Connection arrangement and method for producing a connection arrangement

Abstract

The invention relates to a connection arrangement (100), at least comprising: - a metal flat conductor (1) having a first through-opening (2) and a main extension direction x, - a first metal contact element (3) integrally bonded to the flat conductor (1) in the region of the first through-opening (2), - a second metal contact element (4) integrally bonded to the flat conductor (1), characterised in that - the first contact element (3) has at least one through-opening in the form of a slot (5), wherein the longitudinal axis of the slot (5) and the second metal contact element (4) are oriented with respect to one another in such a way that tolerance compensation is possible at least in the direction x and a direction y orthogonal thereto.

Description

[0001] 2305WO

[0002] One Mobility Autokabel GmbH

[0003] Connection arrangement and method for producing a connection arrangement

[0004] 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.

[0005] In electrical applications, particularly in automotive applications, flat conductors (so-called busbars) are increasingly used. These flat conductors are not only used as power lines, but also as battery cell connectors, module connectors, and similar applications. The flat conductors are generally formed from a flat metallic part. To connect contact elements, it is known to apply the contact elements to the surface of the flat metallic part and preferably join them there by a metallurgical bond, in particular by welding.

[0006] When welding a flat metal part made of one 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 sag at the contact point.

[0007] Besides welding the flat part to the contact element, a mechanical fixing of the contact element to the flat part is also known. In this method, for example, a connecting bolt is pushed 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. Over time, and especially under mechanical stress, such a screw connection can become mechanically unstable, particularly when using aluminum or an aluminum alloy. Due to the contact pressure of the screw and mechanical stress, the material in the area of ​​the through-hole of the flat part can yield, resulting in plastic deformation of the flat part and causing the mechanical connection to loosen.In the worst case scenario, the connection fails and the contact element detaches from the flat part.

[0008] To prevent this, it has already been proposed to place a metallic contact element in the through-hole. This 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 can be placed in the through-hole. A connecting bolt can then be inserted through this through-hole. The contact element thus stabilizes the mechanical connection between the flat part and the connecting bolt.

[0009] The dimensions and three-dimensional bending of the flat conductor must be adapted to its installation situation in the vehicle so that the electrical contact points within the vehicle are connected. However, manufacturing tolerances occur during the three-dimensional bending of flat conductors, both in terms of the spacing between the bends and in the bending angles and radii. This leads to tolerances between the contact points of the flat conductors and the vehicle's periphery. Tolerances also arise during vehicle assembly, both in the body-in-white and in the positioning of the connection components. Flat conductors with small cross-sections exhibit a certain degree of deformability, which allows the conductor to be adjusted in its installation position within the vehicle.

[0010] 2305WO

[0011] One Mobility Autokabel GmbH. With the increasing importance of high-voltage applications, flat conductors with larger cross-sections of 300 mm are also gaining in popularity. 2 and furthermore, they are of greater importance. These flat cables are significantly stiffer and cannot easily be bent within the installation space. Therefore, a contact system is required that allows for compensation of both the tolerances of the vehicle and those of the bends in the flat cables.

[0012] Accordingly, the task is to provide a connection arrangement that improves the compensation of manufacturing tolerances when the connection arrangement is assembled in a motor vehicle.

[0013] This problem is solved by a connection arrangement according to claim 1.

[0014] This document proposes a metallic flat conductor with at least two contact elements. The metallic flat conductor can have a polygonal, particularly quadrilateral, cross-sectional profile. Specifically, it can have a square or rectangular cross-sectional profile. The cross-sectional profile of the flat conductor can consist of two parallel wide sides and two parallel narrow sides. The edges of the flat conductor can also be rounded. A wide surface of the flat conductor extends longitudinally along the wide sides, and a narrow surface extends longitudinally along the short sides. The through-holes preferably extend completely through the metallic flat conductor. The through-holes preferably extend along a surface normal on a wide surface.The through-holes can be punched or drilled.

[0015] A metallic flat conductor can be a power conductor, a battery cell connector, a module connector, a terminal, a crimp terminal, or the like. A metallic flat conductor can be used as a flat conductor in automotive applications for...

[0016] 2305WO

[0017] One Mobility Autokabel GmbH products are used, for example, as energy conductors, battery conductors, or similar applications. A metallic flat conductor can connect a battery to a powertrain, a starter and / or generator, or a drive motor in a motor vehicle, or connect electrical components to each other.

[0018] An electrical component is preferably connected to the metallic flat conductor. 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 contact elements for connecting such electrical components. For example, the contact elements are arranged at opposite ends of the flat conductor, whereby an electrical connection can be provided via the flat conductor between two connecting bolts of a motor vehicle that are contacted at the contact elements.

[0019] According to the invention, the connection arrangement comprises a metallic flat conductor with at least one first through-hole. In the region of the first through-hole, a first metallic contact element is bonded to the flat conductor. Furthermore, a second metallic contact element is bonded to the flat conductor. The first contact element has at least one through-hole, which is formed as an elongated slot. The longitudinal axis of the elongated slot is aligned with the second metallic contact element such that tolerance compensation is enabled in at least two dimensions. The flat conductor has a principal direction x, and the orientation of the elongated slot is such that tolerance compensation occurs in the x direction and the orthogonal y direction.

[0020] The principal extension direction x is determined by arranging the connection arrangement in a three-dimensional coordinate system with the axes x, y and z and positioning it on the x-axis in such a way that the distance between the distal ends of the connection arrangement is as large as possible in the x direction.

