Assembly having a busbar and a fastening element, and contact connection having such an assembly

Abstract

The assembly (22) has a busbar (6) and a fastening element (8, 36), designed in particular as a screw (8), for electrically and mechanically connecting the busbar (6) to an electrical contact component (4). The busbar (6) has an end portion (14) which is formed as a sleeve (16) which extends in a vertical direction (V) and into which the fastening element (8, 36) is at least partially inserted and on which a contact surface (11) rests in the mounted state. The busbar (6) and the fastening element (8, 36) preferably consist of aluminium and the busbar (6) is designed as a sheet-metal strip (12). The assembly (22) is designed in particular as a pole connector, in particular for module poles of a battery. A sufficient clamping length is created by the sleeve (16), and so there is no need for washers. The aluminium screw serves as an additional current path.

Description

[0001] FDST Patent Attorneys, Nuremberg Page 1

[0002] P250045P-MD / BC

[0003] Description

[0004] Assembly with a busbar and a fastening element as well as a contact connection with such an assembly

[0005] The invention relates to an assembly comprising a busbar and a fastening element, in particular designed as a screw, for electrical and mechanical connection of the busbar to an electrical contact component, as well as a contact connection with such an assembly.

[0006] Busbars are used in a variety of electrical applications to electrically connect two electrical contact components. Often, the busbar is connected to the respective contact component using a screw.

[0007] One application example is module connectors, which connect the terminals of individual battery modules, known as module poles. This is particularly important in the automotive sector for electrically powered vehicles, as a large number of such module connectors are used within a (traction) battery. Given the vibrations and fluctuating temperatures that occur during operation, a reliable mechanical and electrical connection is crucial. At the same time, these module connectors must be capable of reliably transmitting high currents.

[0008] Another area of ​​application for such busbars is in control cabinets, for example for industrial plants.

[0009] For reliable mechanical screw fastening, a sufficiently long clamping length is required to ensure adequate screw elasticity for generating and maintaining the desired clamping force. Due to the flat design of the busbars, this is not always the case.

[0010] (Wfs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 2 Screw fastening is not easily possible to ensure a sufficient clamping length without the use of additional elements such as washers.

[0011] Especially in the automotive industry, where the aim is to achieve the most automated assembly possible, such additional elements as washers are disruptive and there is a risk of incorrect assembly.

[0012] Furthermore, a higher number of separation joints when using additional elements can negatively affect the long-term maintenance of the prestressing force.

[0013] Based on this, the invention aims to provide an assembly comprising a busbar and a fastening element, in particular a screw, for a reliable electrical and mechanical connection of the busbar to an electrical contact component. The invention further aims to provide a contact connection between a contact component and such an assembly.

[0014] The problem is solved according to the invention by an assembly with the features of claim 1 and by a contact connection with the features of claim 19.

[0015] The assembly comprises a busbar and a fastening element, which serves to electrically and mechanically connect the busbar to an electrical contact component. In the assembled state, the busbar is electrically and mechanically connected to the contact component via the fastening element, in particular by means of a screw connection.

[0016] The fastening element generally extends in a vertical direction and has a contact surface that is particularly ring-shaped.

[0017] (Wfs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 3 According to a first variant, the fastening element is designed as a fastening bolt, specifically a screw, with a head and a shaft (threaded shaft) adjoining it in a vertical direction. The contact surface is formed in particular by an underside of the head, also referred to as the head bearing surface.

[0018] According to a second variant, the fastening element is designed as a nut having an internal thread whose central axis extends along the vertical direction. The nut particularly features a nut sleeve with a preferably circumferential annular collar that forms the contact surface.

[0019] In the assembled state, the screw is screwed into the contact component. In the case of a nut, a threaded stud, similar to a stud bolt, is typically attached to the contact component. The sleeve is placed on this stud, and the nut is then screwed onto the sleeve.

[0020] The busbar extends at least over a section in a longitudinal direction and, in cross-section, has a width and a thickness, as well as an end section and a middle section. The end section forms a connection section or terminal, which connects the busbar to the contact component. The end section is shaped as a sleeve extending vertically, into which the fastening element is at least partially inserted. In the case of a bolt, the shank passes through the sleeve. In the case of a nut, a portion of its socket is inserted into the sleeve, and the rest protrudes beyond the sleeve. In the assembled state, the fastening element rests on the sleeve with its contact surface. The vertical direction is generally transverse to the longitudinal direction and, in particular, perpendicular to it.

[0021] A busbar is generally an elongated, electrically conductive component with a typically rectangular cross-sectional area, where the width of the busbar is greater than its thickness.

[0022] (Wfs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 4 The width of the busbar is oriented perpendicular to the longitudinal direction. The longitudinal direction forms, in particular, a normal to the cross-sectional area.

[0023] The width of the busbar, for example, ranges from 1 cm to 7 cm, depending on the application. Other widths are also possible. In the previously described application of module connectors, the width falls within the specified range. The thickness of the busbar is typically at least 3, 5, or even 10 times less than its width. For example, specifically for module connectors, the thickness ranges from 1 mm to 5 mm.

[0024] The busbar is preferably designed for transmitting high currents, particularly several tens of amps, for example at least 50 amps or at least 100 amps, and up to, for example, 500 amps. When used as a module connector, 50 to 300 amps are sufficient. For other applications, including those involving an electric battery, larger busbars designed for transmitting several hundred amps are preferred.

