planes.

[0011] The at least one connecting element can serve to compensate for tolerances, movements, etc. Therefore, it can also be understood and described as a flexible compensating element. It can also serve to bridge the gap between the first and second busbars. The at least one connecting element can, for example, be made of an electrically conductive metal. The connecting element can, for example, have an at least substantially elongated shape. A first end of the at least one connecting element can be connected to the first busbar, and a second end of the at least one connecting element can be connected to the second busbar. At least two connecting elements can also be provided, arranged at least substantially parallel to each other.The greater mechanical flexibility of the at least one connecting element compared to the first busbar and / or the second busbar can be understood as greater flexibility, greater elasticity, lower strength, or the like, or as being less stiff, less rigid, less hard, or the like. In other words, the first busbar can, for example, have a first mechanical flexibility, the second busbar a second mechanical flexibility, and the at least one connecting element a third mechanical flexibility, the third flexibility being greater than the first and / or the second flexibility.The mechanical flexibility of at least one connecting element, in particular the higher mechanical flexibility compared to the first busbar and / or the second busbar, can be based on one or more material properties and / or cross-sectional properties that are accordingly different from those of the first busbar and / or the second busbar.

[0012] According to further training, at least one connecting element can have an electrical conductor. The electrical conductor can be more flexible than the first and / or second busbar. The electrical conductor can be understood as a flexible, elongated element, such as an electrical wire, with or without insulation, a cable, with or without insulation, or the like. The electrical conductor is significantly more flexible than the rigid busbars and therefore allows for compensation of movements, tolerances, or similar variations in the busbar arrangement.

[0013] In a further development, the cross-sectional shape of the at least one connecting element can be selected from: round, Z-shape, V-shape, and omega-shape. Accordingly, the at least one connecting element can be designed as a round conductor, etc. According to a further development, the at least one connecting element can have a smaller cross-sectional area than the first busbar and / or the second busbar. By way of example only, the cross-sectional area of ​​the first busbar and / or the second busbar can be at least approximately 120 mm². 2 , in particular at least 180 mm 2 , in particular at least approximately 210 mm 2 , or about 240 mm 2 The cross-sectional area of ​​the at least one connecting element can be correspondingly smaller. For example, the cross-sectional area of ​​the at least one connecting element can be less than 240 mm². 2 , for example, about 190 mm 2This applies if at least one of the first busbars and / or the second busbars has a cross-sectional area of ​​approximately 240 mm². 2 exhibits. The cross-sectional size of at least one connecting element is a controllable property in order to design it flexibly.

[0014] In a further development, at least one connecting element can be made of a material different from that of the first and / or second busbar. The first and / or second busbar can be made of an aluminum material, e.g., pure aluminum or an aluminum alloy, or the like. The at least one connecting element can, for example, be made of a copper material. Accordingly, the busbar assembly can have a material combination of, for example, (first) aluminum (Al) busbar - copper (Cu) connecting element - (second) aluminum (Al) busbar. The material of the at least one connecting element is a controllable property to allow for flexible design. The first and / or second busbar can also be made of a copper material.The at least one connecting element can, for example, be made of an aluminum alloy. Likewise, other materials are conceivable for the first busbar and / or the second busbar, as well as for the at least one connecting element. Various material combinations between the busbars and the connecting element, not listed above, are also possible, for example: (first) copper (Cu) busbar - copper (Cu) connecting element - (second) copper (Cu) busbar. Further, including asymmetrical, material combinations are feasible, such as: (first) aluminum (Al) busbar - aluminum (Al) connecting element - (second) copper (Cu) busbar. According to a further development, the at least one connecting element can be directly bonded to a respective surface of the first busbar and / or the second busbar.This type of connection can be formed, for example, using ultrasonic welding. Ultrasonic welding also allows for an Al-Cu material pairing.

[0015] In a further development, the busbar arrangement can also include at least one electrical contact element. This contact element can be metallurgically connected to one of the first busbars and the other to the second busbar. The at least one connecting element can be directly metallurgically connected to a surface of the at least one electrical contact element. The connection between the respective connections of the first and second busbars to the respective contact element can be formed, for example, by laser welding. The connection between the respective connections of the first and second busbars to the at least one connecting element can be formed, for example, by ultrasonic welding. The use of the at least one contact element may be required, for example, for specific application reasons.

[0016] According to a further development, at least one connecting element can have at least one braided band made of an electrically conductive metal material. A braided band is inherently more flexible than a busbar. For example, the metal material could be a copper alloy, although other electrically conductive metals are also conceivable.

