EP2920847B1 - Plate element with a deep-drawn hole for press-in contacts - Google Patents

Description

The present invention relates to a plate element for conducting current with at least one recess for providing a contact receptacle for a contact element, wherein the plate element has a thickness. The present invention further relates to a component arrangement with such a plate element. The present invention further relates to a method for producing such a plate element of such a component arrangement.

Such plate elements and component arrangements are known in the prior art. Such plate elements are also referred to, for example, as "busbars" or "leaded grids".

The plate element is used to connect to one or more contact elements, especially in high-current applications. Holes are usually milled, drilled or punched into such known plate elements. The contact elements are then welded or soldered into these holes to provide a material connection that carries the current from the contact element to the plate element.

A device for conducting current is known, for example, from the publication DE 10 2004 006 575 A1 known, in which a power distributor for a motor vehicle is provided with at least one stamped grid into which contacts are pressed. The contacts are connected to the stamped grid without soldering. The contact surfaces in thin stamped grids can be too small for the transmission of high currents. In addition, the mechanical stability may not be sufficient under certain circumstances.

From the publication WO 2005 079 127 A1 is an electrical assembly with an electrically conductive contact pin for pressing into an opening in a circuit board. The opening in the circuit board has predetermined dimensions and the contact pin has a defined oversize in at least one partial area to form a press connection. The inserted length of the contact pin is greater than the depth of the circuit board opening. The inserted contact pin rests on the circuit board with an edge area and contacts the contact zone located there in a pressing area, which is preferably cold-welded in a gas-tight manner and wave-soldered to the contact zone there on the opposite side.

Due to assembly tolerances of the contact element, a certain thickness of the plate element or a certain depth of the holes is often required in order to be able to complete the contact satisfactorily. However, the entire thickness of the plate element is often not needed to conduct current, as the currents are relatively low. In practice, such plate elements therefore generally use a lot of material, which can be expensive due to the raw materials used. Furthermore, the welding or soldering process is relatively time-consuming and therefore expensive.
The publication DE 10 2010 033 808 A1 discloses a connection terminal and in particular a busbar with two through-openings into which a bridging device and a test plug are inserted, wherein each of the through-openings is designed in the form of a material passage having a hole collar, wherein the hole collar is essentially square.
The publication EP 1 944 834 A2 discloses a flexible pin for force-fitting insertion into a hole, the pin having two leg portions that come into contact with an inner surface of the hole.

An object of the present invention is therefore to provide a component arrangement for conducting current, which enables material and cost savings.

It is therefore proposed to further develop the plate element mentioned at the outset in such a way that it has a collar section on at least one side which provides at least one recess.

In this way, the advantage is achieved that the plate element itself can be formed with a thickness that is less than the entire depth of the recess or hole or bore. For example, the recess that extends through the plate element and the collar section can have a depth of 2 mm. Of this, 1.2 mm depth can be formed by the collar section, for example. For the thickness of the plate element, only a thickness of 0.8 mm is then required. Therefore, a material saving of over 50% can be achieved. In particular, for example, the plate element can be formed from copper, which is a relatively expensive raw material, whereby this material saving is significant and achieves a substantial cost saving.

A "recess" can be a through hole. A "recess" can also be a blind hole that is deep enough to press in the contact element.

Particularly for high volumes, the collar section can be formed by cold forming, particularly by deep drawing. Instead of drilling, milling or punching, a deep drawing process is carried out; for high volumes, the significant material savings justify such a deep drawing process.

According to the invention, a component arrangement for conducting current according to claim 1 is proposed.

In this way, it is possible to press the contact element into the recess and at least to connect it with a force fit. The pressing pressure and the forces thus created between the leg sections and an inner surface of the recess can also lead to cold welding between the surfaces of the contact element and the surfaces of the recess. This can also A material-locking connection can also be provided. Welding or soldering processes can be dispensed with. In order to enable a contact element to be pressed in, it can be provided in particular that an inner diameter of the at least one recess is smaller than an outer diameter of a respective contact element.

The advantages achieved are in particular that the use of tensile pressure forming creates open recesses with collar sections in the plate element without intentionally changing the thickness of the plate element, which, when the press-in technology is used, accommodate the press-in contacts on all sides. Deep drawing is well known in itself. It can be carried out, for example, with forming tools such as a stamp, drawing rings or a sheet metal holder, but also with active media such as gases or liquids. The use of active energies, such as in high-speed forming, can also be carried out. Other material forming processes can of course also be used. During the press-in process, the basic materials of the contact hollow body and the press-in contact can be welded together without the influence of temperature. The press-in contact can compensate for its own and the positional tolerance. There is no torque and no axial displacement when the press-in contact is pressed into the contact hollow body. The considerable increase in the contact area in the contact hollow body results in low line resistances and low contact resistances, so that high currents can be transmitted.

