Connection arrangement and method for producing a connection arrangement

Abstract

The invention relates to a connection arrangement comprising a metallic flat part having a through-opening, and a metallic contact element arranged in the through-opening, wherein the contact element has a disc-shaped first component and a rod-shaped second component, and the disc-shaped first component is integrally bonded to the flat part on its side facing the flat part. The contact element is an at least two-part assembly of at least the first component and the second component.

Description

[0001]2304WO One Mobility Autokabel GmbH Connection Arrangement and Method for Manufacturing a Connection Arrangement The subject matter relates to a connection arrangement between a metallic flat part and a metallic contact element, as well as a method for manufacturing such a connection arrangement. Flat conductors (so-called busbars) are increasingly used in electrical applications, particularly in automotive applications. Flat conductors are used not only as power lines, but also as battery cell connectors, module connectors, or the like. The flat conductors are generally formed from a metallic flat part. For contacting contact elements, it is known to apply the contact elements to the surface of the metallic flat part and preferably join them there by a metallurgical bond, in particular by welding.When welding a flat metal part made of a first metallic material to a metallic contact element made of a second metallic material, increased contact corrosion can occur at the weld seam, depending on the material combination. Furthermore, when using aluminum or an aluminum alloy, especially for the flat part, the contact point can be damaged under high mechanical stress. When using aluminum or aluminum alloys, the metallic material can flow at the contact point. Besides welding the flat part to the contact element, mechanical fixing of the contact element to the flat part is also known. In this method, for example, a connecting bolt is inserted through a through-hole in the flat part, and the contact element is connected to the connecting bolt. The connecting bolt and / or the contact element are thus mechanically fixed to the flat part.This is usually done by screwing. However, over time, and especially under mechanical stress, such a screw connection can become mechanically unstable, particularly when using aluminum or an aluminum alloy. The clamping force of the screw and mechanical stress can cause the material to flex in the area of ​​the through-hole of the flat part, resulting in plastic deformation of the flat part and leading to the loosening of the mechanical connection. In the worst case, the connection fails and the contact element detaches from the flat part. To prevent this, it has been proposed to place a metallic contact element in the through-hole. The metallic contact element serves as a mechanical and electrical contact point for other connecting elements that are to be attached to the metallic flat part. For example,A sleeve-shaped contact element is arranged in the through-hole. A connecting bolt can be inserted through this through-hole. The contact element thus stabilizes the mechanical connection between the flat part and the connecting bolt. However, it has been found that such contact elements, especially those that are collar-shaped and rest on the flat part around the through-hole, are expensive to manufacture. T-shaped and sleeve-shaped contact elements can be manufactured as turned or forged parts. Such a manufacturing method is complex and therefore undesirable. The object of this invention was to provide a connection arrangement between a flat conductor and a contact element that is particularly simple and cost-effective to manufacture. This object is achieved by a connection arrangement according to claim 1.2304WO One Mobility Autokabel GmbH A metallic flat part with a through-opening is proposed. The metallic flat part can have a polygonal, in particular a quadrilateral, cross-sectional profile. In particular, the metallic flat part can have a square or rectangular cross-sectional profile. The cross-sectional profile of the flat part can be formed from two parallel wide sides and two parallel narrow sides. A wide surface of the flat part extends longitudinally along the wide sides, and a narrow surface extends longitudinally along the short sides. A through-opening preferably extends completely through the metallic flat part. A through-opening preferably extends along a surface normal on a wide surface. A through-opening can be a punched opening or a drilled opening.A metallic flat part can be a flat conductor, a battery cell connector, a module connector, a terminal, a crimp terminal, or the like. A metallic flat part can be used as a flat conductor in automotive applications, for example, as a power conductor, battery conductor, or the like. In a motor vehicle, a metallic flat part can connect a battery to a powertrain, a starter and / or generator, or a drive motor, or connect electrical components to each other. An electrical component is preferably connected to the metallic flat part. This can be an electrical component, a conductor, in particular a round conductor, a flexible conductor, in particular a flexible round conductor, or the like. The connection arrangement has a contact element for connecting such an electrical component. In this case, a metallic contact element is arranged in the through-opening.The contact element is made of two independent components. The contact element has a disc-shaped first component and a rod-shaped second component. The disc-shaped first component rests against the flat part in the area of ​​the through-hole with its side facing the flat part and is bonded to the flat part. The rod-shaped component is arranged in the through-hole. The contact element thus extends at least partially into the through-hole of the flat conductor, with the outer surface of the second component extending along the through-hole of the flat conductor. Preferably, the contact element extends completely through the through-hole. The contact element is formed as a two-part assembly consisting of at least the first component and the second component.In other words, the contact element, when assembled, is formed from two independent components: a first component is the disc-shaped component and a second component is the rod-shaped component. This allows the two components to be manufactured independently. A disc-shaped component can be easily produced as a stamped or pressed part from sheet metal, and a rod-shaped component can be easily produced from a tube or wire. The two components can then be joined to form the metallic contact element. The components can be joined by material bonding, form-fitting, and / or force-fitting. Force-fitting is preferably achieved by applying force through fasteners, for example, a screw passing through both the first and second components.The two components are preferably joined to form the metallic contact element during the joining of the first component to the flat part. This allows the flat part, the first component, and the second component to be provided independently, and the components can preferably be joined sequentially in a multi-stage joining process. 