[0017] In a further training course, at least one braided band can have a cross-sectional size greater than 120 mm. 2 , especially larger than 160 mm 2 , for example, of about 200 mm 2 exhibit.

[0018] Another aspect concerns the electrical system of a motor vehicle. This electrical system features a busbar arrangement as described in the first aspect. The busbar arrangement can, for example, be used to conduct and / or distribute electrical current. Accordingly, it can connect an electrical power source to an electrical load. The busbar arrangement can also be part of a connection point, such as at a vehicle charging socket and / or vehicle battery. Regarding the possible further developments and advantages of the electrical system equipped with the busbar arrangement, please refer to the corresponding explanations in the first aspect.

[0019] Another aspect concerns a method for manufacturing a busbar assembly. The busbar assembly can, for example, be the one described in the first aspect. The method comprises a material-bonded connection of at least one connecting element to a first busbar and a second busbar. The first busbar and the second busbar are arranged at a distance from each other. The at least one connecting element electrically connects the first busbar and the second busbar and is designed to be mechanically more flexible than the first busbar and / or the second busbar.

[0020] Regarding the possible further training and advantages of the busbar arrangement, reference is also made to the corresponding explanations under the first aspect.

[0021] According to further training, at least one connecting element can be directly connected to a respective surface of the first busbar and / or the second busbar by means of ultrasonic welding.

[0022] In a further development, the at least one connecting element can be connected to a surface of at least one electrical contact part, which contact part is arranged between the respective terminals of the first and second busbars and the at least one connecting element and is materially bonded to the respective terminals of the first and second busbars. The at least one connecting element can be directly materially bonded to a surface of the at least one electrical contact part. The connection between the respective terminals of the first and second busbars and the respective contact part can, for example, be formed by laser welding. The connection between the respective terminals of the first and second busbars and the at least one connecting element can, for example, be formed by ultrasonic welding.The use of at least one contact element may be required for specific applications. According to a further development, the at least one connecting element can comprise at least one braided band. The material-bonded connection of the at least one connecting element to the first and second busbars can include: feeding the braided band from a roll to the first busbar or to the respective busbars as an endless band.

[0023] Connect one side of the braided tape to the first and second busbars using a fabric-bonded connection. Cut the braided tape, which is bonded on one side, to the required length. Connect the cut braided tape to the other side of the first and second busbars using a fabric-bonded connection.

[0024] The process can be carried out using a welding machine with an attached or integrated cutting tool. The positioning of the first and / or second busbar can be achieved using a slider, such as a side slider, or similar device. Cutting, for example, to length, the braided tape can cause the braid to unravel or disintegrate. To prevent this, the process can be designed so that the cutting takes place only during or after an initial welding of the braided tape. In this case, the end of the braided tape unwound from the roll is first welded while the other end of the braided tape is still on or attached to the roll. Only then, or afterward, is the braided tape cut, for example, severed, cut to length, etc.

[0025] Alternatively or additionally, if at least one connecting element has at least one braided strand, a wide-dimensioned sonotrode can be used for ultrasonic welding, for example, with a comparatively large sonotrode, so as not to deform the braid's structure. This means the braid can be fed directly from a roll to the ultrasonic welding process without prior processing or preparation. For example, a welding width greater than approximately 30 mm, such as approximately 38 mm for a length of about 200 mm, has been achieved. 2 The conductor cross-section of the connecting element has proven to be suitable.

[0026] In one embodiment, the sonotrode width can be adapted to the width of the respective first and second busbars, taking into account stops and / or clamping devices used when fixing the busbar in the ultrasonic welding device, such as clamping jaws or side slides, which limit the width accessible in the process, i.e. welding width.

[0027] In general, the use of an extra-wide sonotrode can be advantageous, regardless of the type of connector, i.e., whether using one or more individual conductors or a braided band. This advantage arises from the fact that the extra-wide sonotrode allows the connector to be welded in a single operation, irrespective of its design and geometry, within the limits of the current-carrying capacity used. In particular, a braided band can be processed directly from a roll, for example, a stock roll. Similarly, several parallel individual conductors, which together form the connector, can be welded in a single operation if they are arranged side by side and / or one above the other and the total width of the connector, possibly consisting of the several individual conductors, is not significantly wider than the extra-wide sonotrode.

