ELECTRIC COMPONENT, METHOD FOR PRODUCING THE ELECTRIC COMPONENT, AND COMPOSITE MATERIAL STRIP FOR PRODUCING THE COMPONENT

Abstract

The invention relates to a composite material strip for producing an electric component, in particular a resistor, in particular a low-resistance current-measuring resistor, comprising a first material strip (4) made of a copper-containing material, in particular a copper-containing conductor material, for later forming a first connection part of the electric component and comprising a second material strip (3) for later forming a second connection part of the electric component. The first material strip (4) and the second material strip (3) are electrically and mechanically connected together along a longitudinal seam, wherein the second material strip (3) consists of an aluminum-containing material, in particular an aluminum-containing conductor material. The invention further relates to a corresponding production method and to a corresponding component.

Claims

1-20. (canceled)

21. A composite material strip for producing an electric component, comprising: a) a first material strip comprising a copper-containing material for later formation of a first connecting part of the electric component, and b) a second material strip for later formation of a second connecting part of the electric component, wherein the first material strip and the second material strip are connected together electrically and mechanically along a longitudinal seam, c) wherein the second material strip comprises an aluminum-containing material.

22. The composite material strip according to claim 21, further comprising a third material strip comprising a resistance material for later formation of a resistance element of the component, wherein the third material strip is connected electrically and mechanically along a longitudinal seam to the first material strip.

23. The composite material strip according to claim 22, further comprising a fourth material strip comprising the copper-containing material for later formation of a third connecting part of the component, wherein the fourth material strip is connected electrically and mechanically along its longitudinal edge to the third material strip comprising the resistance material.

24. The composite material strip according to claim 21, wherein a) the first material strip comprises two material strips which are joined together along a longitudinal seam, and b) the second material strip comprises two material strips which are joined together along a longitudinal seam.

25. The composite material strip according to claim 23, wherein a) the first material strip is connected to the second material strip by one of the following methods: a1) roll-plating, a2) ultrasound welding, and b) the first material strip is connected to the third material strip by a weld connection, and c) the fourth material strip is connected to the third material strip by a weld connection.

26. The composite material strip according to claim 23, wherein a) the copper-containing material is a conductor material, and b) the aluminum-containing material is a conductor material, and c) the resistance material has a specific electrical resistance which is less than 50×10.sup.−7 Ωm and  greater than 1×10.sup.−8 Ωm, and d) the resistance material has a greater specific electrical resistance than the copper-containing material and the aluminum-containing material.

27. The composite material strip according to claim 26, wherein the resistance material is a copper-manganese alloy.

28. The composite material strip according to claim 26, wherein the third material strip is thinner than the other material strips.

29. The composite material strip according to claim 26, wherein the first material strip and the second material strip and the fourth material strip have the same thickness.

30. A production method for producing an electric component, comprising the following steps: a) providing a first material strip comprising a copper-containing material for later formation of a first connecting part of the electric component, b) providing a second material strip for later formation of a second connecting part of the electric component, and c) joining of the first material strip to the second material strip along a longitudinal seam to form a composite material strip with an electrical and mechanical connection between the first material strip and the second material strip, d) wherein the second material strip comprises an aluminum-containing material.

31. The production method according to claim 30, further comprising the following steps: a) providing a third material strip comprising a resistance material for later formation of a resistance element of the component, and b) joining of the third material strip to the first material strip.

32. The production method according to claim 31, further comprising the following steps: a) providing a fourth material strip comprising the copper-containing material for later formation of a third connecting part of the component, and b) joining of the fourth material strip to the third material strip.

33. The production method according to claim 32, wherein a) the first material strip is connected to the second material strip by one of the following methods: a1) roll-plating, a2) ultrasound welding, and b) the first material strip is connected to the third material strip by a weld connection, and c) the fourth material strip is connected to the third material strip by a weld connection.

34. The production method according to claim 31, wherein a) the composite material strip is assembled from a tri-strip with three joined material strips and a bi-strip with two joined material strips, b) the tri-strip comprises two outer material strips comprising the copper-containing material and a middle material strip comprising the resistance material, c) the bi-strip comprises a material strip comprising the copper-containing conductor material and a material strip comprising the aluminum-containing conductor material, and d) the material strip of the bi-strip comprising the copper-containing material is joined to the material strip one of the two outer material strips of the tri-strip comprising the copper-containing material.