[0021] 2305WO

[0022] One Mobility Autokabel GmbH is located. The distal ends of the connection arrangement can lie on the x-axis or deviate from it.

[0023] The connection arrangement according to the invention allows for improved compensation of tolerances during installation in a motor vehicle, which significantly simplifies assembly, particularly with complexly bent flat conductors. This eliminates the need for manual re-bending of the flat conductor into its installation position, which is difficult with large conductor cross-sections.

[0024] When the connection arrangement according to the invention is installed in a motor vehicle, a contact bolt, for example, is guided through the elongated hole of the first contact element. This bolt serves for the mechanical and electrical contacting of the connection arrangement in the motor vehicle. The bolt is displaceable along the elongated hole, so that manufacturing tolerances of the flat conductor and the motor vehicle can be compensated for. Due to the orientation of the elongated hole according to the invention, tolerance compensation is achieved in two dimensions, whereby the displacement along the x-direction and the y-direction can be accomplished either solely by the first contact element or additionally by further contact elements.

[0025] A first metallic contact element is arranged in the area of ​​the first through-hole of the flat conductor. "In the area of ​​the through-hole" in this context means that the contact element is located adjacent to the through-hole of the flat conductor. The elongated hole of the first contact element preferably overlaps at least partially with the through-hole of the flat conductor, so that a bolt can be inserted through the first through-hole of the flat conductor and the adjacent elongated hole of the contact element. Any contact element with an elongated hole can be used as the first contact element. Preferably, the first contact element extends partially, and more preferably completely, through the first through-hole.

[0026] 2305WO

[0027] One Mobility Autokabel GmbH: The elongated hole of the first metallic contact element represents a through-hole whose projection onto the plane of the flat conductor at least partially overlaps with the through-holes of the flat conductor. Preferably, the projection of an elongated hole onto the plane of the flat conductor lies completely within the through-hole of the flat conductor. An elongated hole within the meaning of the invention is a through-hole whose extent along a longitudinal axis is greater than its extent along a transverse axis orthogonal to this longitudinal axis. The elongated hole has, for example, the shape of a rectangle, a rectangle with rounded corners, an ellipse, or two semicircles connected by parallel lines along its circumference.Preferably, the elongated hole is designed as an elongated opening, along whose long sides two parallel straight lines run and whose narrow sides are closed by semicircles, the diameter of the semicircles corresponding to the distance between the parallel straight lines.

[0028] Preferably, the second contact element is designed as a bolt that is bonded to a surface of the flat conductor or in the area of ​​a second through-hole of the flat conductor. The bolt, also referred to as a connecting bolt, can be understood as a longitudinally extending bolt with two distal end faces. One end face forms the bolt shaft, and the other forms a bolt head. The bolt shaft and bolt head together constitute the connecting bolt. The bolt shaft preferably has a smaller diameter than the bolt head; however, the bolt head and bolt shaft can also have the same diameter. The bolt is designed to serve as a connection element for another electrical component, for example, via a screw connection or another type of connection, such as a force-fit, positive-locking, and / or material-locking connection.If the bolt is bonded to a material connection in the area of ​​a second through-hole of the flat conductor, a portion of the bolt protruding from the second through-hole can serve as a connection for further components. Alternatively or additionally, the bolt can include a blind hole or a through-hole extending along the longitudinal direction of the bolt.

[0029] 2305WO

[0030] One Mobility Autokabel GmbH extends, whereby the blind hole or through-hole can accommodate further components for mechanical and / or electrical connection.

[0031] Preferably, the second metallic contact element has at least one through-hole shaped as an elongated slot. Particularly preferably, the metallic flat conductor has a second through-hole in the region of the second metallic contact element, and the elongated slot of the second contact element lies within the region of the second through-hole and preferably overlaps at least partially with the through-hole of the flat conductor, so that a bolt can be inserted through the second through-hole of the flat conductor and the adjacent elongated slot of the contact element. Any contact element with an elongated slot can be used as the second contact element. Preferably, the second contact element partially, and particularly preferably completely, extends through the second through-hole. The descriptions of the elongated slot of the first contact element apply to the further design and shaping of the elongated slot of the second contact element.

[0032] If the connection arrangement has only one contact element with an elongated hole, direction x represents the main direction of extension of the flat conductor, while the orthogonal direction y preferably runs transversely to the flat conductor in the region of the contact element. If the connection arrangement has at least two contact elements, each with an elongated hole, direction x is also the main direction of extension of the flat conductor, while the orthogonal direction y preferably runs transversely to the flat conductor in the region of one of the contact elements with an elongated hole. The transverse direction of the flat conductor runs between its narrow sides, orthogonal to these.

[0033] In a preferred embodiment, the longitudinal axes of the elongated holes of the first contact element and the second contact element are arranged colli near, parallel, or perpendicular to each other. A perpendicular orientation of the elongated holes is chosen, for example, when connecting bolts of a motor vehicle.

[0034] 2305WO

[0035] One Mobility Autokabel GmbH requires a tolerance in a different dimension for each contact element. A parallel arrangement of the elongated holes allows the flat conductor to be shifted along the same dimension. The collinear arrangement of the elongated holes has proven particularly advantageous and offers tolerance compensation in two dimensions for both contact elements.