2304WO One Mobility Autokabel GmbH. The second component is arranged in the through-opening of the flat part such that an end face of the second component facing away from the first component protrudes from the surface of the flat part on the side facing away from the first component, is flush with it, or is recessed from it. An end face of the second component facing away from the first component is an end face that is not in contact with the first component, is not enclosed by the first component, and is spaced apart from the first component.The distance between the far end face of the second component and the first component is determined by the height of the second component, provided that an end face of the second component rests on a main surface of the first component, or by the height of the second component minus the penetration depth of the second component into the first component, provided that the end face of the second component facing the first component is enclosed by the first component. If the far end face of the second component protrudes from the surface of the flat part on the far side, this end face represents a potential screwing surface for a bolt head and / or other components.If the end face of the second component facing away from the first is flush with the side of the flat part facing away from the first component, the overall height of the connection can be minimized. Optionally, the second component can also be offset with its end face facing away from the first component relative to the side of the flat part facing away from the first component, so that the distal end face of the second component is located within the opening of the flat conductor. The second component can, for example, include a threaded section into which a screw can be inserted. 2304WO One Mobility Autokabel GmbH As already explained at the beginning, connecting a flat part to an electrical component can be problematic if they are made of different metal materials. In particular, contact corrosion can occur at the connection point.To address this, the contact element can be made, at least partially, of a different metallic material than the flat part. The electrical component to be electrically contacted with the flat part can be connected to the contact element's component, whose material is electrically similar to that of the electrical component, and then electrically connected to the flat part via the contact element. It is proposed that the first component be made of a first metallic material and that the second component be made of a second metallic material different from the first. For example, it is possible that the first component is made of a first material similar to the metallic material of the flat part. In this case, the first component can be directly joined to the flat part by a metallurgical bond.The second component can be different from the first and be joined to it in an area that is exposed to little or no environmental influences. This prevents or minimizes contact corrosion between the first and second components. An electrical component made of a second metallic material, similar to the second metallic material of the second component, can be connected to the second component. This also minimizes contact corrosion at this contact point. According to one embodiment, it is proposed that the first component and / or the second component be made of aluminum or an aluminum alloy. In particular, the flat part is made of aluminum or an aluminum alloy, and the first component is also made of aluminum or an aluminum alloy.2304WO One Mobility Autokabel GmbH According to one embodiment, it is proposed that the first component and / or the second component be made of copper or a copper alloy. In particular, the second component is made of a copper alloy. It is also proposed that the first component and / or the second component be made of iron or an iron alloy, in particular steel. In particular, the second component is made of steel. The second component can be arranged in a rod-like form in the through-opening of the flat part and serve as a mechanical contact element. The second component can serve to absorb compressive forces. The second component can increase the mechanical strength of the contact element against compression. The second component can also be referred to as a mechanical contact element. The mechanical contact between the assembly and the flat part is essentially realized via the second component.The first component can be described as an electrical contact element. An electrical connection from the flat part to the assembly is essentially achieved via the first component. Preferably, the materials of the first and second components are selected to have greater strength than the material of the flat part. The materials of the first and second components exhibit an elastic limit Rp0.2 that is greater than the elastic limit of the flat part material. According to one embodiment, it is proposed that the first component be welded to the flat part on its side facing the flat part. The welding between the flat part and the first component results in a low electrical contact resistance, allowing the first component to serve as the electrical component of the contact element.The second component can be welded to the side of the first component facing the flat part at one of its end faces. The second component (2304WO One Mobility Autokabel GmbH) can be inserted through the through-hole and pressed against the first component on the side facing the flat part. The second component can then optionally be welded to the first component. Alternatively, the first component may have a through-hole. This through-hole can be congruent with or geometrically similar to the through-hole of the flat part. This through-hole can be coaxial with the through-hole of the flat part. The second component can be inserted through the through-hole of the first component. The second component can be materially bonded, in particular welded, to the inner surface of the through-hole of the first component.The second component can extend with its opposing end faces from a first distal end of the contact element to a second distal end of the contact element. The first component can be arranged with its through-opening on the second component. In one possible embodiment, the first component then does not project beyond an end face of the second component. In another possible embodiment, the distal end face of the second component rests against a main surface of the first component. The second component projects beyond the first component in at least one dimension. Thus, neither component completely encloses the other, but only partially.The first component provides a contact surface against which the second component rests and extends from this surface in a direction orthogonal to the main surfaces of the first component, away from the first component. In particular, the second component projects into at least a section of the through-opening of the flat conductor into which the first component does not penetrate. For example, the second component extends through the through-opening of the flat conductor to at least 80%, preferably at least 90% of its height, and in particular completely. The first component preferably penetrates the through-opening to a maximum of 60% of its height, and more preferably to a maximum of 40%, and in particular to a maximum of 20% of its height.Accordingly, the portion of the contact element that essentially rests on the surface of the flat part and the portion of the contact element that extends through the through-hole are subdivided into two geometrically simple components, whose geometry and material properties can be independently adapted to the respective requirements. In one embodiment, it is proposed that the second component be welded to the inner surface of the through-hole of the flat part via its outer surface. Welding the second component to the flat part in the area of ​​its through-hole reduces the electrical contact resistance between the contact element and the flat part. Furthermore, the mechanical