[0025] A particular advantage of the assembly according to the invention is the end section of the busbar designed as a sleeve. The sleeve is oriented vertically. It has a length that is at least greater than the thickness of the busbar. The length of the sleeve in the vertical direction is, for example, at least three times, preferably at least five times, or even at least ten times the thickness of the busbar. The length of the sleeve also defines a clamping length. This can therefore be suitably selected by the length of the sleeve. The clamping length, and thus the length of the sleeve, is, for example—especially in the application of a module connector—between 0.8 x bolt diameter (D) and 10 x D, particularly in the range of 1 x D to 3 x D. The bolt diameter is understood to be the nominal diameter of a bolt, in particular the nominal diameter of the screw or, in the case of a nut, the nominal diameter of the bolt.

[0026] (Wfs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 5

[0027] the nominal diameter of the bolt onto which the screw is screwed.

[0028] The vertically elongated sleeve offers a significant advantage over conventional flat terminals on standard busbars: a considerably longer clamping length, thus ensuring reliable clamping over the long term. This extended clamping length provides sufficient elasticity to generate a high clamping force. In particular, it enables, and is preferably used, a so-called hyper-elastic mounting. The long clamping length reliably prevents any loss of clamping force during operation. The design of the comparatively long sleeve thus increases the overall elasticity and therefore the compliance of the mounting bolt (screw / bolt). This eliminates the need for additional components that would otherwise increase the clamping length, such as washers.Preferably, an additional element, in particular a washer, is omitted.

[0029] A further significant advantage lies in the fact that the electrically conductive contact surface of the fastener on the sleeve allows it to participate in the electrical connection, meaning that during operation, some of the current can also flow through the fastener. The fastener is generally a component made of an electrically conductive material, in particular a suitable metal, preferably aluminum. Aluminum exhibits significantly better electrical conductivity compared to a conventional steel fastener.

[0030] According to a preferred embodiment, the busbar is designed as a flat sheet metal strip, in particular a sheet metal bending strip, wherein the sleeve is formed by partially rolling / forming the sheet metal strip. The manufacturing process therefore proceeds as follows: first, a sheet metal strip of the desired length, for example unwound from a supply roll, is provided, which is then bent at the end section so that the

[0031] (Wfs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 6

[0032] A sleeve is formed. The end section is therefore bent around a vertically extending axis. This enables cost-effective and simple manufacturing of the busbar with the sleeve. The busbar's dimensions and, for example, different bends around various axes can also be easily adapted to different requirements or installation space constraints. Overall, the busbar is therefore a simple and cost-effective sheet metal bending component to manufacture.

[0033] Preferably, the sleeve is completely closed, so that an end face of the sheet metal strip extends to and touches a rear section of the sheet metal strip. Alternatively, the sleeve is not completely closed and a vertical opening slot is formed. The slot width is preferably smaller than the shank diameter of the fastening bolt.

[0034] In a preferred embodiment, the end section is coiled in a spiral shape, such that at least one circumferential section of the sleeve is formed by two spiral sections arranged side by side in the radial direction. This creates an enlarged contact area with the head of the fastening bolt and, in particular, also with a contact surface on the contact component, for example, a bearing surface of the terminal post of the battery module. The fastening element therefore rests with its contact surface—as does the contact surface of the terminal post—on the several spiral sections arranged side by side in the radial direction.

[0035] In principle, in a preferred embodiment, the sleeve, when assembled, rests with one end face electrically contacting the fastening element and with the other end face electrically contacting the contact component.

[0036] In a preferred embodiment, the fastening element is captive and securely held to the sleeve. The busbar and fastening element thus form a pre-assembled unit, which can be transported as such to an installation site. The captive mounting prevents installation errors.

[0037] (Wfs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 7 Accidental loss of the fastening element is avoided. This also prevents the risk of electrical short circuits, for example, caused by lost screws in live areas, such as in the battery box of a (traction) battery.

[0038] This also simplifies the provision of components at the assembly site, as the fasteners do not need to be stored and supplied separately, which significantly reduces the assembly effort.

[0039] To create the retention mechanism, in a preferred embodiment at least one radially projecting retaining element is formed on both the fastening element and the sleeve, with the two retaining elements forming a positive locking connection effective in the vertical direction. Preferably, several retaining elements on the sleeve side, in the form of retaining lugs, are distributed around the circumference. These are formed, in particular, at the (upper) end face of the sleeve by bending over sections of the busbar.

[0040] If the fastening element is designed as a bolt, a bolt-side retaining element is preferably formed on the shaft and in particular designed as a circumferential retaining ring.

[0041] If the fastening element is designed as a nut with a nut sleeve, then at least one nut-side retaining element is preferably formed on the sleeve section of the nut sleeve, with which the nut sleeve is inserted into the sleeve. This nut-side retaining element is also preferably designed as a circumferential retaining ring.

[0042] Other methods of securing the fastener against loss can also be used. However, the previously described retention system with the sleeve-side retaining element and, in particular, the ring-shaped retaining element of the fastener offers the distinct advantage that no additional elements for securing the fastener against loss, such as additional press-fit inserts, are required.