[0036] In a further preferred embodiment, the longitudinal axis of the elongated hole of the first contact element and the second contact element are arranged collinearly with each other. A section of the second contact element lies on a straight line along the longitudinal axis of the elongated hole of the first contact element. Preferably, the center of the end face of the second contact element lies on an extension of the longitudinal axis of the first contact element. In this way, tolerance compensation in two dimensions is achieved by means of the elongated hole of the first contact element. The second contact element can optionally be designed without an elongated hole, or the elongated hole of the second contact element can have an orientation that is not collinear with the elongated hole of the first contact element.

[0037] Preferably, the longitudinal axis of at least one elongated hole is neither parallel nor orthogonal to the longitudinal axis of the flat conductor in the area where the contact element is inserted into the flat conductor. Such an oriented elongated hole enables tolerance compensation in two dimensions directly at the elongated hole itself, without the need for additional contact elements.

[0038] The flat conductor of the connection arrangement preferably has a bend, in particular a complex bending geometry. The flat conductor is bent at at least one point, preferably at least two points, in particular at least three points, for example at least four, at least five or at least six points. In an advantageous embodiment, the flat conductor has at least one bend with a bending angle of at least 30°.

[0039] 2305WO

[0040] One Mobility Autokabel GmbH preferably has a bend angle of at least 45°, in particular at least 90°, at least 120°, or at least 150°. For example, the flat conductor has at least two bends, wherein at least one of the bends has a bend angle of at least 90° and at least one of the bends has a bend angle of at least 120°, preferably at least 150°. In particular, the flat conductor has at least two bends in at least two different dimensions (x and y, x and z, or y and z), preferably at least three different dimensions (x, y, and z). The installation of connection assemblies with such complexly bent flat conductors is simplified by the orientation of the longitudinal axis of the elongated hole according to the invention.

[0041] The flat conductor preferably has a length of at least 700 mm, more preferably at least 1000 mm, particularly preferably at least 1500 mm, and especially at least 2000 mm, measured in the straight state or when measured in the bent state along one of the main surfaces between the distal end faces of the flat conductor. For example, the length of the flat conductor is between 1500 mm and 3000 mm. As the length of the flat conductor increases, the total manufacturing tolerances occurring between two distal contact elements of the flat conductor also increase. Furthermore, in motor vehicles, the tolerances between two electrical contact points are also greater the further apart they are. Thus, the connection arrangement according to the invention is particularly suitable for use with long flat conductors.

[0042] The cross-section of the flat conductor is preferably at least 75 mm². 2 , particularly preferably at least 100 mm 2, in particular at least 120 mm 2 , for example 100 mm 2 up to 400 mm 2 The connection arrangement according to the invention is particularly advantageous when using flat conductors with large cross-sections. With increasing cross-section and the associated bending stiffness of the flat conductor, tolerances can no longer be corrected by manual bending.

[0043] 2305WO

[0044] One Mobility Autokabel GmbH can be compensated, whereby the connection arrangement according to the invention can effect this necessary tolerance compensation.

[0045] The flat conductor preferably comprises aluminium, an aluminium alloy, copper and / or a copper alloy.

[0046] The first contact element and / or the second contact element are preferably made of aluminum, an aluminum alloy, copper, a copper alloy, iron, an iron alloy and / or steel.

[0047] Preferably, the materials of the first contact element and / or the second contact element are selected to have greater strength than the material of the flat conductor. The materials of the first and second contact elements exhibit an elastic limit R. P 0.2, which is greater than the elastic limit of the flat conductor material.

[0048] Preferably, the first contact element is designed as a weld eye with a through-hole, the through-hole being configured as an elongated slot. Particularly preferably, the first contact element is formed from at least two sections. The two sections extend in the axial direction of the contact part. A first section has a first circumference, and a second section has a second, larger outer circumference than the first. The second section can thus project radially outwards relative to the first section. When attaching the contact element to the through-hole of the flat conductor, the first contact element is preferably inserted into the through-hole of the flat conductor with its first section. After the contact element has been inserted into the through-hole of the conductor, a friction welding process, for example, can begin.The second section limits the insertion depth of the first contact element in the through-hole of the flat conductor, as the second section forms a stop. During a friction welding process, the contact part is preferably welded in the area of ​​the contact surface.

[0049] 2305WO

[0050] One Mobility Autokabel GmbH welded the flat conductor and the second section of the contact element using friction welding.

[0051] The second section of the first contact element is preferably formed as a flange and serves on the one hand as a contact surface against the flat conductors and on the other hand as an enlarged bearing surface for an electrical contact element or a consumer connection. The contact surface is the surface facing the flat conductor. The bearing surface is the surface opposite it. The bearing surface is preferably shaped as a flat surface. An electrical contact element, another flat conductor, or a nut or washer used for screwing with a bolt can rest on the surface of the flange facing away from the flat conductor. A consumer connection can also be arranged on the bearing surface. The bearing surface can be round, rectangular, square, polygonal, or the like. Along its circumference, the contact surface can have areas that project further outwards and areas that project less far outwards.

[0052] The first and second sections of the first contact element are formed in one piece or in multiple parts. In particular, the first contact element can be formed as a stamped part, milled part, turned part, or forged part.

[0053] In a first preferred embodiment, the second contact element is designed analogously to the first contact element. Thus, in this embodiment, the connection arrangement has two contact elements with elongated holes.

[0054] In a second preferred embodiment, the second contact element is configured as a longitudinally extending bolt having two distal end faces. One end face forms the bolt shank, and the other forms a bolt head. The bolt shank and bolt head together form the connecting bolt. The bolt shank preferably has a smaller diameter than the bolt head; however, the bolt head and bolt shank can also have different diameters.