35. The production method according to claim 31, wherein a) the composite material strip is assembled from a first bi-strip and a second bi-strip, b) the first bi-strip contains a material strip comprising the copper-containing material and a material strip comprising the aluminum-containing material, c) the second bi-strip contains a material strip comprising the resistance material and a material strip comprising the copper-containing material, and d) the material strip of the first bi-strip comprising the copper-containing material is joined to the material strip of the bi-strip comprising the resistance material.

36. The production method according to claim 30, further comprising the step of cutting of an electric component from the composite material strip transversely to the composite material strip.

37. The production method according to claim 36, further comprising the step of bending of the electric component cut from the composite material strip transversely to a longitudinal direction of the or in a current flow direction.

38. The production method according to claim 36, further comprising the step of adjustment of an electrical resistance value of the electric component cut from the composite material strip.

39. An electric component comprising: a) a first connecting part comprising a copper-containing material, and b) a second connecting part, c) wherein the second connecting part comprises an aluminum-containing material and is connected electrically and mechanically to the first connecting part.

40. The electric component according to claim 39, further comprising a) a resistance element comprising a resistance material, wherein the resistance element is connected electrically and mechanically to the first connecting part, and b) a third connecting part comprising the copper-containing material, wherein the third connecting part is connected to the resistance element, so that the resistance element is arranged in a current flow path between the first connecting part and the third connecting part.

41. The electric component according to claim 40, wherein a) the connecting parts are each plate-shaped, and b) the resistance element is plate-shaped, and c) the copper-containing material is copper or a copper alloy.

42. The electric component according to claim 41, wherein the aluminum-containing material is aluminum or an aluminum alloy.

43. The electric component according to claim 41, wherein the aluminum-containing material can be welded better to aluminum than the first conductor material.

44. The electric component according to claim 41, wherein the resistance material is a copper-manganese alloy.

45. The electric component according to claim 41, wherein the resistance material of the resistance element has a greater specific electrical resistance than the copper-containing material of the first connecting part and the aluminium-containing material of the second connecting part.

46. The electric component according to claim 41, wherein the resistance material of the resistance element has a specific electrical resistance which is less than 50×10.sup.−7 Ωm and greater than 1×10.sup.−8 Ωm.

47. The electric component according to claim 41, wherein the component is a resistor having a resistance value which is at least 0.1 μΩ and is at most 1000 μΩ.

48. The electric component according to claim 47, wherein the resistor has a steady current strength of at least 100 A.

49. The electric component according to claim 47, wherein the resistor has a thickness which is at least 0.2 mm and at most 20 mm.

50. The electric component according to claim 47, wherein the resistor has a resistance value with a temperature coefficient of less than 500 ppm/K.

51. The electric component according to claim 47, wherein the resistor has an inductance of less than 10 nH.

52. The electric component according to claim 41, wherein the first connecting part, the second connecting part, the third connecting part and the resistance element are cut from a composite material strip transversely to a longitudinal direction of the composite material strip, and then bent.

53. The electric component according to claim 47, wherein the resistor has a length in a current flow direction which is greater than 10 mm and less than 150 mm.

54. The electric component according to claim 47, wherein the resistor has a width transversely to the current flow direction which is greater than 5 mm and less than 200 mm.

55. The electric component according to claim 47, wherein the resistor has a thickness transversely to a current flow direction which is greater than 0.5 mm and less than 30 mm.

56. The electric component according to claim 41, wherein the resistance element is thinner than the connecting parts.

57. A conductor rail arrangement comprising: a) a first conductor rail comprising an aluminum-containing material, and p1 b) an electric component according to claim 39.

58. The conductor rail arrangement according to claim 57, wherein the second connecting part of the electric component is connected electrically and mechanically to the first conductor rail.

59. The conductor rail arrangement according to claim 57, wherein a) a second conductor rail comprising a copper-containing material is provided, and b) the first connecting part of the electric component contacts the second conductor rail, and c) the second connecting part of the electric component contacts the first conductor rail.

60. The conductor rail arrangement according to claim 57, wherein a) a capacitor is provided with contact tabs comprising an aluminum-containing conductor material, and b) at least one of the contact tabs of the capacitor is connected to the first conductor rail.