[0028] The aspects, designs, variations, and examples described above can, of course, be combined without this being explicitly stated. Each of the described training courses and each example is therefore optional in relation to any of the aspects, designs, variations, and examples, or even combinations thereof. This disclosure is thus not limited to the individual designs and design variations in the described order or to any specific combination of aspects and design variations.

[0029] Brief character description

[0030] An advantageous embodiment of the invention is explained below with reference to the accompanying figures. These show:

[0031] Fig. 1 shows a top view of a busbar arrangement according to an exemplary embodiment.

[0032] Fig. 2 shows a top view of a busbar arrangement according to an exemplary embodiment. Fig. 3 shows a top view of a busbar arrangement according to an exemplary embodiment.

[0033] Fig. 4 shows a top view of a busbar arrangement according to an exemplary embodiment.

[0034] Fig. 5 shows a perspective top view of a busbar arrangement according to an exemplary embodiment.

[0035] Fig. 6 shows a side view of a busbar arrangement and a welding tool according to an exemplary embodiment.

[0036] Fig. 7 shows a side view of a busbar arrangement and a welding tool according to an exemplary embodiment.

[0037] The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are consistently identified by the same reference numerals.

[0038] Detailed description of implementation examples

[0039] Fig. 1 shows a schematic top view of an exemplary electrical busbar arrangement 100. This can be used to conduct and / or distribute electrical energy, such as in a motor vehicle, although its use is not limited to this.

[0040] The busbar assembly 100 comprises a first busbar 110. Furthermore, the busbar assembly 100 comprises a second busbar 120, which is arranged at a distance from the first busbar 110. The distance between the first busbar 110 and the second busbar 120 can, for example, refer to a distance between respective edges, butt surfaces, narrow sides, or the like of the first busbar 110 and the second busbar 120, which are arranged in a common plane or in planes that are at least substantially parallel to each other. The first busbar 110 and / or the second busbar 120 must be designed to be at least substantially rigid or inflexible. This means that they cannot deform excessively under their own weight. For example, the first busbar 110 and / or the second busbar 120 can be made of sheet metal.The first busbar 110 and / or the second busbar 120 are made of an electrically conductive metal material. For example, the first busbar 110 and / or the second busbar 120 can be made of an aluminum material, e.g., pure aluminum or an aluminum alloy, or the like. The first busbar 110 and the second busbar 120 can have the same or different cross-sectional shapes and / or cross-sectional sizes. For example, a rectangular cross-section can be provided. By way of example only, the cross-sectional size of the first busbar 110 and / or the second busbar 120 can be at least 120 mm². 2 , in particular at least 180 mm 2 , in particular at least 210 mm 2 , or about 240 mm 2 However, the busbar arrangement is also suitable for smaller cross-sectional sizes.

[0041] Furthermore, the busbar arrangement 100 has at least one connecting element 130. This at least one connecting element 130 electrically connects the first busbar 110 and the second busbar 120. Moreover, the at least one connecting element 130 is mechanically more flexible than the first busbar 110 and / or the second busbar 120. The greater mechanical flexibility of the at least one connecting element 130 compared to the first busbar 110 and / or the second busbar 120 can be understood as the at least one connecting element 130 exhibiting greater flexibility, greater elasticity, lower strength, or the like, or being less stiff, less rigid, less hard, or the like.In other words, the first busbar can have a first mechanical flexibility, the second busbar a second mechanical flexibility, and the at least one connecting element a third mechanical flexibility, the third flexibility being greater or higher than the first and / or second flexibility. The at least one connecting element 130 serves to compensate for tolerances, movements, etc. Therefore, it can also be understood and referred to as a flexible compensating element. It can also serve to bridge the gap between the first busbar 110 and the second busbar 120. The at least one connecting element 130 is, for example, made of an electrically conductive metal material. The at least one connecting element 130 has, for example, an at least substantially elongated shape.A first end of the at least one connecting element 130 is connected to the first busbar 110 and a second end of the at least one connecting element is connected to the second busbar.

[0042] In at least some embodiments, the at least one connecting element 130 can have or be designed as an electrical conductor that is more flexible than the first busbar 110 and / or the second busbar 120. The electrical conductor can be, for example, a flexible, elongated element such as an electrical wire, with or without insulation, a cable, with or without insulation, or the like. The electrical conductor is significantly more flexible than the rigid busbars and therefore allows for compensation of movements, tolerances, or the like in the busbar arrangement. For example, the cross-sectional shape of the at least one connecting element 130 can be selected from: round, Z-shape, V-shape, and omega-shape. Accordingly, the at least one connecting element 130 can, for example, be designed as a round conductor, etc., as is indicated by way of example in Fig. 1. According to Fig.1. The electrical conductor has, for example, electrical insulation, e.g. an insulating sheath or the like.