[0055] 2305WO

[0056] One Mobility Autokabel GmbH requires that the bolt head and shank have the same diameter. The bolt shank is designed to serve as a connection for another electrical component, for example, via a screw connection or other type of connection, such as a friction-fit, positive-locking, and / or material-locking connection. If the bolt head and shank have the same diameter, these parts of the bolt are defined by their function. The bolt shank is preferably designed as a threaded bolt or as a contact bolt for circular connectors. The connecting bolt is preferably formed in one piece from a single material. The bolt shank preferably has a smaller diameter than the bolt head.The bolt head is preferably bonded to the flat conductor on the surface of the bolt head facing away from the bolt shaft, or bonded to the flat conductor on the surface of the bolt head adjacent to the bolt shaft, in the latter case the bolt shaft being passed through a through-opening of the flat conductor.

[0057] According to the invention, the first and second contact elements are bonded to the flat conductor by a material connection, preferably soldered or welded, and particularly preferably by friction welding, rotary friction welding, ultrasonic welding, pressure welding, resistance welding, or laser welding, especially rotary friction welding. The welding between the flat conductor and the contact elements results in a low electrical contact resistance, allowing the contact elements to serve as electrical connection components.

[0058] Rotary friction welding has proven particularly advantageous. This friction welding can also be ultrasonic welding. In rotary friction welding, the stud is set into oscillation or rotation relative to the flat part. This is achieved by applying pressure to the flat conductor with the contact element, whereby a contact surface of the contact element, while simultaneously moving relative to the longitudinal axis of the contact element, is pressed against a surface of the flat conductor. This generates frictional heat.

[0059] 2305WO

[0060] One Mobility Autokabel GmbH introduces a material at the interface between the contact element and the flat conductor in the area of ​​the contact element's contact surface. The frictional heat causes at least one material at the interface between the flat conductor and the contact element to plasticize. The plasticized materials bond with each other, forming a metallurgical connection.

[0061] In the friction welding process, the contact elements are preferably welded to the flat conductor in the area of ​​the contact surface. Applying pressure to the contact elements presses the welding surface of the contact element against the surface of the conductor. The welding surfaces of the contact elements preferably feature recesses and / or protrusions and / or relief-like structures. These features result in only a small contact area on the flat conductor at the start of the welding process, thus achieving higher temperatures with the same contact pressure.

[0062] For rotary friction welding, it is advantageous if the first and / or second contact element are axially symmetrical about their longitudinal axis. The first and / or second contact element can be rotationally symmetrical, axially symmetrical, elliptical, or similarly shaped about the longitudinal axis. In the case of a non-rotationally symmetrical shape, the first and / or second contact element can be used as an external drive. This means that a rotary friction welding tool can be positioned on the outer circumference of the first and / or second contact element and impart a rotation to the contact element. This rotation can then weld the contact element to the flat part. Particularly preferably, the first and / or second contact element has a section comprising a polygonal envelope that serves as a point of contact for a friction welding tool.Preferred shapes are polygons that approximate the circular shape, for example hexagons, octagons, decagons or dodecagons.

[0063] 2305WO

[0064] One Mobility Autokabel GmbH proposes that, according to one embodiment, the first contact element and / or the second contact element be metallically coated. A metallic coating can be applied to the contact element material. This can be done using a wet chemical process. Depending on the specific application, and in particular on the material of the flat conductor 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 contact elements with the same or different metallic materials. Specifically, the first and / or second contact element can each be coated only in certain areas, while other areas of the contact element remain uncoated.

[0065] It is proposed that a material for the coating be tin, gold, nickel, silver, copper, or an alloy thereof. In particular, electroplated nickel has proven advantageous for coating the first and / or second contact element, especially due to its ductility. A coating of pure nickel is preferably applied as the electroplated nickel. Nickel sulfamate is particularly preferred for electroplating.

[0066] A multi-layer, particularly two-layer, coating is also proposed. In this process, at least one contact element can be coated with a first metallic material in a first step, and in a second step, the coated contact element can be coated with a metallic material different from the first. It has been found that under-nickel plating is particularly advantageous. Here, at least one contact element is first coated with a nickel layer and / or a nickel alloy, especially a nickel-phosphorus alloy. The nickel-containing layer ensures that the contact element is mechanically well protected. A tin, gold, copper, silver, or other metal coating can then be applied over the nickel-containing layer.

[0067] 2305WO

[0068] One Mobility Autokabel GmbH applies an alloy layer. Under-nickel plating and tinning can be advantageous, for example, if the contact element is subsequently soldered or welded to an electrical component. A tin layer can also be useful to provide a good electrical contact layer and avoid the need to remove the tin layer 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.

[0069] According to one embodiment, it is proposed that the coating have a maximum thickness of 10 pm. It has been found that such a layer thickness represents a good compromise between electrical conductivity at the electrical interface between the contact element and the flat conductor 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 pm to 10 pm, preferably 3 pm to 10 pm.

[0070] For a multilayer coating, a maximum coating thickness of 20 pm is proposed. A multilayer coating comprises several superimposed layers of different compositions. Preferably, each of the layers has a maximum thickness of 10 pm.