Furthermore, a method for producing a plate element is proposed, which comprises the steps of providing a plate element and deep-drawing at least one collar section surrounding a respective recess in the plate element. In principle, it is also possible to form the collar section by other cold forming processes.

In addition, a method for producing a component arrangement is proposed, which initially comprises carrying out the above-mentioned method and ultimately comprises a step of pressing in a component having at least two leg sections having contact element in one of the at least one recess.

Pressing in the contact element also opens up more design options. Investment and process costs can also be reduced.

The task posed at the beginning is thus completely solved.

In one embodiment of the plate element, it can be provided that the collar section extends from a surface of the plate element with a collar section height and wherein the collar section height is at least half the thickness of the plate element, in particular wherein the collar section height is twice the thickness.

In this way, a satisfactory press-fit can be achieved, but there is still enough material of a plate element available for current conduction. Furthermore, the material savings in such conditions are significant.

In a further embodiment of the plate element, it can be provided that a depth of the at least one recess extending through the plate element and the collar portion is at least 1.5 times the thickness of the plate element, in particular wherein the depth is twice the thickness.

This can also provide significant material savings with satisfactory press-fitting results. The thickness of the plate element is often sufficient to carry current.

In a further embodiment, it can be provided that the thickness is 0.8 mm, wherein the collar section height is 1.2 mm.

In yet another embodiment, the thickness can be 0.8 mm and the depth 2 mm. In this way, a contact area between the plate element and a contact element can be virtually doubled. This enables higher electrical currents to be discharged and material to be saved due to the reduced thickness of the plate element.

In a further embodiment of the plate element, it can be provided that the collar section with a radius merges onto a surface of the plate element.

In particular, the radius can be 0.2 mm. At an end of the recess opposite the collar section, a radius can also be formed for the transition from the inner surface of the recess to the surface of the plate element. This can also be 0.2 mm, for example.

The surface quality of the plate element can be Ra 0.8. The surface quality of the recess and/or the collar section can be Ra 0.05 to 3.0. Ra stands for the mean roughness in µm. Such a smooth surface enables a contact element to be inserted easily and cold welded reliably.

It can be provided that the plate element is made of copper. This is a highly conductive and high-temperature resistant material. The plate element can alternatively be made of brass or silver.

In a further embodiment, it can be provided that at least one of the at least one recess is designed as a through hole penetrating the plate element and the collar portion.

This allows a contact element to be pressed securely into the plate element. A cross-section of at least one recess can be circular Alternatively, other cross-sectional shapes are also conceivable, e.g. a rectangular or oval cross-section.

In a further embodiment, it can be provided that an inner surface of the at least one recess is coated with tin.

In this way, an improvement in the contact properties between the plate element and the contact element can possibly be provided. In principle, however, it can also be provided that the contact element is also made of copper and neither the contact element nor the component element has a coating.

Each leg portion has outwardly curved side surfaces, with a respective apex of a curvature being in contact with the inner surface.

In this way, contact with the inner surface of the recess can be provided on several sides of a leg portion.

In a further embodiment, the contact element can have two opposite ends, with the contact element having at least two leg sections at each end. In this way, for example, two different plate elements can be easily connected.

It can further be provided that the component arrangement has a single contact element with only one end, on which the at least two leg sections are formed. In this way, a targeted individual connection can be formed.

In a further embodiment, it can be provided that the at least two leg sections of the contact element are made of copper.

In this way, a highly conductive and high-temperature resistant material can be provided for the leg sections, which is also relatively elastic. In principle, a copper alloy can also be used to manufacture at least the leg sections of both the contact element and the plate element.

Furthermore, it can be provided that a surface of the at least two leg sections is coated with tin.

In this way, improved contact can be provided, similar to coating the surfaces of the recess.

In a further embodiment of the component arrangement, it can be provided that the plate element and/or the at least one contact element is designed as a punched grid.

A stamped grid is a flat structure created by stamping. In the case of the plate element, at least one collar section can then be introduced into this flat structure, for example by deep drawing. A common application for stamped grids is the creation of a system of electrical conductors in just one production step, made from a metal strip. The product then resembles a circuit board, as found in mass-produced electronic goods. In further finishing steps, the stamped grid can be electroplated.