fixation of the contact element to the flat part can be optimized.Welding the second component in the through-hole can be achieved, for example, by friction welding, particularly rotary friction welding or ultrasonic welding. For instance, after the first component has been placed on the flat part and optionally already welded to it, the second component is inserted into the through-hole on the side of the flat part opposite the first component and then set into rotation using a friction welding tool. This rotation creates a material bond between an end face of the second component and a surface of the first component, and also between the outer surface of the second component and the inner surface of the through-hole in the flat part.2304WO One Mobility Autokabel GmbH According to one embodiment, it is proposed that the second component is tubular with an opening extending longitudinally along its length. In this case, it can also be referred to as a sleeve-shaped second component. To avoid misunderstandings, it is clarified that a tubular second component is still also rod-shaped. Its outer surface is rod-shaped, with the addition that it has a longitudinally extending opening. The first component can be aligned with the second component such that a center point of the first component aligns with the center point of the second component. A through-opening can also be provided in the first component. In such a first component, a center point of the through-opening of the first component can align with a center point of the second component.The opening in the second component can be centrally located so that the opening of the second component is also aligned with the center point of the first component. In a particularly preferred embodiment, the first component and the second component each have a through-opening, wherein the through-openings can be positioned at least partially congruently, so that a bolt, for example a screw, can be passed through the first and the second component. The bolt head (e.g., screw head) preferably rests against the second rod-shaped component. The surface of the second component adjacent to the flat part, as well as the flat part itself, provide a screwing surface. Preferably, the contact surface between a screw inserted into the second component and the first component is selected such that a contact pressure of at least 10 N / mm² is present at the electrical contact surface. 2after screwing. Alternatively, a screw can also be inserted into the contact element in such a way that the screw head rests against the first component. 2304WO One Mobility Autokabel GmbH The inventors have determined that when using a bolt that is guided through the through-openings of the first and second components, a material-bonded connection of the second component can be dispensed with. In this case, the first disc-shaped component is preferably material-bonded to the flat part, while the second component is inserted into the through-opening of the flat part on the surface of the flat part opposite the first component. The contact element is formed by force-fit joining of the first and second components, with the bolt guided through the through-openings of the components and the flat part holding the components in position relative to each other.The second component preferably contacts, within the through-opening of the flat part, either with its end face the main surface of the first component facing the through-opening, or with its outer surface the inner surface of the first component in the region of the through-opening. Such embodiments simplify the manufacture of the two-part contact element, since only the first component needs to be bonded and the second component is simply inserted. Even a second component that is not bonded fulfills its function as a mechanical contact element for absorbing compressive forces. The end face of the first component facing away from the flat part forms the electrical contact surface.Preferably, the electrical contact surface is selected such that its size corresponds to at least half the conductor cross-section of the flat part, and particularly preferably to at least one and at most four times the conductor cross-section. This is advantageous to provide a sufficiently high current-carrying capacity of the connection and to prevent heating. It is also possible that the diameter of the through-hole of the first component corresponds to an outer diameter of the second component, and that the second component is inserted into the through-hole of the first component (2304WO One Mobility Autokabel GmbH). In this case, a material-locking, form-locking, and / or force-locking connection can be established between the first component and the second component along the end-side circumferential surface of the second component and the inner surface of the through-hole of the first component.It is also proposed that the first component be arranged with its center point on a central axis of the through-opening of the flat part. Alternatively, a through-opening can be provided at the center point of the first component, aligned with the through-opening of the flat part. The diameter of the through-opening of the first component can be greater than, equal to, or less than the diameter of the through-opening of the flat part. According to one embodiment, it is proposed that the second component be tubular with an opening extending longitudinally along the second component, the inner surface of which has an internal thread. The second component can serve as a mechanical component for fixing an electrical attachment; for example, a screw bolt can be screwed into the second component.Particularly if the second component is made of a stronger material than the first component and / or the flat part, such a screw connection in the second component can be mechanically more stable than a direct screw connection of the bolt to the flat part and / or the first component. Additionally or alternatively, the inner surface of the through-hole of the first component can have an internal thread. In such a case, a bolt can be screwed exclusively to the first component or to both the first and second components. A bolt can be screwed to the first and / or the second component at the respective thread. 2304WO One Mobility Autokabel GmbH. It is also possible that the first component has a bolt, in particular a threaded bolt, on the side facing away from the flat part.The first component can be at least partially disc-shaped and, in particular, can rest on the flat part in its disc-shaped area and be welded to it there. On the unwelded side, the first component can have a bolt, in particular a threaded bolt. For rotary friction welding, it is advantageous if the first component and / or the second component are axially symmetrical about their longitudinal axis. The first component and / or the second component can be rotationally symmetrical, axially symmetrical, in particular elliptical or the like about the longitudinal axis. An elongated shape, in particular a polygonal shape, can also be provided. In the case of a non-rotationally symmetrical shape, the first component and / or the second component can be used as an external drive.A rotary friction welding tool can be positioned on the outer circumference of the first and / or second component and impart rotation to the component. This rotation can cause the component to weld to the flat part and / or the other component. According to one embodiment, it is proposed that the first and / or second component be formed as a stamped, milled, turned, or forged part. As a stamped part, the first and second components can be manufactured particularly easily