[0071] According to one embodiment, it is proposed that the first and / or the second contact element is welded to the flat conductor 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 contact element is pressed against the flat conductor with its side facing the flat conductor. Subsequently, the interface between the flat conductor and the contact element is plasticized by the application of welding energy. This can be achieved through frictional energy, electrical energy, or the like. During plasticization, a

[0072] 2305WO

[0073] One Mobility Autokabel GmbH joining zone into which the contact element can penetrate. In particular, the material of the flat conductor may have a lower melting point than the material of the first contact element and / or the coating of the contact element, so that the material of the flat conductor plasticizes first. Applying pressure allows the contact element to penetrate the flat conductor. 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 shallow, the mechanical and electrical properties of the connection deteriorate. Very large penetration depths, on the other hand, require very high welding energy and, furthermore, can lead to mechanically disadvantageous connections in combination with thin flat conductors.

[0074] According to one embodiment, it is proposed that a surface of the contact element facing away from the flat conductor, also referred to as the first end face, protrudes from the surface of the flat conductor in the joined state. Preferably, the flat conductor has insulation, and the first and / or second contact element protrudes from the surface of the insulation facing away from the flat conductor. The contact element is preferably welded to the flat conductor only to such a depth that at least a portion of the contact element protrudes from the surface of the flat conductor, particularly the broad surface of the flat conductor. This prevents a mechanical or electrical component placed on the contact element from coming into direct contact with the flat conductor.

[0075] It is proposed that the first contact element, and particularly preferably also the second contact element, extend through a through-hole in the flat conductor. A second end face opposite the first end face of the contact elements projects from the surface of the flat conductor on the side facing away from the first end face. The projection of the first and / or second end face of the first and / or second contact element from the broad surface of the flat conductor is preferably between 0.1 mm and 1 mm.

[0076] 2305WO

[0077] One Mobility Autokabel GmbH's 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 conductor. In a preferred embodiment, the flat conductor has insulation, and the second end face protrudes at least 0.1 mm from the insulation on the wide surface of the flat conductor.

[0078] Another aspect of the invention is a method according to claim 13 comprising at least the following steps:

[0079] - Providing a flat conductor,

[0080] - Including at least one through-hole in the flat conductor,

[0081] - Providing a first metallic contact element comprising a through-hole shaped as an elongated hole,

[0082] - Providing a second metallic contact element,

[0083] - material-bonded joining of the first contact element in the area of ​​the through-hole of the flat conductor and

[0084] - material-bonded joining of the second contact element to the flat conductor.

[0085] It is proposed that preferably the first contact element be joined to the flat conductor in a material-bonded manner and the second contact element be joined to the flat conductor in a material-bonded manner independently of each other.

[0086] Preferably, the flat conductor is bent before or after preparation, particularly before preparation. In a preferred embodiment of the method, the flat conductor is bent at at least one, preferably at least two, and particularly at least three longitudinal sections. Preferably, the flat conductor is bent at at least one point by at least 30°, more preferably at least 45°, and in particular at least 90° or at least 120°.

[0087] The first contact element and the second contact element are preferably press-welded, friction-welded, or ultrasonically welded to the flat conductor.

[0088] 2305WO

[0089] One Mobility Autokabel GmbH laser welded or resistance welded, especially preferably rotary friction welded or laser welded.

[0090] In friction welding of the contact elements, a friction welding tool is preferably applied as an external drive to the outer contour of the contact element. Contact elements with polygonal outer contours are particularly suitable for this purpose. In a further preferred embodiment, an internal drive of a friction welding tool is inserted into the through-hole of the first contact element and optionally into a through-hole of the second contact element. A torque can also be applied to the contact element particularly effectively via the elongated through-hole, thus effecting a weld.

[0091] The statements regarding the connection arrangement according to the invention also apply to the method according to the invention and vice versa.

[0092] The subject matter is explained in more detail below with reference to a drawing showing an exemplary embodiment. The drawings are not to scale and do not limit the invention in any way. The drawing shows:

[0093] Fig. 1 shows top views of various preferred embodiments of the connection arrangement according to the invention.

[0094] Fig. 2a-d Cross-sectional views of the terminal areas of various preferred embodiments of the connection arrangement according to the invention,

[0095] Fig. 3a-c schematic representations of different embodiments of the lateral surface of the second contact element in top view,

[0096] 2305WO

[0097] One Mobility Autokabel GmbH Fig. 4a-d schematic representations of various embodiments of the outer surface of the first and / or second contact element in top view,

[0098] Fig. 5 is a schematic exploded view of a physical object.

[0099] Connection arrangement in the area of ​​the second contact element,

[0100] Fig. 6 is a schematic exploded view of a physical object.

[0101] Connection arrangement in the area of ​​the first contact element;

[0102] Fig. 7 shows an embodiment of a second contact element in the

[0103] longitudinal section,

[0104] Fig. 8 shows an embodiment of a first and / or second

[0105] Contact element in longitudinal section,

[0106] Fig. 9 shows an embodiment of a section of a complexly bent flat conductor.

[0107] Figures 1 and 1a show top views of various preferred embodiments of the connection arrangement 100 according to the invention. The connection arrangement 100 comprises a bent aluminum flat conductor 1 with insulation 10 removed from both end regions of the flat conductor 1. In the stripped regions, a first contact element 3 and a second contact element 4 are bonded to the flat conductor 1. The first contact element 3 and the second contact element 4 comprise aluminum and are attached to one of the wide surfaces of the flat conductor by friction welding. The first contact element 3 is arranged in a through-hole 5 of the flat conductor 1 and is designed as a bolt with a through-hole 5, the through-hole 5 being formed as an elongated slot. The longitudinal axis 20

[0108] 2305WO

[0109] One Mobility Autokabel GmbH's elongated hole 5 is aligned with the second contact element 4 in such a way that tolerance compensation can take place in at least two dimensions.