Applications for stamped grid packages can be found in areas where high electrical currents have to be distributed in a small space. Such power distributors are used in automobiles, for example. Stamped grids are often designed in such a way that a direct connection to a cable set is possible via multi-pin connectors. Discrete components such as relays or fuses can be mounted on a stamped grid package by inserting suitable connectors.

In a further embodiment of the component arrangement, it can be provided that the component arrangement has a contact element group comprising a plurality of contact elements connected to one another by means of a rail section, and wherein the plate element is assigned a group of recesses, each of which has a collar section.

In this way, high currents, for example up to 100 A, can be handled by creating many individual connections.

In the unclaimed method for producing a plate element, it can also be provided that the plate element is made of copper. Furthermore, it can be provided that in a further step an inner surface of the recess is tinned.

The same applies to the unclaimed method for producing a component arrangement; there too, it can be provided that a surface of the at least two leg sections is tinned before pressing in.

Compared to the welded or soldered connections known from the state of the art between the contact element and the plate element or the busbar, the press-in connection can provide greater design options with lower investment costs and process costs.

It is understood that the features mentioned above and those to be explained below can be used not only in the combination specified in each case, but also in other combinations or on their own, as long as this does not depart from the scope of the present invention as defined in the claims.

Fig. 1

eine schematische Querschnittsansicht einer Ausführungsform eines Plattenelements,

Fig. 2

eine schematische isometrische Ansicht einer möglichen weiteren Ausführungsform eines Plattenelements mit einer Mehrzahl von Aussparungen,

Fig. 3

eine weitere isometrische Ansicht des Plattenelements von Fig. 2,

Fig. 4

eine schematische Querschnittsansicht einer Ausführungsform einer Bauteilanordnung,

Fig. 5

eine schematische Draufsicht auf eine Aussparung in einer Ausführungsform einer Bauteilanordnung,

Fig. 6

eine schematische Draufsicht auf eine Aussparung in einer weiteren Ausführungsform einer Bauteilanordnung,

Fig. 7

eine schematische Draufsicht auf noch eine weitere Ausführungsform einer Bauteilanordnung,

Fig. 8

eine schematische Ansicht der Formgebung eines Schenkelabschnitts entlang einer Linie XIII-XIII in Fig. 4,

Fig. 9

eine weitere Ausgestaltung eine Kontaktelements,

Fig. 10

noch eine weitere Ausgestaltung eine Kontaktelements,

Fig. 11

eine weitere Ausführungsform einer Bauteilanordnung,

Fig. 12

noch eine weitere Ausführungsform einer Bauteilanordnung,

Fig. 13

eine Detailansicht eines Ausschnitts X in der Fig. 12, und

Fig. 14

eine schematisches Ablaufdiagramm eines Verfahrens zum Herstellen eines Plattenelements und eines Verfahrens zum Herstellen einer Bauteilanordnung.

Embodiments of the invention are shown in the drawing and are explained in more detail in the following description. They show:

Fig. 1

a schematic cross-sectional view of an embodiment of a plate element,

Fig. 2

a schematic isometric view of a possible further embodiment of a plate element with a plurality of recesses,

Fig. 3

another isometric view of the plate element of Fig. 2 ,

Fig. 4

a schematic cross-sectional view of an embodiment of a component arrangement,

Fig. 5

a schematic plan view of a recess in an embodiment of a component arrangement,

Fig. 6

a schematic plan view of a recess in a further embodiment of a component arrangement,

Fig. 7

a schematic plan view of yet another embodiment of a component arrangement,

Fig. 8

a schematic view of the shape of a leg section along a line XIII-XIII in Fig. 4 ,

Fig. 9

a further embodiment of a contact element,

Fig. 10

yet another embodiment of a contact element,

Fig. 11

another embodiment of a component arrangement,

Fig. 12

yet another embodiment of a component arrangement,

Fig. 13

a detailed view of a section X in the Fig. 12 , and

Fig. 14

a schematic flow diagram of a method for producing a plate element and a method for producing a component arrangement.

Fig. 1 shows a plate element 10. In the Fig. 1 a section of the plate element is shown around a recess 12. Basically, the plate element 10 has at least one recess, but in particular a plurality of recesses.

The recess has an inner surface 14. The recess has a circular cross-section, but in principle any cross-sectional shape can be provided.