from a sheet of metal.If the first and / or the second component is a milled, turned, or forged part, this is still advantageous compared to a one-piece contact element as known in the prior art, since the two individual components are considerably easier to mill, turn, or forge than a complex component, which, for example, is formed from two different areas with different outer circumferences and different surface areas. In this respect, each individual component can be milled, turned, or forged more easily than if the assembly were formed in one piece. According to one embodiment, it is proposed that the first component and / or the second component be metallically coated. A metallic coating can be applied to the component material. This can be done using a wet chemical process.Depending on the specific application, and in particular on the material of the flat part and / or the material of the electrical component to be attached to the contact element, it may be advantageous to coat the first and second components with the same metallic material. It may also be advantageous to coat the first and second components with different materials. According to one embodiment, it may be advantageous to coat the second component with a different metallic material on an outer surface than on its inner surface and / or end face. In particular, the first and / or the second component may each be coated only in certain areas, while other areas of the component remain uncoated. It is suggested that a suitable coating material be tin, gold, nickel, silver, copper, or an alloy thereof.In particular, electroplated nickel has proven advantageous for coating the first and / or second component, especially due to its ductility. A coating of pure nickel is preferably applied as the electroplated nickel. Nickel sulfamate is particularly preferred for electroplating. A multilayer, especially a two-layer, coating is also proposed. In this process, at least one component can be coated with a first metallic material in a first step, and in a second step, the coated component can be coated with a metallic material different from the first metallic material. It has been found that undercoating with nickel is particularly useful. In this process, at least one 2304WO One Mobility Autokabel GmbH component is first coated with a nickel layer and / or a nickel alloy, in particular a nickel-phosphorus alloy.The nickel-containing layer provides good mechanical protection for the component. A tin, gold, copper, silver, or alloy layer can be applied over the nickel-containing layer. Under-nickel plating and tin plating can be advantageous, for example, if the component is subsequently soldered or welded to an electrical component. A tin layer can also be useful to provide a good electrical contact layer, and the tin layer does not need to be removed in the welding area. In particular, a coating with nickel, gold, copper, or silver—with nickel, copper, and silver being preferred for cost reasons—has proven advantageous in the welding area. According to one embodiment, a coating with a maximum thickness of 10 µm is proposed.It has been found that such a layer thickness represents a good compromise between electrical conductivity at the electrical interface between the component and the flat part on the one hand, and mechanical stability and protection against environmental influences on the other. In particular, a single-layer coating, i.e., a coating comprising a homogeneous layer of a material, has a thickness of 1 µm to 10 µm, preferably 3 µm to 10 µm. For a multi-layer coating, a maximum coating thickness of 20 µm is proposed. A multi-layer coating comprises several superimposed layers of different compositions. Preferably, each of the layers has a maximum thickness of 10 µm. According to one embodiment, it is proposed that the outer diameter of the first component be larger than the inner diameter of the through-hole of the flat part.As previously explained, the first component can be arranged concentrically on the through-opening of the flat part. If the diameter of the first component is larger than the diameter of the through-opening of the 2304WO One Mobility Autokabel GmbH flat part, the first component rests against the through-opening of the flat part in a disc-like fashion. Along the circumference of the through-opening of the flat part, the component can be joined to the flat part by a material bond, in particular by welding. A through-opening in the first component, however, can have the same or a smaller diameter than the diameter of the through-opening of the flat part. According to one embodiment, it is proposed that the first component has a first region on its side facing away from the flat part and a second region on its side facing the flat part, which points towards the flat part. The second region can form a projection.In a cross-section along a longitudinal axis of the first component, a first region and a second region are visible. In the assembled state, the second region faces the flat part. The second region forms a projection. The second region is offset from the first region. The second region has a smaller diameter than the first region. Alternatively, the second region may have a larger diameter than the first region. In a cross-section along a longitudinal axis of the first component, the first component may have a flange-shaped section. In this case, a first region may have a first diameter and a second region a second diameter, and these diameters may differ. Either the diameter of the first region is larger than the diameter of the second region, or the diameter of the first region is smaller than the diameter of the second region.If the diameter of the first section is larger than the diameter of the second section, the second section forms a projection that can penetrate the flat part during welding, thus improving the connection between the first component and the flat part. 2304WO One Mobility Autokabel GmbH. If the diameter of the second section is larger than the diameter of the first section, the second section forms a kind of plate that increases the contact area of ​​the first component on the flat part and offers a larger welding area. An offset occurs at the transition between the first and second sections, where the diameter of the first component changes. In this case, the first section preferably offsets from the second section at an angle, particularly a right angle. However, it is also possible that there is a rounded transition between the first and second sections.A rounded offset, particularly in the form of a fillet, is desired. A chamfer between the first and second regions, especially a 45-degree chamfer, is particularly preferred. According to one embodiment, the projection is proposed to be cylindrical or conical. The second region forms the projection. The projection is located on the side of the component facing the flat part. This projection can be cylindrical or conical. The projection can have a through-hole, particularly a cylindrical through-hole. If the projection is conical, it can taper towards the flat part. This offers the advantage that, during welding, the projection initially rests on the flat part with a smaller contact area, and during welding, the projection, which widens towards the first region, gradually penetrates the weld zone.The small contact area promotes rapid melting of the weld zone, enabling shorter cycle times for the welding process. In one embodiment, it is proposed that the second area has a larger diameter than the first. In this case, the first component has a flange or plate in the second area. The second area forms a larger contact surface on the flat part, as previously explained. 