[0110] As shown in Figure 1a, the elongated hole 5 of the first contact element 3 has a longitudinal axis 20 that is oriented such that it intersects the second contact element 4. The elongated hole 5 is thus collinear with the second contact element 4. The second contact element 4 is designed as a bolt, for example, as shown in Figure 7. The orientation of the elongated hole 5 allows for movement along the x- and y-directions during assembly of the connection assembly 100, thus compensating for tolerances in two dimensions and facilitating the assembly of the connection assembly 100 in a motor vehicle.

[0111] As shown in Figure 1b, the second contact element 4, analogous to the first contact element 3, is designed as a bolt with a through-hole 5 in the form of an elongated slot. Both contact elements 3 and 4 are each inserted into a through-hole of the flat conductor 1. The elongated slots 5 of the contact elements 3 and 4 each have a longitudinal axis 20 that is collinear with each other. The alignment of the elongated slots 5 allows for adjustment along the x- and y-directions of both contact elements 3 and 4 during assembly of the connection arrangement 100. Furthermore, the collinear alignment allows the arrangement to be moved along the longitudinal axis 20 even after the arrangement has been placed onto contact bolts inserted into the elongated slots 5.

[0112] In the embodiment shown in Figure 1c, the second contact element 4 is also designed analogously to the first contact element 3 as a bolt with a through-hole 5 in the form of an elongated slot. Both contact elements 3 and 4 are each inserted into a through-hole in the flat conductor 1. The elongated slots 5 of the contact elements 3 and 4 each have a longitudinal axis 20, with the longitudinal axes 5 being aligned parallel to each other. The alignment of the elongated slots 5 allows both contact elements 3 and 4 to be moved along the x- and y-directions when the connection assembly 100 is mounted.

[0113] 2305WO

[0114] One Mobility Autokabel GmbH and an associated tolerance compensation during the assembly of the connection arrangement 100 in a motor vehicle.

[0115] According to the embodiment shown in Figure 1d, the second contact element 4 is also designed analogously to the first contact element 3 as a bolt with a through-hole 5 in the form of an elongated slot. Both contact elements 3 and 4 are each inserted into a through-hole of the flat conductor 1. The elongated slots 5 of the contact elements 3 and 4 each have a longitudinal axis 20, with the longitudinal axes 5 being perpendicular to each other. Thus, displacement along the x-direction is possible for the first contact element 3 and displacement along the y-direction for the second contact element 4. The interaction of the contact elements 3 and 4 therefore allows for tolerance compensation in both dimensions.

[0116] Figures 2a-d show cross-sectional views of various preferred embodiments of the respective end regions of the flat conductor 1 with contact elements 3, 4. The first contact element 3 is designed as a bolt with a through-hole in the form of an elongated hole 5 and is mounted in a through-hole 2 of the flat conductor 1. This results in a contact element with the basic shape of a sleeve with a projection. In the area of ​​the projection, which is designed as a bolt head, a friction welding tool can preferably be applied to the outer surface 6 of the first contact element 3, and the first contact element 3 can be welded in the through-hole 2 of the flat conductor. Preferably, the first contact element 3 is designed as described in Figure 8.

[0117] As shown in Figure 2a, the second contact element 4 is designed as a bolt, preferably as a bolt according to Figure 7, and is applied to the surface of the flat conductor 1, on which the projection of the first contact element 3 extends from the flat conductor 1. The outer surface 6 of the bolt head of the second contact element 4 is preferably used as a contact surface for a friction welding tool.

[0118] 2305WO

[0119] One Mobility Autokabel GmbH The embodiment of figure 2b corresponds essentially to the embodiment of figure 2a, in contrast to which the second contact element 4 is arranged on the main surface of the flat conductor 1 facing away from the projection of the first contact element 3.

[0120] The embodiment of Figure 2c corresponds essentially to the embodiment of Figure 2a, except that the second contact element 4 is designed analogously to the first contact element 3. The contact elements 3 and 4 are arranged with their projection and outer surface 6 on the same main surface of the flat conductor 1.

[0121] In Figure 2d, the first contact element 3 and the second contact element 4 are arranged on opposite main surfaces of the flat conductor 1. Otherwise, the embodiment of Figure 2d corresponds to that of Figure 2c.

[0122] Figures 3a-c show schematic representations of various embodiments of the lateral surface of the second contact element 4 in a top view of the bolt head in the area of ​​the projection. According to Figures 3a-c, the respective edges that bound the lateral surface 6 are shown. The edges form a polygonal lateral surface 6.

[0123] Figure 3a shows an embodiment in which the lateral surface 6 is decagonal with straight edges 22.

[0124] Figure 3b shows a hexagonal lateral surface 6 with straight edges.

[0125] Figure 3c shows an octagonal lateral surface 6 with straight edges.

[0126] A friction welding tool that encompasses the cylindrical surface 6 along its edges can be welded in the tangential direction by means of the resulting positive locking.

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[0128] One Mobility Autokabel GmbH transmits a large torque to the contact element 4. Due to the polygonal surface 6, the friction welding tool can engage the contact element 4 with a low radial contact force thanks to the positive locking mechanism. This positive locking ensures that the friction welding tool is fixed relative to the contact element 4 in the direction of rotation. The positive locking is particularly effective in the direction of rotation (tangential direction).