Description

[0060] Further advantageous refinements of the invention are characterized in the subclaims or explained in more detail below, together with the description of the preferred exemplary embodiments of the invention, with reference to the figures. The drawings show:

[0061] FIGS. 1A-1F various successive production stages in the production of a composite material strip according to the invention,

[0062] FIGS. 2A-2F the method steps from FIGS. 1A-1F in a cross-section view,

[0063] FIG. 3 the production method according to FIGS. 1A-1F and 2A-2F in the form of a flow diagram,

[0064] FIGS. 4A-4F various production steps in the production of an alternative exemplary embodiment of a composite material strip according to the invention,

[0065] FIGS. 5A-5F the method steps from FIGS. 4A-4F in a cross-section view,

[0066] FIG. 6 the production method according to FIGS. 4A-4F and 5A-5F in the form of a flow diagram,

[0067] FIG. 7 a diagrammatic cross-section view through a component according to the invention for electrical contacting,

[0068] FIG. 8 a modification of FIG. 7,

[0069] FIG. 9 a diagrammatic depiction to illustrate the production of a current-measuring resistor made from a composite material strip with three strips,

[0070] FIG. 10 a diagrammatic depiction for production of a current-measuring resistor made from a composite material strip with four material strips,

[0071] FIG. 11 a diagrammatic depiction of the connection of an aluminum conductor rail to a battery terminal with a current-measuring resistor,

[0072] FIG. 12 a diagrammatic depiction of the connection of an aluminum conductor rail to a copper conductor rail,

[0073] FIG. 13 a modification of FIG. 12,

[0074] FIG. 14 a diagrammatic depiction of the connection of an aluminum conductor rail to a copper conductor rail,

[0075] FIG. 15 a modification of FIG. 14,

[0076] FIG. 16 a modification of FIGS. 14 and 15,

[0077] FIG. 17 a diagrammatic depiction of the connection of a copper conductor rail to an aluminum electrolyte capacitor, and

[0078] FIG. 18 a modification of FIG. 5F.

[0079] In the description below, initially a first exemplary embodiment is described as depicted in FIGS. 1A-1F, 2A-2F and 3. FIGS. 1A-1F each show various method stages of the production method according to the invention for producing a finished composite material strip 1 as depicted in FIG. 1F. FIGS. 2A-2F show a top view of the individual method stages according to FIGS. 1A-1F. FIG. 3 however shows the production method in the form of a flow diagram.

[0080] In a first method step S1, firstly a bi-strip 2 is assembled from an aluminum strip 3 and a copper strip 4, for example by laser induction roll-plating along a longitudinal seam 5.

[0081] In a second step S2, a further bi-strip 6 is assembled from a Manganin® strip 7 and a copper strip 8, for example by electron beam welding.

[0082] In a third step S3, the two bi-strips 2, 6 are joined together by electron beam welding. Here the copper strip 4 is welded to the Manganin® strip 7, which can easily take place by electron beam welding.

[0083] In a further step S4, the resulting composite material strip 9 is joined to a further aluminum strip 10 by electron beam welding.

[0084] In a next step S5, the composite material strip shown in FIGS. 1F and 2F is then divided into individual current-measuring resistors transversely to the strip longitudinal direction, for example by punching transversely to the strip longitudinal direction.

[0085] In an optional step S6, the separated current-measuring resistors may then be bent.

[0086] Finally, in a step S7, the resistance value of the separated current-measuring resistors is adjusted, which may take place in the conventional fashion.

[0087] FIGS. 4A-4F, 5A-5F and 6 show a modification of the exemplary embodiment described above according to FIGS. 1A-1F, 2A-2F and 3, so to avoid repetition, reference is made to the above description wherein the same reference numerals are used for corresponding details.

[0088] One feature of this exemplary embodiment is that instead of a bi-strip 6, a tri-strip 6′ is provided. The tri-strip 6′, in addition to the copper strip 8 and the Manganin® strip 7, comprises a further copper strip 8′.

[0089] FIG. 7 shows a simplified cross section depiction of an electric component 11 according to the invention for electrical contacting, for example of conductor rails.

[0090] The component 11 consists of two plate-shaped aluminum parts 12, 13, and two also plate-shaped copper components 14, 15.

[0091] The two aluminum components 12, 13 and the two copper components 14, 15 are respectively connected together electrically and mechanically by electron beam welding.

[0092] The connection between the aluminum component 13 and the copper component 14 however takes place by laser induction roll-plating.

[0093] FIG. 8 shows a modification of FIG. 7. Here a component 11′ is provided which is assembled from a single aluminum component 12′ and a single copper component 14′ by laser induction roll-plating.