2304WO One Mobility Autokabel GmbH. In another embodiment, it is proposed that the second area, in the longitudinal direction of the contact element, has a material thickness equal to or less than that of the first area. The second area is the area that, in the joined state, forms the weld surface through which the contact element is welded to the flat part.It is proposed that the second region penetrates the flat part at least partially, and in particular completely, during welding in the longitudinal direction of the contact element. It may be advantageous, for example, for the second region to at least partially plasticize during welding. In this case, it is preferred that the material thickness of the second region be less than that of the first region. According to one embodiment, it is proposed that the second region has a cross-sectional area perpendicular to the longitudinal axis of the contact element, which is geometrically similar to or congruent with the cross-sectional area perpendicular to the longitudinal axis of the contact element of the first region. In a top view of the first and second regions, i.e., parallel to the longitudinal direction, the cross-sectional areas of the regions can be geometrically identical, geometrically similar, or geometrically different from one another.For example, geometrically similar cross-sectional areas with different diameters can be provided. Cross-sectional areas can be polygonal with straight or curved edges. It is also possible for the cross-sectional areas to be elongated with rounded corners, similar to a slotted hole. In particular, the outer circumference of the area with the larger diameter can be polygonal. The outer circumference of the area with the smaller diameter can be axially symmetrical or rotationally symmetrical. A polygonal circumference can be angular with straight edges, in particular at least triangular. A polygonal circumference can be multi-circular with curved edges. The circumference can be meandering with areas projecting further outwards and areas projecting less far outwards. A polygonal outer circumference can be suitable for an external drive of a friction welding tool.A friction welding tool can encompass the circumference of the area with the larger diameter. Due to its polygonal shape, this allows for particularly effective torque application to the component, enabling the contact element to be welded to the flat part by rotary friction welding. As previously explained, the cross-sectional areas of the first and second areas can be different, geometrically similar, or geometrically identical. According to one embodiment, it is proposed that the first component, and in particular the second area, has a profiled surface, especially a concave or convex surface, on its side facing the flat part. The shape of the surface can be selected depending on the welding process used, for example, rotary friction welding, pressure welding, resistance welding, or the like.The shape can also be chosen depending on the material combination between the material of the flat part and the material of the first component. It is also possible for the surface to be profiled with protrusions. The protrusions can be evenly or irregularly distributed around a central point of the first component. In particular, the protrusions can be arranged at equal angular intervals and at the same or varying distances from the center point of the first component. The protrusions can preferably be undercut, such that one diameter of the protrusions increases towards the flat part when joined. This allows molten material from the welding process to flow behind the protrusions and solidify there, thus ensuring particularly good mechanical stability of the weld.2304WO One Mobility Autokabel GmbH According to one embodiment, it is proposed that the first component is welded to the flat part with a penetration depth of at least 0.2 mm, preferably between 0.2 mm and 2 mm, and particularly preferably between 0.2 mm and 1.5 mm. During welding, the first component is pressed against the flat part with its side facing the flat part. Subsequently, the interface between the flat part and the first component is melted by applying welding energy. This can be achieved through frictional energy, electrical energy, or the like. During melting, a joining zone is created into which the first component can penetrate. In particular, the material of the flat part can have a lower melting point than the material of the first component and / or the coating of the first component, so that the material of the flat part melts first. By applying pressure, the first component can penetrate into the flat part.It has been found that a penetration depth of 0.2 mm to 2 mm is advantageous both mechanically and electrically. If the penetration depth is too small, the mechanical and electrical properties of the joint deteriorate. Very large penetration depths, on the other hand, require very high welding energy and, furthermore, can lead to mechanically disadvantageous joints in combination with thin flat parts. According to one embodiment, it is proposed that the second area, in the welded state, is completely immersed in the flat part. As explained previously, the second area can form a projection. It is proposed that the second area has a material thickness such that it corresponds to the penetration depth of the first component into the flat part in the welded state.The first component is preferably designed as a single piece, wherein the first area and the second area denote different sections of the first component. The second component is also preferably designed as a single piece. 2304WO One Mobility Autokabel GmbH According to one embodiment, it is proposed that a surface of the first component facing away from the flat part protrudes from the surface of the flat part in the joined state. Preferably, the flat part has insulation, and the first component protrudes from the surface of the insulation facing away from the flat part. The first component is preferably welded to the flat part only with such a penetration depth that at least a part of the first component protrudes from the surface of the flat part, in particular the wide surface of the flat part.This prevents a mechanical or electrical component placed on the first component from coming into direct contact with the flat part. It is also proposed that an end face of the second component, facing away from the first component, protrudes from the surface of the flat part, is flush with it, or is recessed from it. Preferably, an end face of the second component protrudes from the wide surface of the flat part. The protrusion of the first and / or second component from the wide surface of the flat part is preferably between 0.1 mm and 1 mm. A minimum dimension of 0.1 mm ensures that, in the area of ​​the through-hole and the electrical contact element, an electrical and / or mechanical component resting against the contact element does not come into direct contact with the flat part.In a preferred embodiment, the flat part has insulation, and the first component protrudes at least 0.1 mm from the insulation on the broad surface of the flat part. It is particularly preferred if the first component and the second component of the metallic contact element are made of two different materials. It is also preferred if the materials have different ductilities. In particular, the first disc-shaped component comprises aluminum, an aluminum alloy, copper, or a copper alloy, and the second rod-shaped component comprises aluminum, an aluminum alloy, iron, an iron alloy, or, in particular, steel. These materials have proven to be particularly advantageous for