[0043] Furthermore, in at least some embodiments, the at least one connecting element 130 can have a smaller cross-sectional area than the first busbar 110 and / or the second busbar 120. For illustrative purposes only, the cross-sectional area of ​​the first busbar and / or the second busbar can be at least approximately 120 mm². 2 , in particular at least 180 mm 2 , in particular at least approximately 210 mm 2 , or about 240 mm 2 The cross-sectional area of ​​the at least one connecting element 130 can therefore be smaller or less. For example, the cross-sectional area of ​​the at least one connecting element 130 can be less than 240 mm². 2 , for example, about 190 mm 2This applies if at least one of the first busbar 110 and / or the second busbar 120 has a cross-sectional area of ​​approximately 240 mm². 2 The busbar arrangement 100 may, for example, comprise an arrangement and / or material combination of, for example, (first) aluminum (Al) busbar 110 - copper (Cu) connecting element 130 - (second) aluminum (Al) busbar 120. Furthermore, the at least one connecting element 130 may be made of a material different from that of the first busbar 110 and / or the second busbar 120. The first busbar and / or the second busbar may be made of an aluminum material, e.g., pure aluminum or an aluminum alloy, or the like. The at least one connecting element 130 may, for example, be made of a copper material. Accordingly, the busbar arrangement 100 may comprise an arrangement and / or material combination of, for example, (first) aluminum (Al) busbar 110 - copper (Cu) connecting element 130 - (second) aluminum (Al) busbar 120.

[0044] As shown in Fig. 1, the at least one connecting element 130 can, in at least some embodiments, be directly bonded to a respective surface of the first busbar 110 and / or the second busbar 120. This respective connection can be formed, for example, by ultrasonic welding. Ultrasonic welding also allows for an Al-Cu material pairing. As indicated in Fig. 1, for example, the ends of the electrical conductor can be stripped and bonded to the first busbar 110 and the second busbar 120, respectively.

[0045] Fig. 2 shows the busbar arrangement 100 according to a further embodiment in a schematic top view.

[0046] Accordingly, the at least one connecting element 130 can, in at least some embodiments, also have at least two individual connecting elements 130. These can be arranged at least substantially parallel to each other.

[0047] For example, the connecting elements 130 can each be designed as an electrical conductor that is more flexible relative to the first busbar 110 and / or the second busbar 120.

[0048] As shown in Fig. 2, the respective connecting element 130 can, in at least some embodiments, be directly bonded to a respective surface of the first busbar 110 and / or the second busbar 120. This respective connection can be formed, for example, by ultrasonic welding. Ultrasonic welding also allows for an Al-Cu material pairing. As indicated in Fig. 2, the ends of the electrical conductor can, for example, be stripped and bonded to the first busbar 110 and the second busbar 120, respectively.

[0049] Fig. 3 shows a schematic top view of the busbar assembly 100 according to a further embodiment. As in Fig. 1, a single or multiple connecting element 130 is provided. In contrast to the embodiment according to Fig. 1, the busbar assembly 100 according to Fig. 3 also has at least one electrical contact part 140. This is materially bonded to a respective surface of the first busbar 110 and the second busbar 120. The at least one connecting element 130 can be directly materially bonded to a surface of the at least one electrical contact part 140. The connection between the respective surfaces of the first busbar 110 and the second busbar 120 to the respective contact part can, for example, be formed by laser welding.The connection between the respective busbars 110 and 120 to the at least one connecting element 130 can be formed, for example, by ultrasonic welding. The use of the at least one contact element may be required for specific application reasons.

[0050] At least one electrical contact part 140 can be used as a connection part, also terminal.

[0051] Fig. 4 shows the busbar arrangement 100 according to a further embodiment in a schematic top view. As in Fig. 3, at least one electrical contact part 140 is again provided or arranged between the respective busbar 110 or busbar 120 and the at least one connecting element 130.