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[0044] Alternatively or additionally to the previously described locking mechanism, one version uses such an additional retaining element. This element secures the fastening element, in particular the screw, within the sleeve by force and / or friction, thus preventing it from being lost.

[0045] The manufacturing process involves first cutting the edge of the sheet metal strip at the end section, for example by punching, laser cutting, or other cutting methods, so that individual protruding tabs are formed at the edge. The sleeve is then formed by bending and rolling the end section. During assembly, the fastening bolt is first inserted vertically into the formed sleeve. Subsequently, the initially vertically protruding tabs are bent inwards so that they extend radially inwards, creating the desired axial positive fit with the shaft-side retaining element.

[0046] In a preferred embodiment, the width of the busbar is generally smaller in the end section than in the middle section. This is, for example, a consequence of the fact that, in the preferred embodiment, the end section, and preferably only the end section, is trimmed at its edges.

[0047] In a preferred embodiment, the busbar is therefore generally trimmed at one side edge in the end section. Preferably, it is only trimmed at the edge of the end section; that is, the middle section, for example, is not trimmed. A further advantage of this edge trimming of the busbar in the end section is that it creates a defined (metallic) contact surface on which the head lands, thus achieving the lowest possible electrical contact resistance.

[0048] In a preferred embodiment, the width of the busbar in the end section, and in particular the width of the section of the sheet metal strip forming the sleeve, is generally less than or equal to the width in the middle section.

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[0050] Preferably, the busbar is provided with insulation, in particular formed by a layer of lacquer, which completely surrounds the busbar, at least in one initial state. This insulation is removed, at least partially, in the end section, particularly at the required electrical contact surfaces, especially only or at least in the contact area between the head and the sleeve, and preferably also in the contact area between the sleeve and the contact component. This achieves, for example, increased contact reliability (protection against accidental contact), particularly in the central section, and simultaneously ensures a good electrical connection in the electrical contact area. Alternatively or additionally to a layer of lacquer, an insulating sheath is applied (only) in the central section, for example, in the form of a slip-on insulating sleeve, specifically a so-called heat-shrink tube.

[0051] In a preferred embodiment, the fastening element and / or the busbar are made of aluminum. Preferably, both components are made of aluminum. This achieves good electrical conductivity while maintaining low weight. Preferably, the assembly contains no other metals and, in particular, no other materials, so that the assembly is made of a single material and is readily recyclable. Because both components are made of aluminum, problems with contact corrosion are also avoided. Compared, for example, to an assembly with a copper busbar and a steel fastening element (screw or nut), a significantly lower weight is achieved. Compared to steel, aluminum also exhibits significantly higher electrical conductivity.

[0052] In a preferred embodiment, the central section is horizontally oriented, and a transition section is arranged between the central section and the end section. In this transition section, the sheet metal strip is rotated, in particular by 90°, such that the sheet metal strip is vertically oriented after the transition section. The vertically oriented end section with the sleeve extending in the vertical direction generally adjoins the transition section. "Horizontally oriented" here means that the central section extends within a horizontal plane defined by the

[0053] (Wfs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 10 The conductor rail is spanned in the longitudinal and transverse directions in which its width extends. In the transition section, the conductor rail is therefore twisted around a central axis, thus changing its orientation. Therefore, when using a sheet metal bending strip for the conductor rail, the transition section allows for the central section to be horizontally aligned.

[0054] In a preferred embodiment, the central section is vertically spaced from a lower edge of the sleeve. In the final assembly, this ensures, for example, that this central section is not in contact with any component surface and preferably does not rest against any component surface, but is completely surrounded by air. This results in good cooling and reduces thermal stress compared to a situation where the busbar rests on a component.

[0055] This central section is preferably positioned in a central area of ​​the sleeve with respect to the vertically oriented sleeve, i.e., it runs, for example, at half the height of the sleeve within a central plane.

[0056] As an alternative to the horizontal orientation of the central section, this section is oriented vertically. In this preferred embodiment, the central section runs within a vertical plane defined by both the longitudinal and vertical directions. In this embodiment, the central section transitions directly into the end section with the sleeve. The vertical orientation also exhibits good thermal performance and allows for efficient heat dissipation.

[0057] In a preferred embodiment, the busbar has a further end section opposite the sleeve, which is designed as a (further) contact section for electrical and mechanical contact with another contact component. This further end section therefore forms another connection terminal in addition to the sleeve. The central section lies between the two opposing connection terminals (end sections). This is, depending on

[0058] (\\fs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 11 The design variant is either horizontally or vertically oriented. With a horizontal orientation of the central section, a transition section is formed on both sides of the central section, as described previously.

[0059] In a preferred embodiment, the further end section also forms a (further) sleeve. The same preferred embodiments and advantages apply to this sleeve as previously described for the (first) sleeve. This further sleeve is associated with a further fastening element, which is, in particular, retained within the sleeve in a captive manner. The further sleeve and the further fastening element are, in particular, identical to the previously described sleeve and fastening element. The two fastening elements attached to the two sleeves are, in particular, of the same type or identical, i.e., both being screws or both being nuts. Alternatively, they are of different types, i.e., one fastening element being a screw and the other a nut.