fulfilling the respective electrical and mechanical requirements as an electrical contact element and as a mechanical contact element.If both the first and second components are made of aluminum, different aluminum alloys are selected. The second component may project beyond a through-opening of the first component. Preferably, the end face of the second component facing away from the first component is not recessed relative to the adjacent main surface of the flat part, but either sits flush with the main surface of the flat part or, more preferably, projects beyond the adjacent main surface of the flat part. This facilitates, for example, screwing the components onto the end face of the second component. According to one embodiment, a clearance fit between the second component and the through-opening of the flat part can be provided. If the second component is bonded to the flat part along its outer surface, a clearance fit can only exist before the component is joined to the flat part.If the connection arrangement does not involve a direct connection between the second component and the flat part, a clearance fit between the flat part and the second component is possible. The second component serves as a mechanical contact element, particularly for mechanically stabilizing the connection. A direct contact surface between the outer surface of the second component and the inner surface of the through-hole of the flat part is not necessary. The largest diameter of the second component is preferably smaller than the smallest diameter of the through-hole of the flat part. 2304WO One Mobility Autokabel GmbH. According to one embodiment, it is proposed that the first component be press-welded, friction-welded, ultrasonically welded, laser-welded, or resistance-welded to the second component.It is also proposed that the first component be press-welded, friction-welded, ultrasonically welded, laser-welded, or resistance-welded to the flat part. Press welding allows the components to be joined to each other and / or to the flat part in a particularly simple and materially bonded manner. According to one embodiment, it is proposed that an outer circumference of the first component and / or an inner circumference of the through-hole of the first component and / or an inner circumference of the through-hole of the second component be polygonal with straight or curved side edges or be oblong. Particularly with a polygonal and oblong outer circumference, the first component can provide a contact surface for a friction welding tool. A polygonal and oblong outer contour makes it particularly easy to apply torque to one of the components or the assembly in the sense of an external drive.In the case of an internal drive, a friction welding tool can be inserted into the through-opening of the first component and / or the through-opening of the second component. If the inner circumference is polygonal or oblong, a torque can also be applied particularly effectively to one of the components or the assembly, thus effecting a weld. A further aspect is a method according to claim 15. It is proposed that, preferably independently of one another, the first component is materially joined to the flat part and the first component is materially joined to the second component. Two joining steps are proposed. In a first joining step, a connection can be formed between the first component and the flat part 2304WO One Mobility Autokabel GmbH, and in a second joining step, a connection can be formed between the first component and the second component.In a first joining step, a connection can be formed between the first component and the second component, and in a second joining step, a connection can be formed between the assembly and the flat part. It is proposed that the first component is first joined to the flat part by a material bond, and then the second component is joined to the first component by a force-fit, form-fit, and / or material bond. After joining the second component to the first component, the components form an assembly. The connection of the assembly to the flat part is ensured by the material bond of the first component. In one embodiment of the method, it is proposed that the first component and the second component are first joined to form an assembly by a material bond. The assembly, including the second component, is then inserted into the through-opening of the flat part.The assembly is joined to the flat part, at least in the area of ​​the first component, by means of a material bond. The contact element consisting of the first and second components can be manufactured first. This makes it possible to stock the contact element and insert it into the flat part in a single operation. The two components can be manufactured independently of each other. The two components can be made from different metallic materials. After the assembly has been assembled, it can be inserted into the through-opening of the flat part. Subsequently, a material bond can be established between the assembly and the flat part, in particular via a material bond between the first component and the flat part.2304WO One Mobility Autokabel GmbH In a further preferred embodiment of the method, the first component is first bonded to the through-opening of the flat part by a material bond, and the second component is then bonded to the first component by a force-fit and / or form-fit. Particularly preferably, the first component and the second component each have a through-opening, wherein, after the second component is inserted into the through-opening of the flat part, a bolt is inserted through the through-openings of the components, which connects the components by a force-fit. The subject matter is explained in more detail below with reference to a drawing showing exemplary embodiments. In the drawing: Fig. 1 shows a schematic exploded view of a connection arrangement of the type; Fig. 2a, b show top views of a first component according to exemplary embodiments; Fig.Fig. 3 a, b Top views of a first component according to exemplary embodiments; Fig. 4 a, b Top views of a first component according to exemplary embodiments; Fig. 5 a, b Top views of a first component according to exemplary embodiments; Fig. 6 a, b Top views of a first component according to exemplary embodiments; Fig. 7 ab Top views of a second component according to exemplary embodiments; Fig. 8a-b Top views of a second component according to exemplary embodiments; Fig. 9 ab Top views of a second component according to exemplary embodiments; Fig. 10 ab Top views of a second component according to exemplary embodiments; Fig. 11a-e Sectional views of a first component according to exemplary embodiments; Fig. 12a-c Views of an assembly according to exemplary embodiments; Fig. 13 a sectional view of a joined connection arrangement according to an exemplary embodiment. Fig. 1 shows a connection arrangement 100 in an exploded view.Shown is a flat part 2 with a through-opening 4 and a metallic contact element 6 consisting of a first component 8 and a second component 10. The first component 8 can be referred to as an electrical contact element, and the second component 10 can be referred to as a mechanical contact element. The first component 8 and the second component 10 are joined together at an end face 10a of the second component 10. The end face 10a of the second component 10 rests against the side of the first component 8 facing the flat part 2 and is joined there by a material bond. The side of the first component 8 facing the flat part 2 is joined to the flat part 2 by a material bond, at least partially, preferably completely, around the through-opening 4. The contact element 6 is formed as a