[0052] In contrast to Fig. 3, the embodiment shown in Fig. 4 provides at least two individual connecting elements 130. These can be arranged at least substantially parallel to each other. For example, the connecting elements 130 can each be designed as an electrical conductor that is more flexible relative to the first busbar 110 and / or the second busbar 120. According to Fig. 4, in at least some embodiments, the respective connecting element 130 can be directly bonded to a surface of the respective electrical contact part 140. This bond can be formed, for example, by ultrasonic welding. Ultrasonic welding also allows for an Al-Cu material pairing. As indicated in Fig. 4, the ends of the electrical conductor can, for example, be stripped and bonded to the respective electrical contact part 140.

[0053] Fig. 5 shows a perspective view of another embodiment of the busbar arrangement 100. Accordingly, the at least one connecting element 130 has at least one braided band made of an electrically conductive metal. A braided band is inherently more flexible than a busbar. For example, the metal can be a copper alloy, although other electrically conductive metals are also conceivable. By way of example only, the at least one braided band can have a cross-sectional area greater than 120 mm². 2 , especially larger than 160 mm 2 , for example, of about 200 mm 2 exhibit, without limitation.

[0054] According to Fig. 5, the at least one connecting element 130, i.e., the at least one braided band, can in at least some embodiments be directly bonded to a respective surface of the first busbar 110 and / or the second busbar 120. This respective connection can be formed, for example, by ultrasonic welding. Ultrasonic welding also allows for an Al-Cu material pairing. As indicated in Fig. 5, the ends of the braided band can, for example, be bonded to the first busbar 110 or the second busbar 120.

[0055] It should be noted that it is also possible to combine the braided band with at least one electrical contact part 140 mentioned above, although this is not explicitly shown in the figures. In this regard, please refer to the description above, which applies equally here.

[0056] Figures 6 and 7 each illustrate the material-bonded connection of the at least one connecting element 130 to either the first busbar 110 or the second busbar 120, or to the at least one electrical contact part 140, which may be optionally provided. According to Figure 6, the at least one electrical connecting element 130 is designed as an electrical conductor. According to Figure 7, the at least one electrical connecting element 130 is designed as a braided band.

[0057] As mentioned above, the material-bonded joining can be achieved using an ultrasonic welding process. According to Figures 6 and 7, a sonotrode 210 and an associated anvil 220 can be provided as a welding tool, welding machine, or the like. The sonotrode 210 and / or the anvil 220 can be movable relative to the workpiece, i.e., the busbar 110, 120, the electrical contact part 140, and / or the at least one connecting element 130, as indicated by arrows in Figures 6 and 7.

[0058] Based on Figures 1 to 7, an exemplary procedure for manufacturing a busbar arrangement, e.g. the busbar arrangement 100 described above, will now be explained.

[0059] The method comprises a material-bonded connection of the at least one connecting element 130 to the first busbar 110 and the second busbar 120. The first busbar 110 and the second busbar 120 are arranged at a distance from each other. The at least one connecting element 130 electrically connects the first busbar 110 and the second busbar 120 to each other and is designed to be mechanically more flexible than the first busbar 110 and / or the second busbar 120.

[0060] As indicated, for example, in Figures 6 and 7, the at least one connecting element 130 can be directly connected to a respective surface of the first busbar and / or the second busbar by ultrasonic welding. It is also possible for the at least one connecting element to be connected to a surface of the at least one electrical contact part 140. The connection between the respective first busbar 110 and the second busbar 120 to the respective contact part 140 can, for example, be formed by laser welding. The connection between the respective first busbar 110 and the second busbar 120 to the at least one connecting element 130 can, for example, be formed by ultrasonic welding.

[0061] As mentioned above, the at least one connecting element 130 can, in at least some embodiments, comprise at least one braided band. The material-bonded connection of the at least one connecting element 130 to the first busbar 110 and the second busbar 120 can comprise: feeding the braided band from a roll to one of the first busbar 110 and / or the second busbar 120 as an endless band; material-bonded connection of one side of the braided band to one of the first busbar 110 and / or the second busbar 120; cutting the braided band, bonded on one side, to a specified length; and material-bonded connection of the cut braided band to the other side of the first busbar and the second busbar.

[0062] The process can be carried out using a welding machine (see, for example, Figs. 6 and 7) with an attached or integrated cutting tool. The positioning of the first busbar 110 and / or the second busbar 120 can be achieved using a slide, e.g., a side slider, or the like. Since cutting, e.g., to length, the braided tape can cause the braid to loosen or unravel, the process can prevent this by performing the cutting only during or after an initial welding of the braided tape. In this case, the end of the braided tape unwound from the roll is first welded while the other end of the braided tape is still on or attached to the roll. Only then, or afterward, is the braided tape cut, e.g., severed, cut to length, etc.Alternatively or additionally, if at least one connecting element 130 has at least one braided band, a wide-dimensioned sonotrode can be used for ultrasonic welding, for example with a comparatively large sonotrode, in order not to deform the braid in its structural form. For example, a welding width greater than approximately 30 mm has been found. 2 , for example, of about 38 mm 2 proved to be suitable.