[0060] In a preferred embodiment, the two sleeves each extend vertically only over a portion of the width, in particular only over half the width. According to a first preferred variant, the two sleeves are arranged vertically offset from one another, in particular such that one sleeve is positioned at a lower edge of the busbar and the other sleeve at an upper edge. Alternatively, both sleeves are formed on the same edge, in particular at the lower or upper edge. This achieves the particular advantage that – in an arrangement of several busbars / assemblies in series – the end sleeve of a leading busbar and the front sleeve of a trailing sleeve can be stacked vertically on top of each other and fastened to the contact component using a common fastening element.When assembled, the two sleeves are stacked on top of each other and connected to the contact component via the common fastening element.

[0061] (Wfs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 12

[0062] As an alternative to designing the further end section as an additional sleeve, in a preferred embodiment it is designed as a connecting lug with a through-hole for a fastening bolt. A connecting lug is understood to be a flat end piece of the busbar, which extends in particular in the previously described horizontal plane and is not formed into a sleeve.

[0063] This design, with the sleeve at one end and the connecting lug at the other, is particularly advantageous when several such assemblies are arranged in series. Preferably, two adjacent busbars are connected and contacted via a common mounting bolt. For this purpose, the connecting lug of a leading busbar is placed onto the sleeve of a trailing busbar, and the mounting bolt is passed through the through-hole and the sleeve.

[0064] Preferably, the through-hole is open on one side, allowing the connecting tab to be guided laterally to the shaft of the subsequent mounting bolt, i.e., the mounting bolt of the downstream busbar. This is particularly important for the captive retention of the mounting bolt in the sleeve, as it would not be possible to insert the mounting bolt through a circumferentially closed through-hole in such a pre-assembled unit. The subsequent mounting bolt is, for example, a screw or, alternatively, a stud bolt attached to the contact component.

[0065] In a practical design, a stepped section adjoins the connecting flange towards the central section. The connecting flange with this stepped section therefore forms a step, which in side view is shaped particularly like a Z with two horizontal sections connected by a vertical section. This design offsets the connecting flange vertically. The connecting flange is thus raised to a different, higher vertical plane. Due to the stepped design...

[0066] (\\fs2012\gsi-software\winpat5\document\amM154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 13 The connecting lug is preferably guided to the level of the upper edge of the sleeve of the subsequent busbar and / or the sleeve at the end of the busbar opposite the connecting lug. The connecting lug can therefore be placed on the sleeve of a subsequent busbar and rests on it when mounted.

[0067] In a preferred embodiment, the busbar has a curved compensating section for length adjustment in the longitudinal direction. In this section, the busbar is bent, for example, in an S-shape or Z-shape, so that a certain degree of length variability and elasticity is achieved in the longitudinal direction. Such a compensating section allows for the compensation of assembly tolerances. This is particularly advantageous when arranging a large number of such busbars, especially in a serial arrangement.

[0068] In a contact connection according to the invention between such an assembly and an electrical contact component, the sleeve is fastened to the contact component by means of the fastening bolt. Preferably, a washer is omitted. Therefore, no further additional elements are required or provided. The electrical and mechanical connection is made exclusively by the fastening bolt. The head rests directly on the sleeve, which in turn rests directly on a contact surface of the contact component.

[0069] In a preferred embodiment, the contact component is a terminal pole of a battery, for example a battery pole, a module pole or a cell pole.

[0070] Generally, two contact components are connected via the assembly. In the case of a battery, for example, two terminals are connected. The assembly thus forms a terminal connector.

[0071] In a battery, several battery cells are typically connected together to form a battery module. The individual battery cells then have

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[0073] Each cell has (exactly two) poles, which are each connected to each other in a suitable manner via pole connectors.

[0074] Each battery module also has (exactly two) module poles, which are appropriately connected to each other via pole connectors (module connectors). The assembly described above is used, for example, for such pole connectors at the module level.

[0075] The multiple interconnected battery modules ultimately form the entire battery, which has (exactly two) battery terminals. The assembly described above is also suitable for connection to such a battery terminal.

[0076] The battery in question is specifically a (traction) battery of an electrically powered vehicle, which provides the energy for the vehicle's electric propulsion. Such traction batteries typically have a capacity of at least 25 kWh nowadays, preferably at least 50 kWh or even at least 60 kWh.

[0077] As previously described, the fastening element is primarily designed as a screw. The corresponding contact component has a thread into which the screw can be inserted. For example, a thread is inserted in the center of each terminal. Alternatively, the contact component may simply have a bore or a blind hole if a thread-forming screw is used.

[0078] When the fastening element is designed as a nut, a fixed screw bolt is formed on the contact component.

[0079] In one embodiment, several contact components are electrically connected to each other in series or parallel via at least two assemblies, wherein two adjacent busbars are preferably attached to a respective contact component via a common mounting bolt.

[0080] For this purpose, the assembly in the version with the sleeve is particularly relevant.

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[0082] The connection is inserted at one end section and the connecting tab at the other end section, as previously described. Alternatively, the version with the two sleeves is used, in which the sleeves extend only over approximately half the width and can be stacked on top of each other.

[0083] Exemplary embodiments of the invention are explained in more detail below with reference to the figures. These show simplified representations of the following:

[0084] FIG 1 shows a highly simplified sectional view of a contact connection with two contact components connected to each other via a busbar, which are designed as terminals of a battery.