two-part assembly and, in its joined state, is arranged in the through-opening 4.The metallic materials for the first component 8 and the second component 10 have already been described. The first component 8 and the second component 10 can be made of the same or different metallic materials. The flat part 2 preferably comprises aluminum, particularly preferably annealed aluminum. The first component and the second component are preferably made of the following material combinations: aluminum / aluminum, copper / copper, aluminum / copper, steel / steel, or steel / aluminum, including alloys, where the first-mentioned material can be used for the first component 8 and the second-mentioned material for the second component 10, or vice versa. The first component 8 and the second component 10 can be coated with at least one metallic material.The first component 8 and the second component 10 can be coated with different metallic materials. Each component 8 and the second component 10 can be coated with one or more layers of the same or different metallic materials. The first component 8 can be joined to the second component 10 by pressure welding, friction welding, rotary welding, ultrasonic welding, laser welding, resistance welding, or the like. The first component 8 can also be joined to the flat part 2 by pressure welding, friction welding, rotary welding, ultrasonic welding, resistance welding, or the like. Fig. 2a shows a top view of a first component 8 according to an exemplary embodiment. The first component 8 according to Fig. 2a can have an axially symmetric, in particular rotationally symmetric, cross-section.A circular cross-section is shown, but an elliptical cross-section is also possible. Fig. 2b shows the first component 8 according to Fig. 2a with a through-opening 12. In the example shown, the through-opening 12 is oblong, but it can also be axially symmetrical or rotationally symmetrical, in particular elliptical or circular. As an alternative to the oblong through-opening 12, the first component 8 according to Fig. 2b can also have a polygonal, for example hexagonal, through-opening 12 or a non-through hexagonal recess, which facilitates the insertion of the component 8 during welding. Fig. 3a shows a first component with a polygonal, octagonal cross-section with straight side edges. Fig. 3b shows a corresponding first component 8 with a through-opening 12. Here, the through-opening 12 is polygonal with rounded side edges, in this case a quadrilateral.Figure 4a shows a first component 8 with a polygonal cross-section and rounded side edges, here a quadrilateral. Figure 4b shows a corresponding first component 8 with a polygonal opening 12 with straight side edges, here a square. Figure 5a shows a first component 8 with a cross-section that has an axially symmetric, in particular rotationally symmetric, enclosing outer contour. The enclosing outer contour includes recesses, in particular semicircular recesses. The recesses can be arranged at equal angular intervals around the center point of the first component 8. Figure 5b shows a corresponding first component 8 with a polygonal opening 12, here a hexagonal shape. Figure 6a shows a first component 8 with an elongated circular body. This is in the form of an oblong hole. Figure 6b shows a corresponding first component 8 with a circular opening 12.Figure 7a shows a cross-section of a second component 10. According to Figure 7a, the second component is circular without a through-opening. Figure 7b shows a corresponding first component 10 with a through-opening 14. This is polygonal with straight sides, here rectangular. Figure 8a shows a second component 10 with a polygonal outer circumference with straight edges, here rectangular, rhomboid-shaped. Figure 8b shows a corresponding first component 10 with a through-opening 14, which is circular. Figure 9a shows a second component 10 with an elongated circular body. Figure 9b shows a corresponding first component 10 with a through-opening 14, which is oblong. Figure 10a shows a second component 10 with a square cross-sectional area. Fig. 10b shows a corresponding first component 10 with a through-opening 14 in the form of an elongated hole.The through-openings 12, 14 of an assembly in which the first component 8 is joined to the second component 10 can be geometrically identical and congruent to one another when the components 8, 10 are joined together. It is also possible for the outer circumference of a second component 10 to be congruent to the inner circumference of a through-opening 12. The second component 10 can be inserted into the through-opening 12. In particular, an interference fit between the through-opening 12 and the outer circumference of the second component 10 is preferred. The first component 8 can be welded to the second component 10 along this fit. Figures 11a-e show cross-sections along the longitudinal axis of the first component 8. In the joined state, the second component 10 rests on the flat part 2 with a surface 8a. According to Fig. 11a, the first component 8 has a rectangular cross-section and may optionally have the through-opening 12.The embodiment of Figure 11a is advantageous with regard to a large welding area and economical manufacturing of the first component 8. 2304WO One Mobility Autokabel GmbH On the side 8a facing the flat part 2, the first component 8 can have a projection 16, as shown in Figure 11b. The projection 16 is frustoconical according to Figure 11b. It tapers towards the flat part 2. According to Figure 11c, the projection 16 can also be cylindrical, in particular hollow cylindrical. In the embodiments of Figures 11b and 11c, defined welding surfaces are provided for welding with the flat part 2 and the second component 10, and the positioning of the components relative to each other is simplified. According to Figure 11d, the surface 8a facing the flat part 2 can have convex recesses to receive material molten during welding. According to Figure 11c, the surface 8a facing the flat part 2 can have convex recesses for receiving material molten during welding.11e can have concave, outwardly projecting protrusions 16 on the surface 8a facing the flat part 2. According to Figs. 12a-c, cross-sections along the longitudinal axis through a metallic contact element 6 are shown. According to Fig. 12a, the first component 8 and the second component 10 are joined together and have no through-opening. According to Fig. 12b, the components 8-10 have through-openings 12, 14, which are aligned with each other, in particular congruently arranged one above the other. As shown in Fig. 12c, the first component 10 can be joined in the through-opening 12 of the first component 8. Welding between the first component 8 and the second component 10 can take place in the area of ​​the through-opening 12. The second component 10 can project from the surface of the first component 8. 2304WO One Mobility Autokabel GmbH Fig.13 shows a connection arrangement with a flat part 2 and a metallic contact element 6 in the joined state.It can be seen that the metallic contact element 6 projects from the surface of the flat part 2 by a distance A. This distance can be between 0.2 and 1 mm. Furthermore, it is shown that the second component 10 projects from the opposite surface of the flat part 2 by a distance B. This distance can be formed according to distance A. 2304WO One Mobility Autokabel GmbH Reference numeral 2 Flat part 4 Through-opening of the flat part 2 6 Contact element 8 First component 8a Surface 10 Second component 10a End face 12 Through-opening of the first component 8 14 Through-opening of the second component 10 16 Projection 100 Connection arrangement 2304WO One Mobility Autokabel GmbH.