[0129] Figures 4a-d show schematic representations of different embodiments of the lateral surface of the first contact element 3 and / or second contact element 4 in top view.

[0130] Figure 4a shows an embodiment in which the lateral surface 6 is decagonal with straight edges 22.

[0131] Figure 4b shows a hexagonal lateral surface 6 with straight edges.

[0132] Figure 4c shows an octagonal lateral surface 6 with straight edges.

[0133] Figure 4d shows a circular cylindrical surface 6. In Figure 4d, as well as in all other contact elements 3, 4 with an elongated hole 5 as a through-opening, the friction welding tool can also be attached to the elongated hole 5 as an internal drive. This is particularly advantageous for further simplifying the friction welding of the contact element.

[0134] The embodiments of Figures 3a-c and 4a-d have an envelope approximating a circular shape or a circular envelope in the area of ​​the lateral surface 6 and are therefore advantageous in order to minimize burr formation during friction welding.

[0135] Figure 5 shows an exploded view of a connection arrangement in the area of ​​the second contact element 4. A flat part 1 and a second contact element 4 are shown.

[0136] 2305WO

[0137] One Mobility Autokabel GmbH metallic contact element 4. The metallic contact element 4 is designed as a bolt comprising a bolt head 8 and a bolt shank 7. The bolt head 8 has a shank-facing end face 9c facing away from the bolt shank 7 and a shank-facing end face 9b facing the bolt head 7, while the bolt shank has an end face 9a. The shank-facing end face 9c of the bolt head 8 is metallurgically bonded to the flat part 1.

[0138] Figure 6 shows a schematic exploded view of a physical connection arrangement in the area of ​​the first contact element 3 and, optionally, depending on the design of the second contact element 4. Figure 6 shows a flat part 1 and a contact element 3, 4 designed as a bolt. The flat part 1 has a through-opening 2. The contact element 3, 4 is designed as a bolt comprising a bolt head 8 and a bolt shank 7. The bolt head 8 has a shank-facing end face 9c and a shank-facing end face 9b, while the bolt shank has an end face 9a. The contact element 3, 4 is inserted through the through-opening 6 with its bolt shank 6. The shank-facing end face 9b of the bolt head 8 is bonded to the flat part 1. The length of the bolt shank 6 can be at least equal to the height of the flat part 1.Thus, the bolt shaft 6 can be fully inserted into the through-hole 2. If necessary, the bolt shaft 6 protrudes from the wide surface of the flat conductor 1 on the opposite side. The contact element 3, 4 has a through-hole in the form of an elongated slot 5, which extends from the end face 9c of the bolt head facing away from the shaft to the end face 9a of the bolt shaft.

[0139] Figure 7 shows an embodiment of a second contact element 4 in longitudinal section, in which the bolt head 8 is shaped like a plate. In a first region 8a, which faces the bolt shaft 6, the bolt head 8 is plate-shaped with a circumferential surface 6. In region 8b, which faces the bolt shaft

[0140] 2305WO

[0141] The bolt head 8, facing away from the side of One Mobility Autokabel GmbH 6, has a conical shape with an inclination of 5°. A relief groove 11 may be provided at the transition between the bolt shank 7 and the bolt head 8. The end face of a bolt shank 7 may be tapered. The second contact element 4 can be welded to the flat part 1 at the end face 9c, with the bolt head 8 being gripped by a friction welding tool in the area 8a.

[0142] Figure 8 shows an embodiment of a first contact element 3 and, depending on the embodiment, a second contact element 4 in longitudinal section. The contact element 3, 4 is formed in the shape of a bolt with a bolt head 8 and a bolt shank 7. The bolt head 8 has an end face 9c facing away from the bolt shank 7 and an end face 9b facing the bolt head 7, while the bolt shank has an end face 9a. The bolt head 8 has a diameter that tapers along the longitudinal axis. The end face 9b of the bolt head 8 is frustoconical. The end face 12 has an angle of inclination 12 to a plane perpendicular to the longitudinal axis of the contact element 3 of between 1° and 10°, preferably 5°. During welding, the end face 9b initially lies in the area of ​​the bolt shank.

[0143] 7 on the flat part 1. During welding, the truncated cone of the end face 9b gradually penetrates the flat part 1. The plasticized material is displaced radially outwards. A relief groove 13 can be provided at the transition between the bolt shank 7 and the bolt head 8. The relief groove 13 serves to ensure that the end face 9b can rest fully on the flat conductor 1. The relief groove 13 removes any impurities at the transition between the bolt shank 7 and the bolt head 8, so that when the end face 9b is placed on the flat conductor 1, it can rest directly and fully on it without any interfering material being present at this transition.

[0144] Figure 9 shows an embodiment of a section of a complexly bent flat conductor 1 of the connection arrangement according to the invention. The distal ends of the flat conductor 1 and the contact elements arranged there are not shown.

[0145] 2305WO

[0146] One Mobility Autokabel GmbH The flat conductor 1 has two opposing wide sides 1a and two opposing narrow sides 1b, with the wide sides 1a being connected to each other via the two narrow sides 1b. A terminal end is located at each distal end of the flat conductor 1. The flat conductor 1 has three bends 14 of 90° each. At the first bend 14a, the flat conductor, which runs parallel to the x-axis, is bent by 90° and then runs along the z-axis. At the second bend 14b, the flat conductor is bent back by 90° and initially runs parallel to the x-axis. At the third bend 14c, the flat conductor is bent around the narrow side 1b and then runs parallel to the y-axis.