[0085] FIG 2 a perspective view of a busbar according to a first embodiment with two end sections designed as sleeves and a horizontally oriented central section, which transitions into the opposite end sections via a transition section, FIG 3 a perspective view of a pre-assembled assembly with a busbar according to a second embodiment with two end sections designed as sleeves and a vertically oriented central section wherein a screw is captive held in each of the sleeves,

[0086] FIG 4 shows a perspective view of two pre-assembled modules with a sleeve and a further end section designed as a connecting lug; FIG 5 shows a simplified side view of a contact connection between several contact components designed as connecting poles using the modules according to FIG 4.

[0087] FIG 6 shows a perspective view of two assemblies, each with two sleeves arranged offset from each other in the vertical direction.

[0088] FIG 7 shows a partial view of a busbar with a spiral sleeve,

[0089] FIG 8 shows a partial and partially cut-out view of an assembly with an additional element as a captive fastener, as well as

[0090] (Wfs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 16 FIG 9 a partial and cutaway view of a pre-assembled component with a nut as a fastening element.

[0091] FIG 1 shows a simplified sectional view of an electrical contact connection 2 between two contact components 4 and each of a specially designed busbar 6, as explained in more detail below.

[0092] The two contact components 4 are, in particular, terminals, especially module terminals of an electric battery. The busbar 6 is attached to each contact component 4 by means of a fastening element, not shown in FIG. 1, designed as a screw 8 (see, for example, FIG. 3). Each contact component 4 has a thread 10 into which the screw 8 can be screwed.

[0093] The busbar 6 generally extends in a longitudinal direction L. The two contact components 4 are separated from each other in the longitudinal direction L. The screw 8, and thus also the thread 10, extends in a vertical direction V. Furthermore, a transverse direction Q is defined, which extends into the plane of the image in FIG. 1. The vertical direction V, the longitudinal direction L, and the transverse direction Q are each oriented perpendicular to each other.

[0094] The busbar 6 according to FIG. 1 is shown again in a perspective view in FIG. 2. The busbar 6 is generally formed from a sheet metal strip 12, which is formed into a sleeve 16 extending in the vertical direction V, at least in one end section 14 and, in the embodiment according to FIG. 1 and FIG. 2, at the end section 14 and at a further end section 15. The sheet metal strip 12 is generally designed as a solid metal strip and is made of aluminum. This means that the material of the sheet metal strip 12 consists of at least 85% aluminum by volume and is, in particular, an aluminum alloy.

[0095] The busbar 6 and thus also the sheet metal strip 12 are generally considered in cross-section as flat components with a particularly rectangular shape.

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[0097] cross-section formed and have a width B and a thickness D, where the width B corresponds, for example, to at least five times the thickness D.

[0098] A central section 18 is formed between the two end sections 14, 15, which in the embodiment shown in FIG. 2 is horizontally oriented. This means that the central section 18 is oriented within a horizontal plane spanned by the longitudinal direction L and the transverse direction Q.

[0099] The central section 18 transitions via a transition section 20 into the respective end section 14. In the transition section 20, the sheet metal strip 12 is twisted in on itself and about a central axis, specifically by 90°. This transforms the horizontal orientation of the central section 18 into a vertical orientation, so that the respective end sections 14, 15, and thus the sleeve 16, extend as desired in the vertical direction V.

[0100] In the embodiment shown in FIG 2, the sleeve 16 is designed as a closed sleeve, in which a front end edge of the conductor rail 6 / of the respective end section 14, 15 rests against a section of the sheet metal strip 12 oriented further towards the central section 18.

[0101] According to an alternative embodiment shown in FIG. 7, the respective end sections 14, 15 are spirally formed and thus partially coiled. This results in a circumferential section of the sleeve 16 being formed by (at least or exactly) two adjacent spiral sections, thereby increasing the contact area for the screw 8.

[0102] To form the busbar 6 shown in FIG. 2, a metal strip is first unwound from a roll or spool and cut to the desired length, so that a flat sheet metal strip 12 of the required length is provided. In further processing steps, the central section 18 is formed by twisting / twisting it relative to the end sections 14, 15. Furthermore, the end sections 14, 15 are essentially rolled up around the sleeve 16.

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[0104] to form. Overall, the busbar 6 can therefore be formed from a simple sheet metal strip 12 by one or more forming processes.

[0105] FIG. 3 shows an assembly 22 consisting of the busbar 6 and, in the exemplary embodiment, two screws 8. In this embodiment as well, the two opposing end sections 14, 15 of the busbar 6 are each formed into sleeves 16, as previously described with reference to FIG. 2.

[0106] In contrast to the embodiment shown in FIG. 2, the central section 18 is now vertically oriented. It extends within a vertical plane defined by the vertical direction V and the longitudinal direction L. In this embodiment, the central section 18 transitions directly, without a transition section 20, into the respective vertically oriented end sections 14 and 15. Therefore, during manufacturing, the central section 18 does not need to be rotated relative to the end sections 14 and 15, as is the case with the busbar shown in FIG. 2. Otherwise, the manufacturing process is identical.