Claims

- 1 - 2304WO One Mobility Autokabel GmbH Patent claim 1. Connection arrangement (100) comprising: - a metallic flat part (2) with a through-opening (4), - a metallic contact element (6) arranged in the through-opening (4), wherein - the contact element (6) has a disc-shaped first component (8) and a rod-shaped second component (10), the disc-shaped first component (8) is materially bonded to the flat part (2) on its side facing the flat part (2), and the rod-shaped second component (10) is at least partially arranged in the through-opening (4), characterized in that,- that the contact element (6) is an assembly consisting of at least two parts, comprising at least the first component (8) and the second component (10), and - that an end face of the second component (10) facing away from the first component (8) projects from the surface of the flat part (2) on the side of the flat part (2) facing away from the first component (8), is flush with the surface of the flat part (2), or is recessed relative to the surface of the flat part (2).

2. Connection arrangement (100) according to claim 1, characterized in that - the first component (8) is formed from a first metallic material, and that the second component (10) is formed from a second metallic material different from the first metallic material, and preferably the first component (8) is formed from aluminum, an aluminum alloy, copper, or a copper alloy, and the second component (10) is formed from aluminum, an aluminum alloy, iron, or an iron alloy, in particular steel.

2.

3. Connection arrangement (100) according to claim 1 or 2, characterized in that the first component (8) projects into the through-opening (4) of the flat part (2) to a maximum of 60% of its height, and the second component (10) extends through the through-opening (4) of the flat part (2) to at least 80% of its height.

4. Connection arrangement (100) according to any one of the preceding claims, characterized in that the first component (8) is welded to the flat part (2) on its side facing the flat part (2), and that the second component (10) is connected to the side of the first component (8) facing the flat part (2) by a material-fit, form-fit, and / or force-fit connection at one of its end faces. 5.Connection arrangement (100) according to one of the preceding claims, characterized in that the second component (10) is welded with its outer surface to an inner surface of the through-opening (4) of the flat part (2).

6. Connection arrangement (100) according to one of the preceding claims, characterized in that the second component (10) is tubular with an opening extending longitudinally along the second component (10), in particular that a center point of the opening of the second component (10) is aligned with a center point of the first component (8) and / or that the first component (8) is arranged with its center point on a central axis of the through-opening (4) of the flat part (2). 2304WO One Mobility Autokabel GmbH. - 3 - 7. Connection arrangement (100) according to one of the preceding claims, characterized in that the second component (10) is tubular with an opening extending in the longitudinal direction of the second component (10), wherein an inner surface of the opening has an internal thread.

8. Connection arrangement (100) according to one of the preceding claims, characterized in that the first component (8) has a through-opening (12) and / or that the through-opening (12) of the first component (8) and the through-opening (4) of the flat part (2) are coaxial and / or that the second component (10) is arranged in the through-opening (12) of the first component (8) and / or that an inner surface of the through-opening (12) of the first component (8) has an internal thread. 9.Connection arrangement (100) according to one of the preceding claims, characterized in that the first component (8) has a threaded bolt on the side facing away from the flat part (2). Connection arrangement (100) according to one of the preceding claims, characterized in that the first component (8) and / or the second component (10) is metallically coated, in particular that the coating is at least two layers and / or that the first component (8) and the second component (10) are coated with the same metallic material. Connection arrangement (100) according to one of the preceding claims, characterized in that 2304WO One Mobility Autokabel GmbH. - 4 - - that an outer diameter of the first component (8) is larger than an inner diameter of the through-opening (4) of the flat part (2).

12. Connection arrangement (100) according to one of the preceding claims, characterized in that - the first component (8) is welded to the flat part (2) with a penetration depth of at least 0.2 mm, preferably between 0.2 mm and 2 mm.

13. Connection arrangement (100) according to one of the preceding claims, characterized in that - an end face of the first component (8) facing away from the flat part (2) projects from the surface of the flat part (2) and / or that an end face of the second component (10) facing away from the first component (8) projects from the surface of the flat part (2), in particular that the projection is at least 0.1 mm, in particular that the projection is between 0.1 mm and 1 mm. 14.Connection arrangement (100) according to one of the preceding claims, characterized in that the first component (8) is press-welded to the second component (10) and / or that the first component (8) is press-welded to the flat part (2).

15. Method for manufacturing a connection arrangement (100) according to one of the preceding claims, in which a flat part (2) is provided, a through-opening (4) is produced in the flat part (2), a first component (8) is provided, a second component (10) is provided, characterized in that 2304WO One Mobility Autokabel GmbH. - 5 - - that the first component (8) is joined to the flat part (2) by a material bond and the second component (10) is at least partially arranged in the through-opening (4) of the flat part (2). 2304WO One Mobility Autokabel GmbH

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