The recess is surrounded by a collar portion 16 on one side 21 of the plate element 10. The recess 12 extends through a plate body 18 of the plate element 10 and the collar portion 16.

The collar section extends on the side 21 from a surface 20 of the plate body 18. It thus protrudes from the plate surface 20 by a collar section height 25. A thickness of the plate body 18 of the plate element 10 is identified by the reference numeral 22. A depth of the recess 12 is identified by the reference numeral 24. A diameter of the recess is identified by the reference numeral 26. A collar section height 25 designates the amount by which the collar section 16 protrudes from the surface 20.

In particular, a thickness 22 of the plate body 18 can be approximately 0.8 mm. The collar section height 25 can be 1.2 mm. The depth 24 of the recess 12 therefore results in a total depth of 2 mm, which is sufficient for a press-fitting process. A diameter 26 of the recess 12 can also be 2 mm.

A surface quality of the plate arrangement can be Ra 0.8. A radius 28 with which the collar section 16 merges onto the surface 20 can be 0.2 mm.

In a further embodiment, it can also be provided that the diameter 26 is 1.45 mm and the total depth 24 is 1.5 mm.

In principle, the depth 24 can be at least 1.5 times the thickness 22.

The Fig. 2 shows an isometric view of an embodiment of a plate element 10. As shown, in principle several recesses 12 can be provided in the plate element 10.

In the Fig. 3 is a representation of Fig. 2 opposite side. As shown, each recess 12 has a collar portion 16.

The Fig. 4 shows an embodiment of a component arrangement 30.

Identical elements are marked with the same reference symbols and will not be explained again below.

A contact element 32 is pressed into the recess 12 so that it contacts the Fig. 4 The contact element 32 has two leg sections 34, 36, which come into contact with the inner surface 14 at least at contact points 40, 42 when pressed in. The leg sections 34, 36 are arranged at one end 37 of the contact element 32. The leg sections 34, 36 have a surface 38. The surface can be tinned. The same applies to the inner surface 14, which can also be tinned. The inner surface 14 and the leg sections 34, 36 can also be uncoated. For a material both for the leg sections 34, 36 or for the entire contact element 32 can be made of copper. The plate element 10 can also be made of copper.

Fig. 5 shows a top view of the recess 12. One looks at one end 44 of the leg sections 34, 36. A side surface 39 of the leg sections 34, 36 can be formed straight, so that approximately the Fig. 5 visible contact of the leg sections 34, 36 with the inner surface 14. As can be seen, a cross section of the leg sections 34, 36 can be designed such that two contact points 40, 40' or 42, 42' are obtained for each leg section. In this way, a stable 4-point contact can be provided.

In the Fig. 6 A further embodiment is shown. It can also be provided in principle that the side surfaces 39 are each designed with a curvature 46. In this way, the leg sections 34, 36 can also come into contact with the inner surface 14 laterally and thus provide further contact points.

In the Fig. 7 It is shown that in principle more than two leg sections can be provided, namely further leg sections 48, 50. The contact element can thus also have, for example, three or four leg sections in order to provide more contact points to the inner surface 14 than is possible with two leg sections 34, 36.

In the Fig. 8 is a schematic view along a line XIII-XIII, as for example in the embodiment in Fig. 6 would be designed. From the Fig. 8 The design of the side surface 39 of the leg sections is thus visible. As already described above, the side surfaces 39 have curvatures 46. This results in additional contact points 52, 54 to the inner surface 14 of the recesses.

In the Fig. 9 A further embodiment of a contact element 32 is shown. The contact element has two opposite ends 74 and 76 each has at least two leg sections 34, 36 or 34', 36'. This makes it possible to arrange two plate elements 10 opposite one another on a connecting body 32.

In the Fig. 10 a group 80 of several contact elements 32, 32', 32", 32" is shown. These are connected to one another by means of a rail section. If, for example, high electrical currents, such as 200 A, are to be absorbed, a rail section 78 with four contact elements 32, 32', 32", 32" can be used. Each contact element 32, 32', 32", 32 can be provided with two branch sections 34, 36.

In the Fig. 11 a further embodiment of a component arrangement 30 is shown. When the group 80 of several contact elements 32, 32', 32" is pressed into a group 82 of a corresponding number of recesses 12, 12', 12", a multiple press-in connection is formed. Each contact element 32, 32', 32" adapts to each recess 12 and each collar section 16 by deforming. A high-current connection is created between the plate element 10 and the rail section 78. The increased contact lengths of the collar sections make it possible to conduct very high currents.