[0107] As can be seen in FIG. 3, each screw 8 has a head 8A and a shank 8B extending vertically V from it. The shank is provided with an external thread, which can also be a self-tapping thread. At its lower end, oriented towards the shank 8B, the head 8A has a widened, annular bearing surface, also referred to as the head bearing, which forms a contact surface 11. In the assembled state, the head 8A rests on an upper circumferential rim of the respective sleeve 16.

[0108] The screw 8 is captive in a respective sleeve 16. For this purpose, the screw 8 has a shank-side retaining element, not shown in detail in FIG. 3, which is designed in particular as a circumferential retaining ring. Correspondingly, the sleeve 16 has at least one and preferably several sleeve-side retaining elements 24. These are formed around the circumference of the sleeve 16 and in particular at its upper edge. Specifically, the

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[0110] The sleeve-side retaining elements 24 are designed as retaining lugs that project radially inwards and form a positive fit with the shaft-side retaining ring, so that the screw 8 cannot fall out of the sleeve 16 against the vertical direction V.

[0111] To produce the sleeve-side retaining elements 24, a respective end section 14 is typically cut off at the edge in a suitable manner, so that vertically projecting lugs are initially created. After the screw 8 is inserted into the sleeve 16, these are bent radially inwards.

[0112] As an alternative to a retention device with retaining elements 24, the embodiment shown in FIG. 8 uses an additional retention element 25. In this embodiment, this element is designed as an additional sleeve inserted between the shaft 8B and the sleeve 16. This sleeve is, for example, designed as a molded plastic part or as a spring sleeve. It serves to retain the fastening element in the sleeve 16 in the vertical direction V in a form-fit and / or force-fit or friction-fit manner.

[0113] Overall, this provides a pre-assembled module 22, which is particularly suitable for automated assembly.

[0114] The sleeves 16 according to FIG 2 are preferably identical to the sleeves 16 shown in FIG 3 and also hold screws securely.

[0115] Figure 4 shows a further embodiment in which each busbar 6 forms the sleeve 16 only at one end section 14. At the opposite, further end section 15, a connecting lug 28 is formed as a flat sheet metal section. The connecting lug 28 has a through-hole 30, which in the exemplary embodiment is open to one side and specifically in the transverse direction Q.

[0116] (\\fs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 20

[0117] In the exemplary embodiment, a stepped section 32 is further connected to the connecting lug 28, which together with the connecting lug 28 forms a step that is designed in the form of a Z in side view.

[0118] In the embodiment shown in FIG. 4, the central section 18 is oriented vertically. Alternatively, it is also possible for this central section 18 to be oriented horizontally.

[0119] The connecting tab 28 and also the portion of the stepped section 32 oriented towards the central section 18 are horizontally oriented. In the exemplary embodiment, a transition section 20 is therefore formed in which the horizontal orientation of the stepped section 32 is transformed into the vertical orientation of the central section 18.

[0120] This stepped design generally raises the connecting flag 28 upwards in the opposite direction to the vertical direction V.

[0121] Figure 4 shows two assemblies 22. Due to the special design of the connecting lug 28, particularly in conjunction with the stepped section 32, such a busbar 6 is especially suitable for an electrically series or parallel connection of several such assemblies 22. In such an arrangement, a front busbar 6 with its connecting lug 28 is placed on the upper edge of the sleeve 16 of a trailing, rear busbar 6. Fastening with a respective contact element 4 is achieved via a common screw 8, which passes through the through-hole 30 and through the sleeve 16.

[0122] During assembly, before screwing, the connecting lug 28, and thus the entire busbar 6, is pivoted laterally in the direction of the arrow shown and rotated about an axis of rotation formed by the screw 8 of the front busbar 6, so that the through-hole 30 receives the shaft 8B. This enables a particularly compact and component-saving serial arrangement of several such assemblies 22.

[0123] (\\fs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 21

[0124] FIG 5 shows an example of another contact connection 2 in which several contact components 4 are serially connected to each other via several assemblies 22, as shown in FIG 4.

[0125] The contact components 4 are in particular connection poles of battery modules of an electric battery.

[0126] Preferably, the respective central section 18 at each contact connection 2 is free, i.e., it does not rest on components but is instead completely surrounded by air (see in particular FIG. 1 or FIG. 5). This allows for good heat dissipation.

[0127] Figure 6 shows an embodiment in which each busbar 6 has a sleeve 16 at its end. In contrast to the embodiment shown in Figure 3, each sleeve 16 extends vertically only over a portion (less than %) of the width B of the busbar 6, preferably only over half of the width B. In this embodiment, the two end sleeves 16 of each busbar 6 are arranged offset from each other in the vertical direction V. Preferably, one sleeve is located at the bottom edge and the other sleeve at the top edge. Alternatively, both sleeves are located on the same edge. A step is therefore typically formed at the transition from the end section 14 to the middle section 18.

[0128] This configuration serves to connect two successive busbars 6. An end sleeve 16 of the leading busbar 6 and a front sleeve 16 of a trailing busbar are arranged one above the other, so that they are aligned vertically V. In the final assembly state, the two sleeves 16 are connected to each other by a common fastening element, in particular a screw 8, which passes through both sleeves 16.

[0129] (Wfs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 22 The sleeves 16 are dimensioned such that, when stacked, they have a total vertical length that is, for example, between 0.7 and 1.5 times the width B of the busbar. In particular, the total length corresponds to the width B or at least substantially to the width B (e.g., + / - 10%).