[0063] The aspects, designs, variants, and examples described above can, of course, be combined without this being explicitly stated. Each of the described training courses and each example is therefore optional to any of the aspects, designs, variants, and examples, or even combinations thereof. This disclosure is thus not limited to the individual designs and design variants in the described order or to any specific combination of aspects and design variants. REFERENCE SIGN LIST

[0064] 100 electrical busbar arrangement

[0065] 110 (first) busbar 120 (second) busbar

[0066] 130 connecting element

[0067] 140 electrical contact part

[0068] 210 (Ultrasonic) welding tool

[0069] 220 (ultrasonic) welding tool

Claims

PATENT CLAIMS 1. Busbar arrangement (100) comprising: a first busbar (110), a second busbar (120) which is arranged spaced apart from the first busbar (110), and at least one connecting element (130) which electrically connects the first busbar (110) and the second busbar (120) and is designed to be mechanically more flexible than the first busbar (110) and / or the second busbar (120).

2. Busbar arrangement according to claim 1, wherein the at least one connecting element (130) has an electrical conductor which is more flexible relative to the first busbar (110) and / or the second busbar (120).

3. Busbar arrangement according to claim 1 or 2, wherein a cross-sectional shape of the at least one connecting element (130) is selected from: round, Z-shape, V-shape and Omega-shape.

4. Busbar arrangement according to one of the preceding claims, wherein the at least one connecting element (130) has a cross-sectional area smaller than that of the first busbar (110) and / or the second busbar (120).

5. Busbar arrangement according to one of the preceding claims, wherein the at least one connecting element (130) is made of a material different from that of the first busbar (110) and / or the second busbar (120).

6. Busbar arrangement according to one of the preceding claims, wherein the at least one connecting element (130) is directly bonded to a respective surface of the first busbar (110) and / or the second busbar (120).

7. Busbar arrangement according to one of claims 1 to 5, further comprising at least one electrical contact part (140) which is materially connected to a respective of the first busbar (110) and the second busbar (120), wherein the at least one connecting element (130) is directly materially connected to a surface of the at least one electrical contact part (140).

8. Busbar arrangement according to one of the preceding claims, wherein the at least one connecting element (130) comprises at least one braided band made of an electrically conductive metallic material.

9. Busbar arrangement according to claim 8, wherein the at least one braided band has a cross-sectional area greater than 120 mm² 2 exhibits.

10. Electrical on-board network for a motor vehicle, comprising a busbar arrangement (100) according to one of the preceding claims.

11. Method for manufacturing a busbar arrangement (100), comprising: joining at least one connecting element (130) with a first busbar (110) and a second busbar (120) by means of a material bond, wherein the first busbar (110) and the second busbar (120) are spaced apart from each other, and wherein the at least one connecting element (130) electrically connects the first busbar (110) and the second busbar (120) and is designed to be mechanically more flexible with respect to the first busbar (110) and / or the second busbar (120).

12. Method according to claim 10, wherein the at least one connecting element (130) is directly connected to a respective surface of the first busbar (110) and / or the second busbar (120) by means of ultrasonic welding.

13. Method according to claim 10, wherein the at least one connecting element (130) is connected to a surface of at least one electrical contact part (140) that is located between the respective first busbar (110) and the second busbar (120) and the at least one connecting element (130). arranged and connected to the respective first busbar (110) and second busbar (120) in a material-bonded manner.

14. Method according to one of claims 11 to 13, wherein the at least one connecting element (130) comprises at least one braided band, and the material-bonded joining of the at least one connecting element (130) to the first busbar (110) and the second busbar (120) comprises: Feeding the braided tape from a roll to the respective end of the first busbar (110) and the second busbar (120) as an endless tape, joining one side of the braided tape to the first busbar (110) and the second busbar (120) in a material-bonded manner, Cutting the braided tape, which is joined on one side by a material bond, to a length appropriate to the intended length, and joining the cut braided tape to the other side of the first busbar (110) and the second busbar (120) by a material bond.

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