In the Fig. 12 and 13 a further embodiment of a component arrangement 30 is shown. Fig. 13 shows a detailed view X in the Fig. 12 .

A plurality of contact elements 32, 32', which are formed separately from one another, are connected to the plate element 10. Using deep drawing, the collar sections 16 are formed in such a way that open collar sections 16 with an inner diameter 26 and the thickness 22 of the plate element 10 are formed from the plate element 10 by tensile pressure forming. The depth 24 is approximately twice as long as the thickness 22, i.e. 24 can be 1.8 times to 2.5 times as long as the thickness 22. A contact element 32 has two opposing bent leg sections 34, 36, which leave a leg gap 35 between them.

In Fig. 14 schematic flow diagrams of a non-claimed method 60 for producing a plate element and of a non-claimed method 62 for producing a component arrangement are shown.

The method 60 for producing a plate element begins in a start step 64, wherein a plate element is first provided in a step 66.

In a step 68, the collar sections 16 and the recesses 12 are then provided in the plate element 10 by deep drawing. In principle, the recesses 12, in particular with a smaller diameter, can also be provided before deep drawing, for example when casting the plate element or by being introduced in advance in another way. In any case, the collar sections 16 are formed by deep drawing. This method then ends in a stop step 72. In principle, after deep drawing, it can be provided to tin the inner surface 14 of the recesses 12.

In the method for producing a component arrangement 62, the steps 64, 66, 68 and, if necessary, tinning are also carried out first. A contact element with at least two leg sections described above is provided. This contact element is pressed into one of the at least one recesses 12 with the leg sections 34, 36 or additionally 48, 50. In principle, the pressing-in process 70 can be repeated and thus a plurality of contact elements can be pressed into one recess each. In this way, it can be provided, for example, that as in the Fig. 2 and 3 shown, nine recesses are provided and nine contact elements are pressed in, one contact element in each recess.

During the connection process in the pressing-in step 70, the contact element 32 is connected to the respective recess 12 and the associated collar section 16, for example with a stroke of approximately 0.1 seconds. Due to the fact that an inner diameter 26 is smaller than an outer diameter 84 of the branch sections 34, 36 of the contact element 32, a very high pressing pressure is created, which leads to a welding of the materials of the contact element 32 and the plate element 10 without the influence of temperature. A direct, elastic connection with a very high specific electrical conductivity is created. Because a contact surface has been enlarged due to a collar section 16, currents of, for example, 20 A and more can be passed on in a 12 V vehicle electrical system.

The method for producing a component arrangement then also ends in a stop step 72.

Claims (6)

1. Component arrangement (30) for current conduction comprising

   a plurality of press-in contact elements (32), each having at least two leg portions (34, 36, 48, 50) at at least one end (37) and each leg portion (34, 36, 48, 50) having outwardly curved side surfaces (39), wherein the plurality of press-in contact elements (32) are connected to one another via a rail portion (78); and

   a plate element (10) for conducting current, which has a thickness (22) and a plurality of circular recesses (12) for providing a contact receptacle for a press-in contact element (32), wherein each recess (12) is surrounded by a collar portion (16) on at least one face (21) of the plate element;

   wherein

   the at least two leg portions (34, 36, 48, 50) are each pressed into a recess (12) and are each in contact with an inner surface (14) of the relevant recess (12), wherein a relevant vertex (52, 54) of a curvature (46) is in contact with the inner surface (14);

   the recesses and collar portions are provided by deep drawing;

   the thickness of the plate element is approximately 0.8 mm, and

   the collar portions (16) extend from a surface (20) of the plate element (10) with a collar portion height (25) which is in the range of 0.4 mm to 1.6 mm.
2. Component arrangement according to claim 1, characterized in that the collar portion (16) merges with a radius (28) onto a surface (20) of the plate element (10).
3. Component arrangement according to one of claims 1 to 2,
   characterized in that the recesses (12) are each designed as a through hole penetrating the plate element (10) and the collar portion (16).
4. Component arrangement according to any of claims 1 to 3,
   characterized in that the inner surface (14) of the recesses (12) is coated with tin.
5. Component arrangement according to claim 1, characterized in that at least the at least two leg portions (34, 36, 48, 50) of the contact element (32) are made of copper.
6. Component arrangement according to claim 1 or claim 5,
   characterized in that a surface (38) of the at least two leg portions (34, 36, 48, 50) is coated with tin.

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