[0130] The variant shown in FIG. 6 illustrates an embodiment in which the central section 18 is oriented in the vertical direction V. In principle, this section can be horizontally oriented – similar to the illustration in FIG. 2 – and transition via transition sections 20 into the vertically oriented end sections 14.

[0131] The sleeves 16 therefore generally have a reduced length in the vertical direction V compared to the embodiment of FIG. 2 or FIG. 3. The two sleeves 16 of a respective busbar 6 preferably have the same length in the vertical direction V. In the variants of FIG. 2 or FIG. 3, the sleeves 16 have a length in the vertical direction V that corresponds in particular to the width B or at least substantially to the width B (e.g. + / - 10%) of the busbar 6.

[0132] If the two sleeves 16 of a busbar 6 are aligned on the same edge side, the following busbar 6 is rotated 180° around a central longitudinal axis.

[0133] Furthermore, as can be clearly seen in FIGS. 1, 5, and 6, additional components, in particular washers, are omitted. The vertically oriented sleeve 16 provides a sufficiently long clamping length for the screw 8, thus ensuring a consistently high clamping force.

[0134] As previously explained, in a preferred embodiment, during the manufacture of each busbar 6, at least one edge of the end section 14 is treated by a cutting process, specifically for forming the sleeve-side retaining elements 24. Preferably, both opposite edge surfaces are treated.

[0135] (\\fs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 23 treated by a cutting process, for example a punching process or a laser cutting process, so that the busbar 6 has a section 34 with a reduced width B in the end section 14, as can be seen from FIG. 8 or FIG. 9. In particular, the edge has a step. Any oxide layers or insulating layers are reliably removed by this, so that a good electrical contact connection can be formed overall.

[0136] In a preferred embodiment, which is not shown in detail here, the busbar 6 is provided with insulation, particularly in the central section 18, which is formed, for example, by a coating of lacquer.

[0137] The manufacturing process involves, for example, first providing a metal strip with circumferential insulation and cutting it to the desired length, resulting in a flat strip 12. The subsequent cutting process in the end section 14 removes the insulation and exposes the electrically conductive contact surfaces.

[0138] This cutting treatment of the end sections 14 typically results in the width B of the sheet metal strip 12 being smaller in the end section 14 (i.e., in the section with reduced width) than in the remaining sections and specifically smaller than in the middle section 18. The width B in the end section 14 is, for example, between 0.8 mm and 6 mm smaller than in the other sections of the busbar 6.

[0139] The clamping length, and thus the length of the sleeve 16 in the vertical direction V, can easily be adapted to a specific requirement.

[0140] In a preferred embodiment, the busbar 6 has a compensating section, not shown in detail here, which serves to compensate for length differences. Within the compensating section, the busbar 6 is optionally S-shaped or Z-shaped, such that it provides a suitable

[0141] (\\fs2012\gsi-software\winpat5\document\arnt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 24

[0142] exhibits longitudinal elasticity L in order to compensate for length tolerances between two longitudinally spaced contact components 4 during assembly.

[0143] Figure 9 shows an embodiment in which a nut 36 is used as a fastening element. This nut has a sleeve with an internal thread. In a central area, an outer annular flange is formed, the underside of which forms the contact surface 11. In the fully assembled state, the nut 26 rests against an end face of the sleeve 16 and is clamped against it. Above the annular flange, a force application is shown by way of example in the form of an external polygon.

[0144] The nut 36 has a sleeve section below the contact surface 11, which engages in the sleeve 16. Preferably, the ring flange divides the nut 36 in half.

[0145] The nut 36 is preferably held in the sleeve in a captive manner. For this purpose, in the exemplary embodiment, the nut 36 has a radially projecting retaining element 38 on the lower sleeve section, which is designed in particular as an annular collar. This forms a positive locking connection in the vertical direction with the sleeve-side retaining elements 24, which are designed as lugs, as already explained previously in connection with the screw 8. The captive mechanism and the assembly of the nut 36 in the sleeve 16 are carried out in the same way as for the screw 8.

[0146] For fastening to the contact component 4, in particular a terminal pole, a (fixed) screw bolt (stud bolt) is attached to this, onto which the busbar 6 with the respective sleeve is placed. The nut is screwed onto this screw bolt and thus clamped against the busbar 6.

[0147] All previously described variants of the busbar 6 can also be combined with such a nut 36.