[0147] 2305WO

[0148] One Mobility Autokabel GmbH Reference mark

[0149] 100 connection arrangement

[0150] 1 flat conductor

[0151] 1 a Broadsides of the flat conductor

[0152] 1 b Narrow sides of the flat conductor

[0153] 2. Through-opening of the flat conductor 1

[0154] 3 first metallic contact element

[0155] 4 second metallic contact element

[0156] 5. Slotted hole, through-hole in the form of a slotted hole

[0157] 6 Surface area of ​​the contact elements

[0158] 7 bolt shaft

[0159] 8 bolt head

[0160] 8a first area of ​​the bolt head

[0161] 8b second area of ​​the bolt head

[0162] 9 end faces

[0163] 9a End face of the bolt shaft

[0164] 9b shaft-facing end face of the bolt head

[0165] 9c end face of the bolt head facing away from the shaft

[0166] 10 Insulation

[0167] 11 Free stitch

[0168] 12 Inclination

[0169] 13 Free stitch

[0170] 14 bends

[0171] 14a first bend

[0172] 14b second bend

[0173] 14c third bend

[0174] 20 Longitudinal axis of the elongated hole 5

[0175] 2305WO

[0176] One Mobility Autokabel GmbH

Claims

2305WO One Mobility Autokabel GmbH Patent claims 1. Connection arrangement (100) comprising at least: a metallic flat conductor (1 ) with a first through-opening (2) and a main extension direction x, a first metallic contact element (3) bonded to the flat conductor (1 ) in the region of the first through-opening (2) in a material-locking manner, a second metallic contact element (4) bonded to the flat conductor (1 ), characterized in that the first contact element (3) has at least one through-opening formed as an elongated hole (5), wherein the longitudinal axis of the elongated hole (5) and the second metallic contact element (4) are aligned to each other in such a way that a tolerance compensation is possible at least in direction x and an orthogonal direction y thereto.

2. Connection arrangement (100) according to claim 1 , characterized in that the second metallic contact element (4) is designed as a bolt which is bonded to a surface of the flat conductor (1 ) or in the area of ​​a second through-opening (2) of the flat conductor (1 ).

3. Connection arrangement (100) according to claim 1 or 2, characterized in that the second metallic contact element (4) has at least one through-opening shaped as an elongated hole (5).

4. Connection arrangement (100) according to claim 3, characterized in that, that the longitudinal axis of the elongated hole (5) of the first contact element (3) and the longitudinal axis of the elongated hole (5) of the second contact element (4) are arranged colli near, parallel or perpendicular to each other.

5. Connection arrangement (100) according to one of the preceding claims, characterized in that the longitudinal axis of the elongated hole (5) of the first contact element (3) and the second contact element (4) are arranged collinearly to each other.

6. Connection arrangement (100) according to one of the preceding claims, characterized in that the longitudinal axis of at least one elongated hole (5) is not arranged parallel and not orthogonal to the longitudinal axis of the flat conductor (1) in the area in which the contact element (3, 4) is connected to the flat conductor (1).

7. Connection arrangement (100) according to one of the preceding claims, characterized in that the flat conductor (1 ) has at least one bend (14), preferably at least two bends (14), particularly preferably at least three bends (14), in particular at least two bends (14) in two different dimensions.

8. Connection arrangement (100) according to claim 7, characterized in that the flat conductor (1 ) has at least one bend (14) with a bending angle of at least 90°, preferably at least 120°, in particular at least 150°.

9. Connection arrangement (100) according to one of the preceding claims, characterized in that the flat conductor (1) comprises aluminium or copper. 2305WO One Mobility Autokabel GmbH 10. Connection arrangement (100) according to one of the preceding claims, characterized in that the first metallic contact element (3) and / or the second metallic contact element (4) is made of aluminium or an aluminium alloy or of copper or a copper alloy or of iron or an iron alloy, in particular steel.

11. Connection arrangement (100) according to one of the preceding claims, characterized in that the first contact element (3) and / or the second contact element (4) is welded to the flat conductor (1), preferably press welded, friction welded, ultrasonically welded, laser welded or resistance welded.

12. Connection arrangement (100) according to one of the preceding claims, characterized in that the first contact element (3) and / or the second contact element (4) is metallically coated, preferably with tin, gold, nickel, silver, copper or an alloy thereof, in particular with a nickel-phosphorus alloy.

13. Method for manufacturing a connection arrangement (100) according to one of the preceding claims, in which a flat conductor (1) is provided, at least one through-hole is provided in the flat conductor (1), a first metallic contact element (3) comprising a through-hole formed as an elongated hole (5) is provided, a second metallic contact element (4) is provided, the first contact element (3) is joined in the region of the through-hole of the flat conductor (1) by a material bond, and the second contact element (4) is joined to the flat conductor (1) by a material bond. 2305WO One Mobility Autokabel GmbH wherein the longitudinal axis of the elongated hole (5) of the first contact element (3) is aligned such that tolerance compensation is enabled in at least two dimensions.

14. Method according to claim 13, wherein the flat conductor (1) is bent before or after provision, preferably bent at least 90° at one point.

15. Method according to claim 13 or 14, wherein the first contact element (3) and the second contact element (4) are connected with the Flat conductors (1) are press-welded, friction-welded, ultrasonically welded, laser-welded or resistance-welded, preferably rotary friction-welded or laser-welded. 2305WO One Mobility Autokabel GmbH

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