[0094] FIG. 9 shows a diagrammatic depiction for production of a current-measuring resistor 16 from a composite material strip 17 which consists of an aluminum strip 18, a copper strip 19 and a Manganin® strip 20.

[0095] The current-measuring resistor 16 here consists of a resistance element 21 made of Manganin®, two connecting parts 22, 23 made of copper, and two connecting parts 24, 25 made of aluminum.

[0096] The connecting parts 22, 24, 23, 25 are here thus arranged on the same side of the resistance element 21, which is known in itself from the patent application EP 0 605 800 A1 cited initially.

[0097] FIG. 10 shows a modification of the exemplary embodiment according to FIG. 9, so to avoid repetition, initially reference is made to the above description of FIG. 9, wherein the same reference numerals are used for corresponding details.

[0098] One feature of this exemplary embodiment is firstly that the composite material strip 17 also comprises a further copper strip 26. The two connecting parts 23, 22 are here arranged therefore on opposite sides of the resistance element 21, which is also known in itself from EP 0 605 800 A1.

[0099] FIG. 11 shows a diagrammatic depiction to illustrate the electrical connection of an aluminum conductor rail 27 via an aluminum connector 28 to a battery terminal 29 of a negative pole 30 of the battery 31.

[0100] Here again, a connection may be produced between the aluminum world of the aluminum conductor rail 27 on one side, and the copper world of the battery terminal 29 on the other.

[0101] FIG. 12 shows a diagrammatic depiction for connection of an aluminum conductor rail 32 to a copper conductor rail 33 via a screw connection 34, a current-measuring resistor 35 and a weld connection 36.

[0102] FIG. 13 shows a modification of FIG. 12, wherein the current-measuring resistor 35 is replaced by a single copper conductor rail 37.

[0103] FIGS. 14-16 show different variants for connecting an aluminum conductor rail 38, 39 to a copper conductor rail 40.

[0104] The two aluminum conductor rails 38, 39 are here connected together respectively via different variants of a weld connection 41.

[0105] FIG. 17 shows a diagrammatic depiction for connection of a copper conductor rail 42 by means of an aluminum copper component 43 to an aluminum electrolyte capacitor 44.

[0106] FIG. 18 finally shows a modification of FIG. 2F, so to avoid repetition, reference is made to the above description.

[0107] One feature of this modification is that the aluminum strip 3 is thinner than the other strips.

[0108] The invention is not restricted to the preferred exemplary embodiments described above. Rather, many variants and modifications are possible which also make use of the inventive concept and therefore fall within the scope of protection. In particular, the invention also claims protection for the subject and features of the subclaims, independently of the claims to which they refer.

LIST OF REFERENCE NUMBERS

[0109] 1 Composite material strip

[0110] 2 Bi-strip

[0111] 3 Aluminum strip

[0112] 4 Copper strip

[0113] 5 Longitudinal seam

[0114] 6 Bi-strip

[0115] 6′ Tri-strip

[0116] 7 Manganin® strip

[0117] 8 Copper strip

[0118] 8′ Copper strip

[0119] 9 Composite material strip

[0120] 10 Aluminum strip

[0121] 11 Component

[0122] 11′ Component part

[0123] 12 Aluminum part

[0124] 12′ Aluminum component part

[0125] 13 Aluminum part

[0126] 14 Copper component

[0127] 14′ Copper component

[0128] 15 Copper component

[0129] 16 Current-measuring resistor

[0130] 17 Composite material strip

[0131] 18 Aluminum strip

[0132] 10 Copper strip

[0133] 20 Manganin® strip

[0134] 21 Resistance element

[0135] 22 Connecting part made of copper

[0136] 23 Connecting part made of copper

[0137] 24 Connecting part made of copper

[0138] 25 Connecting part made of copper

[0139] 26 Copper strip

[0140] 27 Aluminum conductor rail

[0141] 28 Aluminum connector

[0142] 29 Battery terminal

[0143] 30 Negative pole of the battery

[0144] 31 Battery

[0145] 32 Aluminum conductor rail

[0146] 33 Copper conductor rail

[0147] 34 Screw connection

[0148] 35 Current-measuring resistor

[0149] 36 Weld connection

[0150] 37 Copper conductor rail

[0151] 38 Aluminum conductor rail

[0152] 39 Aluminum conductor rail

[0153] 40 Copper conductor rail

[0154] 41 Weld connection

[0155] 42 Copper conductor rail

[0156] 43 Aluminum copper component

[0157] 44 Aluminum electrolyte capacitor