[0148] (\\fs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 25

[0149] Reference symbol list

[0150] 2 Contact connection

[0151] 4 Contact component

[0152] 6 busbar

[0153] 8 screws

[0154] 8A Head

[0155] 8B shaft

[0156] 10 threads

[0157] 11 Contact area

[0158] 12 metal strips

[0159] 14 Final Section

[0160] 15 further end section

[0161] 16 Sleeve

[0162] 18 Middle section

[0163] 20 Transition section

[0164] 22 assembly

[0165] 24 Sleeve-side retaining element 25 Anti-loss element 28 Connection flag

[0166] 30 through hole

[0167] 32 stepped section

[0168] 34 Section with reduced width 36 Nut

[0169] 38 nut-side retaining element

[0170] V Vertical direction

[0171] L Longitudinal direction

[0172] Q transverse direction

[0173] B width

[0174] Thickness

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Claims

FDST Patent Attorneys, Nuremberg, page 26 Claims 1. Assembly (22) comprising a busbar (6) and a fastening element (8, 36) designed in particular as a fastening bolt (8) or nut (36) for electrically and mechanically connecting the busbar (6) to an electrical contact component (4), wherein the fastening element (8, 36) extends in a vertical direction (V) and has a contact surface (11) in particular annular, and the busbar (6) extends at least section by section in a longitudinal direction (L) and, viewed in cross-section, has a width (B) and a thickness (D) as well as an end section (14) and a middle section (18), characterized in that the end section (14) of the busbar (6) is formed as a sleeve (16) extending in a vertical direction (V), into which the fastening element (8, 36) is at least partially inserted and on which the fastening element (8, 36) rests with a contact surface (11) in the assembled state.

2. Assembly (22) according to the preceding claim, characterized in that the busbar (6) is a sheet metal strip (12), and the sleeve (16) is formed by partially bending the sheet metal strip (12).

3. Assembly (22) according to one of the preceding claims, characterized in that the end section (14) is wound in a spiral shape, such that at least one circumferential section of the sleeve (16) is formed by two spiral sections arranged next to each other in a radial direction.

4. Assembly (22) according to one of the preceding claims, characterized in that the fastening element (8, 36) is captive on the sleeve (16) and in a preferred embodiment the fastening element (8, 36) and the sleeve (16) each have a retaining element (24, 38) projecting in a radial direction and the two retaining elements (24, 38) form a positive locking effect in the vertical direction (V). (Wfs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 27 5. Assembly (22) according to one of the preceding claims, characterized in that the width (B) in the end section (14) is less than or equal to the width (B) in the middle section (18).

6. Assembly (22) according to one of the preceding claims, characterized in that the busbar (6) is provided with insulation, in particular formed by a layer of lacquer, which is removed at least in the contact area between the head and the sleeve (16).

7. Assembly (22) according to one of the preceding claims, characterized in that the fastening element (8, 36) and the busbar (6) are made of aluminium.

8. Assembly (22) according to one of the preceding claims, characterized in that the central section (18) is horizontally oriented and that a transition section (20) is arranged between the central section (18) and the end section (14), in which the sheet metal strip (12) is rotated in particular by 90°, so that the sheet metal strip (12) is vertically oriented following the transition section (20).

9. Assembly (22) according to one of claims 1 to 8, characterized in that the central section (18) is aligned in the vertical direction (V).

10. Assembly (22) according to one of the preceding claims, characterized in that the busbar (6) has a further end section (15) opposite the sleeve (16), which is designed as a contact section for electrical and mechanical contact with a further contact component (4).

11. Assembly (22) according to the preceding claim, characterized in that the further end section (15) forms a further sleeve (16) through which a further fastening element (8, 36) is guided in a manner that is particularly secure against loss. (\\fs2012\gsi-software\winpat5\docurnent\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 28 12. Assembly (22) according to the preceding claim, characterized in that the two sleeves (16) each extend in the vertical direction (V) only over a partial length of the width (B), in particular only over half the width (B), and are arranged in the vertical direction (V) either offset from each other or both are arranged on an edge side of the busbar (6), such that in an arrangement of two busbars (6) the sleeve (16) of a first busbar (6) and the sleeve (16) of a second busbar (6) can be stacked on top of each other in the vertical direction (V).

13. Assembly (22) according to claim 10, characterized in that the further end section (15) forms a connecting lug (28) with a through hole (30) for a further fastening element (8, 36).

14. Assembly (22) according to the preceding claim, characterized in that the through hole (30) is open on one side, so that the further end section (15) can be brought laterally to a shaft (8B) of the further fastening element (8, 36).

15. Assembly (22) according to one of claims 12 to 14, characterized in that several busbars (6) are connected to each other, wherein - In the case of the embodiment according to claims 13 or 14, the connecting lug (28) of a first busbar (6) is connected to the sleeve (16) of a second busbar (6) via the further fastening element (8, 36) which is passed through the through hole of the connecting lug (28) and through the sleeve (16) of the first busbar, - In the case of the embodiment according to claim 12, the sleeve (16) of a first busbar (6) and the sleeve (16) of a second busbar (6) are arranged vertically one above the other, using the further fastening element (8, 36), which in particular is passed through the two sleeves (16). (\\fs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026 FDST Patent Attorneys, Nuremberg Page 29 16. Assembly (22) according to one of the preceding claims, characterized in that the busbar (6) has a curved compensating section for length compensation in the longitudinal direction (L).

17. Contact connection (2) between an electrical contact component (4) and an assembly (22) according to one of the preceding claims, wherein the sleeve (16) is attached to the contact component (4) by means of the fastening element (8, 36), in particular without an intermediate washer.

18. Contact connection (2) according to the preceding claim, wherein the two contact components (4) each constitute a terminal of a battery.

19. Contact connection (2) according to one of the two preceding claims, in which several contact components (4) with at least two assemblies (22) are connected in series to each other, wherein two busbars (6) are jointly attached to a respective contact component (4) via a common fastening element (8, 36). (\\fs2012\gsi-software\winpat5\document\amt\4154557.docx) Last saved: March 25, 2026

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